Yamaha XSR MTM690 2016 User manual

2016
SERVICE MANUAL
MTM690
MTM690-U
B34-F8197-E0

EAS20002
MTM690/MTM690-U
SERVICE MANUAL
©2015 by MBK Industrie
First edition, November 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.

EAS20003
IMPORTANT
This manual was produced by MBK Industrie. primarily for use by Yamaha dealers and their qualified
mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any-
one who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Yamaha Motor Company, Ltd. and MBK Industrie are continually striving to improve all of its models.
Modifications and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
4
6
2

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
Silicone fluid
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S

EAS10003 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
MULTI-FUNCTION METER UNIT .............................................................1-2
IMPORTANT INFORMATION .........................................................................1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-7
REPLACEMENT PARTS...........................................................................1-7
GASKETS, OIL SEALS AND O-RINGS ....................................................1-7
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-7
BEARINGS AND OIL SEALS ....................................................................1-8
CIRCLIPS ..................................................................................................1-8
RUBBER PARTS.......................................................................................1-8
BASIC SERVICE INFORMATION...................................................................1-9
QUICK FASTENERS.................................................................................1-9
ELECTRICAL SYSTEM...........................................................................1-10
SPECIAL TOOLS ..........................................................................................1-14

IDENTIFICATION
1-1
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the seat. This information will be needed to order
spare parts.
1
1

FEATURES
1-2
EAS20008
FEATURES
EAS30982
MULTI-FUNCTION METER UNIT
WARNING
EWA17650
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The multi-function meter unit is equipped with
the following:
• a speedometer
• a tachometer
• a fuel meter
• an eco indicator
• a transmission gear display
• a multi-function display
TIP
• Except when switching to the brightness con-
trol mode or to display the clock, turn the key to
“ON” before using the bottom and top set but-
tons.
• For the UK: To switch the speedometer and
multi-function display between kilometers and
miles, set the multi-function display to the
odometer mode or a tripmeter mode, and then
press the bottom set button for three seconds.
Speedometer
The speedometer shows the vehicle’s traveling
speed.
Tachometer
The tachometer allows the rider to monitor the
engine speed and keep it within the ideal power
range.
NOTICE
ECA19660
Do not operate the engine in the tachometer
red zone.
1. Transmission gear display
2. Tachometer
3. Eco indicator “ECO”
4. Speedometer
5. Multi-function display
6. Fuel meter
1. Top set button
2. Bottom set button
1
2
3
4
5
6
1
2
1. Tachometer
2. Tachometer red zone
Red zone
10000 r/min and above
1
2

FEATURES
1-3
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full tank) towards “E” (empty
tank) as the fuel level decreases. When the last
segment and frame start flashing, refuel as soon
as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in the fuel tank
electrical circuit, the fuel level segments, frame,
and “ ” flash repeatedly. If this occurs, check
the electrical circuit. Refer to “SIGNALING SYS-
TEM” on page 8-21.
Eco indicator
This indicator comes on when the vehicle is be-
ing operated in an environmentally friendly, fuel-
efficient manner. The indicator goes off when
the vehicle is stopped.
TIP
Consider the following tips to reduce fuel con-
sumption:
• Avoid high engine speeds during acceleration.
• Travel at a constant speed.
• Select the transmission gear that is appropri-
ate for the vehicle speed.
Transmission gear display
This display shows the selected gear. The neu-
tral position is indicated by “–” and by the neutral
indicator light.
Multi-function display
The multi-function display is equipped with the
following:
• an odometer
• two tripmeters
• a fuel reserve tripmeter
• an instantaneous fuel consumption display
• an average fuel consumption display
• a coolant temperature display
• an air temperature display
•aclock
• a brightness control mode
The odometer shows the total distance the vehi-
cle has traveled.
The tripmeters show the distance traveled since
they were last reset.
TIP
• The odometer will lock at 999999 and cannot
be reset.
• The tripmeter will reset to 0 and continue
counting after 9999.9 is reached.
1. Frame
2. Fuel meter
1. Eco indicator “ECO”
1
12
1
1. Neutral indicator light “ ”
2. Transmission gear display
1. Multi-function display
1
2
1

