Yamaha FAZER FZ1-SA Owner'S Manual Download Page 66 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

6

EAU22080

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
To increase the clutch lever free play,
turn the adjusting bolt in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).

NOTE:

If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.

EAU36501

Rear brake light switch

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, have a Yamaha dealer ad-
just the brake light switch.

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

U5D0E0E0.book Page 19 Wednesday, October 11, 2006 11:04 AM

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Summary of Contents for FAZER FZ1-SA

Page 1: ...5D0 28199 EA FZ1 SA OWNER S MANUAL ...

Page 2: ... Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue 1 Aug 2002 Revolution record No Contents Date To change contact person and integrate type designation 9 Jun 2005 General manager of quality assurance div representative name and signature MORIC CO LTD 1450 6 Mori machi Shuchi gun Shizuoka 437 0292 JAPAN Telephone 81 538 85 0757 Facsimile 81 538 85 04...

Page 3: ... enjoy all advantages of your FZ1 SA The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer...

Page 4: ... you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death t...

Page 5: ... 2006 by Yamaha Motor Co Ltd 1st edition September 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5D0E0E0 book Page 2 Wednesday October 11 2006 11 04 AM ...

Page 6: ...R 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing panels 6 6 Checking the spark plugs 6 7 Engine oil and oil filter cartridge 6 8 Coolant 6 11 Replacing the air filter element 6 12 Adjusting the engine idling speed 6 14 Checking the throttle cable free play 6 15 Valve clearance 6 15 Tires 6 16 Cast wheels 6 18 Adjusting the clutch lever free play 6 1...

Page 7: ... 6 33 Replacing an auxiliary light bulb 6 33 Troubleshooting 6 34 Troubleshooting charts 6 35 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U5D0E0E0 book Page 2 Wednesday October 11 2006 11 04 AM ...

Page 8: ... have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other motor...

Page 9: ...ld or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exh...

Page 10: ...e extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearanc...

Page 11: ...uate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fal...

Page 12: ...ction system fuse page 6 29 6 Storage compartment page 3 20 7 Passenger seat lock page 3 18 8 Shock absorber assembly spring preload adjusting ring page 3 22 9 Shock absorber assembly rebound damping force adjusting screw page 3 22 10 Shift pedal page 3 14 11 Idle adjusting screw page 6 14 12 Engine oil drain bolt page 6 8 13 Engine oil filter cartridge page 6 8 U5D0E0E0 book Page 1 Wednesday Octo...

Page 13: ...rake fluid reservoir page 6 20 6 Engine oil filler cap page 6 8 7 Front brake fluid reservoir page 6 20 8 Front fork rebound damping force adjusting screw page 3 20 9 Engine oil level check window page 6 8 10 Brake pedal page 3 15 11 Coolant reservoir page 6 11 12 Luggage strap holder page 3 24 U5D0E0E0 book Page 2 Wednesday October 11 2006 11 04 AM ...

Page 14: ...er page 3 14 2 Left handlebar switches page 3 13 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 8 5 Right handlebar switches page 3 13 6 Throttle grip page 6 15 7 Brake lever page 3 15 U5D0E0E0 book Page 3 Wednesday October 11 2006 11 04 AM ...

Page 15: ...IATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the cod...

Page 16: ... bow keep it in a safe place and only use it for code re registering EAU10550 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stal...

Page 17: ...hed off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU10941 Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before ...

Page 18: ...s not a malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11423 Coolant temperature warni...

Page 19: ...INSTRUMENT AND CONTROL FUNCTIONS 3 5 3 CAUTION ECA10020 Do not operate the engine if it is overheated U5D0E0E0 book Page 5 Wednesday October 11 2006 11 04 AM ...

Page 20: ...Go ahead with riding 117 139 C 243 283 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 35 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 35 U5D0E0E0 book Page 6 Wednesday October 11 2006 ...

Page 21: ...e the wheels to lock during emergen cy braking If the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on or remains on have a Yamaha dealer check the electrical circuit EAU38620 Immobilizer system indicator light The e...

Page 22: ...ght ness control mode NOTE Be sure to turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to...

