YAMAHA XSR 700 2021 Repair Manual

Periodic maintenance an d a djustment
6-15
6
EAU60451
Replacin g the air filter ele-
ment an d cleanin g the check
hoseThe air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Have a Yamaha dealer replace
the air filter element more frequently if
you are riding in unusually wet or dusty
areas. However, the air filter check
hose can be easily reached and should
be frequently checked and cleaned if
necessary.
To clean the air filter check hose
1. Remove the air filter check hose under the air filter case. 2. Clean and then install the hose.
EAU21386
Checkin
g the throttle grip free
playMeasure the throttle grip free play as
shown.
Periodically check the throttle grip free
play and, if necessary, have a Yamaha
dealer adjust it.
1. Air filter check hoseZAUM1348
1
1. Throttle grip free play
Throttle grip free play:
3.0–5.0 mm (0.12–0.20 in)
1
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Periodic maintenance an d a djustment
6-16
6
EAU21403
Valve clearanceThe valves are an important engine
component, and since valve clearance
changes with use, they must be
checked and adjusted at the intervals
specified in the periodic maintenance
chart. Unadjusted valves can result in
improper air-fuel mixture, engine
noise, and eventually engine damage.
To prevent this from occurring, have
your Yamaha dealer check and adjust
the valve clearance at regular intervals.TIPThis service must be performed when
the engine is cold.
EAU64412
TiresTires are the only contact between the
vehicle and the road. Safety in all con-
ditions of riding depends on a relatively
small area of road contact. Therefore, it
is essential to maintain the tires in good
condition at all times and replace them
at the appropriate time with the speci-
fied tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
WARNING
EWA10504
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.  The tire air pressure must be
checked and a djuste d on col d
tires (i.e., when the temperature
of the tires equals the am bient
temperature).
 The tire air pressure must be
a d juste d in accor dance with the
ri din g speed and with the total wei
ght of ri der, passen ger, car-
g o, an d accessories approve d
for this mo del.
WARNING
EWA10512
Never overloa d your vehicle. Opera-
tion of an overload ed vehicle coul d
cause an acci dent.Col d tire air pressure:
1 person: Front:225 kPa (2.25 kgf/cm², 33 psi)
Rear: 250 kPa (2.50 kgf/cm², 36 psi)
2 persons:
Front:225 kPa (2.25 kgf/cm², 33 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
Maximum load :
Vehicle:
168 kg (370 lb)
The vehicle’s maximum load is the
combined weight of the rider, pas-
senger, cargo, and any accessories.
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Periodic maintenance an d a djustment
6-17
6
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
TIPThe tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
WARNING
EWA10472

Have a Yamaha d ealer replace
excessively worn tires. Besi des
b ein g ille gal, operatin g the vehi-
cle with excessively worn tires
d ecreases ri din g sta bility an d
can lea d to loss of control.
 The replacement of all wheel
and b rake-relate d parts, inclu d-
in g the tires, shoul d b e left to a
Yamaha dealer, who has the
necessary professional knowl-
e dg e an d experience to do so.
 Ride at mo derate spee ds after
chan gin g a tire since the tire
surface must first be “ broken
in” for it to d evelop its optimal
characteristics.
Tire information
This model is equipped with tubeless
tires and tire air valves.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
WARNING
EWA10902
 The front an d rear tires shoul d
b e of the same make an d d e-
si gn, otherwise the han dlin g
1. Tire sidewall
2. Tire tread depthMinimum tire trea d d epth (front an d
rear): 1.6 mm (0.06 in)
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
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Periodic maintenance an d a djustment
6-18
6 characteristics of the motorcy-
cle may
be different, which
coul d lea d to an acci dent.
 Always make sure that the valve
caps are securely installe d to
prevent air pressure leaka ge.
 Use only the tire valves an d
valve cores listed below to
avoi d tire d eflation durin g a ri de.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha.
WARNING
EWA10601
This motorcycle is fitte d with super-
hi gh-spee d tires. Note the followin g
points in or der to make the most ef-
ficient use of these tires.  Use only the specified replace-
ment tires. Other tires may run
the dan ger of burstin g at super
hi gh spee ds.
 Bran d-new tires can have a rel-
atively poor g rip on certain roa d
surfaces until they have been
“ b roken in”. Therefore, it is a d-
visa ble before doin g any hi gh-
speed ridin g to ri de conserva-
tively for approximately 100 km
(60 mi) after installin g a new tire.
 The tires must be warme d up
b efore a hi gh-spee d run.
 Always a djust the tire air pres-
sure accor din g to the operating
con ditions.
EAU21963
Cast wheelsTo maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
 The wheel rims should be
checked for cracks, bends, warp-
age or other damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
 The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Front tire:
Size:120/70 ZR 17M/C(58W)
Manufacturer/model: MICHELIN / ROAD 5
Rear tire:
Size:180/55 ZR 17M/C(73W)
Manufacturer/model:
MICHELIN / ROAD 5
FRONT an d REAR:
Tire air valve:
TR412
Valve core: #9100 (original)
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Periodic maintenance an d a djustment
6-19
6
EAU33893
A djustin g the clutch lever free
playMeasure the clutch lever free play as
shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as fol-
lows.
To increase the clutch lever free play,
turn the clutch lever free play adjusting
bolt at the clutch lever in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).
TIPIf the specified clutch lever free play
cannot be obtained as described
above, proceed as follows.1. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
2. Loosen the locknut at the crank- case.
3. To increase the clutch lever free play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free
play, turn the adjusting nut in di-
rection (b).