FEATURES
1-4
Push the bottom set button to switch the display
between odometer “ODO”, tripmeters “TRIP 1”
and “TRIP 2”, instantaneous fuel consumption
“km/L” or “L/100 km”, average fuel consumption
“AVE_ _._ km/L” or “AVE_ _._ L/100 km”, cool-
ant temperature “_ _ °C”, ambient temperature
“Air_ _ °C”, and clock “_ _:_ _” in the following or-
der:
ODO →TRIP 1 →TRIP 2 →km/L or L/100 km
→AVE_ _._ km/L or AVE_ _._ L/100 km →_ _
°C →Air_ _ °C →Clock _ _:_ _ →ODO
For the UK:
Push the bottom set button to switch the display
between odometer “ODO”, tripmeters “TRIP 1”
and “TRIP 2”, instantaneous fuel consumption
“km/L”, “L/100 km” or “MPG”, average fuel con-
sumption “AVE_ _._ km/L”, “AVE_ _._ L/100 km”
or “AVE_ _._ MPG”, coolant temperature “_ _
°C”, and ambient temperature, and “Air_ _ °C”,
and clock “_ _:_ _” in the following order:
ODO →TRIP 1 →TRIP 2 →km/L, L/100 km or
MPG →AVE_ _._ km/L, AVE_ _._ L/100 km or
AVE_ _._ MPG →_ _ °C →Air_ _ °C →Clock
_ _:_ _ →ODO
TIP
• Push the top set button to switch the display in
the reverse order.
• The fuel reserve tripmeter and error code dis-
plays come on automatically, while the bright-
ness control mode is accessed separately.
If the lower segment and frame of the fuel meter
start flashing, the display automatically changes
to fuel reserve tripmeter “TRIP F” and starts
counting the distance traveled from that point. In
this case, push the bottom set button to switch
the display between the various tripmeter,
odometer, and fuel consumption modes in the
following order:
TRIP F →km/L or L/100 km →AVE_ _._ km/L
or AVE_ _._ L/100 km →_ _ °C →Air_ _ °C →
Clock _ _:_ _ →ODO →TRIP 1 →TRIP 2 →
TRIP F
For the UK: TRIP F →km/L, L/100 km or MPG
→AVE_ _._ km/L, AVE_ _._ L/100 km or AVE_
_._ MPG →_ _ °C →Air_ _ °C →Clock _ _:_ _
→ODO →TRIP 1 →TRIP 2 →TRIP F
To reset a tripmeter, select it by pushing the bot-
tom set button, and then push the top set button
for one second.
If you do not reset the fuel reserve tripmeter
manually, after refueling and traveling 5km (3mi)
it resets automatically and disappears from the
display.
Instantaneous fuel consumption
The instantaneous fuel consumption display can
be set to either “km/L” or “L/100 km”; or for the
UK, “MPG” or “km/L” or “L/100 km”.
• “km/L”: The distance that can be traveled on
1.0 L of fuel under current riding conditions.
• “L/100 km”: The amount of fuel necessary to
travel 100 km under current riding.
• “MPG”: The distance that can be traveled on
1.0 Imp.gal of fuel under current riding condi-
tions.
To switch the instantaneous fuel consumption
display settings, push the bottom set button for
two second.
TIP
If traveling at speeds under 20 km/h (12 mi/h), “_
_._” is displayed.
Average fuel consumption
1. Instantaneous fuel consumption display
1. Average fuel consumption display
1
1