4. Tighten the locknut.
EAU37914
Checkin g the brake lever free
playThere should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14212
A soft or spon gy feelin g in the b rake
lever can in dicate the presence of
air in the hy draulic system. If there is
air in the hy draulic system, have a
Yamaha dealer blee d the system be-
fore operatin g the vehicle. Air in the
hy draulic system will diminish the
1. Clutch lever free play adjusting bolt
2. Clutch lever free playClutch lever free play:
5.0–10.0 mm (0.20–0.39 in)2
1
(b)(a)
1. Locknut
2. Clutch lever free play adjusting nut
1
2
(a)(b)
1. No brake lever free play
1
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Periodic maintenance an d a djustment
6-20
6 b
rakin g performance, which may re-
sult in loss of control and an acci-
d ent.
EAU36505
Brake li ght switchesThe brake light should come on just
before braking takes effect. The brake
light is activated by switches connect-
ed to the brake lever and brake pedal.
Since the brake light switches are
components of the anti-lock brake sys-
tem, they should only be serviced by a
Yamaha dealer.
EAU22393
Checkin g the front an d rear
b rake pa dsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36891
Front brake pa ds
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn to
the point that a wear indicator almost1. Brake pad wear indicatorZAUM1833
1
1
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Periodic maintenance an d a djustment
6-21
6
touches the brake disc, have a
Yamaha dealer replace the brake pads as a set.
EAU46292
Rear brake pa ds
Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that a wear
indicator groove almost appears, have
a Yamaha dealer replace the brake
pads as a set.
EAU40262
Checkin g the brake flui d levelBefore riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake Rear
brake
WARNING
EWA16011
Improper maintenance can result in
loss of b raking a bility. O bserve
these precautions:  Insufficient brake flui d may al-
low air to enter the b rake sys-
tem, re ducing brakin g
performance.
 Clean the filler cap before re-
moving . Use only DOT 4 b rake
flui d from a seale d container.
1. Brake pad wear indicator grooveZAUM1834
1
1
1. Minimum level markZAUM1350
1
1. Minimum level mark
Specified b rake flui d:
DOT 4ZAUM1376
1
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Periodic maintenance an d a djustment
6-22
6 
Use only the specified b rake flu-
i d ; otherwise, the ru bber seals
may deteriorate, causin g leak-
a g e.
 Refill with the same type of
brake flui d. A ddin g a brake flui d
other than DOT 4 may result in a
harmful chemical reaction.
 Be careful that water or d ust
d oes not enter the brake flui d
reservoir when refillin g. Water
will si gnificantly lower the boil-
in g point of the flui d an d may re-
sult in vapor lock, an d d irt may
clo g the ABS hy draulic unit
valves.
NOTICE
ECA17641
Brake flui d may damag e painted
surfaces or plastic parts. Always
clean up spille d flui d imme diately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake fluid level goes down suddenly, have a
Yamaha dealer check the cause before further riding.
EAU22734
Chan gin g the brake flui dHave a Yamaha dealer change the
brake fluid every 2 years. In addition,
have the seals of the master cylinders
and brake calipers, as well as the brake
hoses replaced at the intervals listed
below or sooner if they are damaged or
leaking.
 Brake seals: every 2 years
 Brake hoses: every 4 years
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Periodic maintenance an d a djustment
6-23
6
EAU22762
Drive chain slackThe drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU60046
To check the drive chain slack
1. Place the motorcycle on the side- stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into the neutral position.
3. Push down on the drive chain un- der the end of the drive chain
guard.
4. Measure distance A between the drive chain guard and the center
of the chain as shown. 5. If distance A is incorrect, adjust it
as follows. NOTICE: Improper
d rive chain slack will overloa d
the en gine as well as other vital
parts of the motorcycle an d can
lea d to chain slippa ge or b reak-
a g e. If d istance A is more than
58.0 mm (2.28 in), the chain can
d amag e the frame, swin garm,
an d other parts. To prevent this
from occurrin g, keep the drive
chain slack within the specifie d
limits.
[ECA23070] EAU59921
To a
djust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack. 1. Loosen the locknut at each end of the swingarm, and then loosen the
axle nut.
2. To tighten the drive chain, turn the drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward.
1. Drive chain guide
2. Drive chain slack
Distance A:51.0–56.0 mm (2.01–2.20 in)
2
1
1. Axle nut
2. Locknut
2
1
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Periodic maintenance an d a djustment
6-24
6
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain slack adjusting plates
are in the same position for proper
wheel alignment.
3. Tighten the axle nut, and then
tighten the locknuts to the speci-
fied torques.
4. Make sure that the drive chain slack adjusting plates are in the
same position, the drive chain
slack is correct, and the drive
chain moves smoothly.
EAU23027
Cleanin g an d lu bricatin g the
d rive chainThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10584
The drive chain must be lu bricated
after washin g the motorcycle, ri din g
in the rain or ri din g in wet areas.1. Clean the drive chain with a drive
chain cleaner and a small soft
brush. NOTICE: To prevent dam-
a g in g the O-rin gs, do not clean
the drive chain with steam
cleaners, hi gh-pressure wash-
ers or inappropriate solvents.
[ECA11122]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain
lubricant. NOTICE: Do not use
en gine oil or any other lu bri-
1. Drive chain slack adjusting nut
1. Alignment marks
2. Drive chain slack adjusting plate
1
(a)(b)
2
1
Ti ghtenin g torques:
Axle nut: 150 N·m (15 kgf·m, 111 lb·ft)
Locknut:
16 N·m (1.6 kgf·m, 12 lb·ft)
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