FEATURES
1-5
This display shows the average fuel consump-
tion since it was last reset.
The average fuel consumption display can be
set to either “AVE_ _._ km/L”, “AVE_ _._ L/100
km” or “AVE_ _._ MPG” (for the UK).
• “AVE_ _._ km/L”: The average distance that
can be traveled on 1.0 L of fuel.
• “AVE_ _._ L/100 km”: The average amount of
fuel necessary to travel 100 km.
• “AVE_ _._ MPG”: The average distance that
can be traveled on 1.0 Imp.gal of fuel.
To switch the average fuel consumption display
settings, push the bottom set button for two sec-
onds.
To reset the average fuel consumption, push the
top set button for one second.
TIP
After resetting the average fuel consumption, “_
_._” will be shown until the vehicle has traveled
1 km (0.6 mi).
Coolant temperature
This display shows the coolant temperature from
40 °C to 116 °C in 1 °C increments.
If the message “HI” flashes, stop the vehicle,
then stop the engine and let the it cool.
TIP
• When the coolant temperature is below 40 °C,
“Lo” will be displayed.
• The coolant temperature varies with changes
in the weather and engine load.
Air temperature
This display shows the air temperature from –9
°C to 99 °C in 1 °C increments. The temperature
displayed may vary from the actual ambient tem-
perature.
TIP
• When the air temperature is below –9 °C, “Lo”
will be displayed.
• The accuracy of the temperature reading may
be affected when riding slowly (under 20 km/h
[12.5 mi/h]) or when stopped at traffic signals,
railroad crossings, etc.
Clock
The clock displays time in 12-hour format. Even
when the key is not in the “ON” position, the
clock can be viewed for 10 seconds by pushing
the bottom set button.
To set the clock
1. Coolant temperature display
1
1. Air temperature display
1. Clock
1
1

FEATURES
1-6
1. Turn the main switch to “ON”.
2. Push the bottom set button and top set button
together for two seconds and the hour digits
will start flashing.
3. Push the top set button to set the hours.
4. Push the bottom set button and the minute
digits will start flashing.
5. Push the top set button to set the minutes.
6. Push the bottom set button to confirm set-
tings and start the clock.
TIP
• When setting the hours and minutes, push the
top set button briefly to increase the increment
value one by one, or push and hold the button
to increase the increment value continuously.
Brightness control
The brightness level of the multi-function meter
unit panel can be adjusted to suit the rider’s pref-
erence.
To adjust the brightness
1. Turn the main switch to “OFF”.
2. Push and hold the bottom set button.
3. Turn the main switch to “ON” and continue
pushing the bottom set button until the dis-
play switches to the brightness control mode.
4. Push the top set button to set the brightness
level.
5. Push the bottom set button to confirm the se-
lected brightness level and exit the bright-
ness control mode.
TIP
There are 6 brightness level settings.
1. Brightness level display
1

IMPORTANT INFORMATION
1-7
EAS20009
IMPORTANT INFORMATION
EAS30006
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-14.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS30007
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS30008
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS30009
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease

IMPORTANT INFORMATION
1-8
EAS30010
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
NOTICE
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
EAS30012
RUBBER PARTS
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to
contact the parts.

BASIC SERVICE INFORMATION
1-9
EAS20010
BASIC SERVICE INFORMATION
EAS30013
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin in with a screwdriver. Make sure that the
pin is flush with the fastener’s head.
Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.

BASIC SERVICE INFORMATION
1-10
EAS30014
ELECTRICAL SYSTEM
Electrical parts handling
NOTICE
ECA16600
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
NOTICE
ECA16751
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.
NOTICE
ECA16760
Be sure to connect the battery leads to the
correct battery terminals. Reversing the bat-
tery lead connections could damage the
electrical components.
NOTICE
ECA16771
When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery lead.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being
connected, a spark could be generated,
which is extremely dangerous.
NOTICE
ECA16610
Turn the main switch to “OFF” before dis-
connecting or connecting an electrical com-
ponent.

BASIC SERVICE INFORMATION
1-11
NOTICE
ECA16620
Handle electrical components with special
care, and do not subject them to strong
shocks.
NOTICE
ECA16630
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
TIP
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5
seconds before turning the main switch back to
“ON”.
Checking the electrical system
TIP
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
NOTICE
ECA14371
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, tak-
ing care not to loosen or damage the leads.
NOTICE
ECA16640
For waterproof couplers, never insert the
tester probes directly into the coupler. When
performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
a