Page 23: ... A and TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 4 L 0 90 US gal 0 75 Imp gal the left segment of the fuel meter will start flashing and the odom eter display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the ...

Page 24: ...rature display indi cates the temperature of the coolant Push the RESET button to switch the coolant temperature display to the air intake temperature display NOTE When the coolant temperature display is selected C is displayed for one second and then the coolant tempera ture is displayed CAUTION ECA10020 Do not operate the engine if it is overheated Air intake temperature mode The air intake temp...

Page 25: ...OTE If the display indicates error code 52 this could be caused by transponder in terference If this error code appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may...

Page 26: ...and then re lease the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to con firm the selected brightness level The display will return to the odom eter or tripmeter mode EAU12331 Anti theft alarm optional This model can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more informat...

Page 27: ...tch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTIO...

Page 28: ... length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch whi...

Page 29: ...a ABS Anti lock Brake System features a dual electronic con trol system which acts on the front and rear brakes independently The ABS is monitored by an ECU Electronic Con trol Unit which will have recourse to manual braking if a malfunction occurs WARNING EWA10090 The ABS performs best on long braking distances On certain rough or gravel roads the braking distance may be longer with than without ...

Page 30: ... 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is...

Page 31: ...arts EAU13320 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium ...

Page 32: ...10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU39322 Seats Passenger seat To remove the passenger s...

Page 33: ... as shown and then pull the seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock it in place 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Rider seat lock lever 1 Projection 2 Seat holder U5D0E0E0 book Page 19 Wednesday October 11 2006...

Page 34: ...they will not get wet When washing the motorcycle be careful not to let any water enter the storage compartment EAU39332 Adjusting the front fork Each front fork leg is equipped with a spring preload adjusting bolt the right front fork leg is equipped with a re bound damping force adjusting screw and the left front fork leg with a com pression damping force adjusting screw WARNING EWA14670 Always ...

Page 35: ...crew in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b NOTE Be sure to perform this adjustment on the right front fork leg Compression damping force The compression damping force is ad justed on the left front fork leg only To increase the compression damping 1 Current setting 2 Front fork cap bolt Spring preload se...

Page 36: ...lways represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary EAU39341 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and a rebound damping force adjusting screw CAUTION ECA10...

Page 37: ...e specifications due to small differ ences in production the actual number of clicks always represents the entire adjusting range To obtain a precise ad justment it would be advisable to check the number of clicks of the rebound damping force adjusting mechanism and to modify the specifications as nec essary WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er ...

Page 38: ...rest EAU41940 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor CAUTION ECA15610 The EXUP system has been set and extensively tested at the Y...

Page 39: ...idestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15321 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side sta...

Page 40: ...the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle shou...

Page 41: ...ences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not wor...

Page 42: ... or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 20 6 20 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir...

Page 43: ...16 6 18 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened T...

Page 44: ...d and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 25 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15710 The following warning lights and in dicator light should come on for a few seconds then go off Oi...

Page 45: ... may be defective and the brake system reverts to conven tional braking If this occurs have a Yamaha dealer check the system as soon as possible The immobilizer system indica tor light should come on when the key is turned to ON and then go off after a few seconds If the indicator light does not come on or does not go off or if it flashes and the display indi cates a two digit error code have a Ya...

Page 46: ... the engine while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read t...

Page 47: ...he engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTIO...

Page 48: ...ot familiar with mainte nance work have a Yamaha dealer do it for you EAU17541 Owner s tool kit The owner s tool kit is located under the passenger seat See page 3 18 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrenc...

Page 49: ...EADING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check ope...

Page 50: ...se Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Brake and clutch lever pivot shafts Lubricate with lithium soap based grease 17 Brake and shift pedal pivot shafts Lubricate with lithium soap based grease 18 Sidestand centerstand Check operation Lubricate 19 Sidestand switch Check operation 20 Front fork Check operation and for oil leakage 2...

Page 51: ...e switches Check operation 28 Moving parts and ca bles Lubricate 29 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 30 Air induction system Check the air cut off valve reed valve and hose for dam age Replace the entire air induction system if necessary 31 Muffler and exhaust pipe Check the ...

Page 52: ...usty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U5D0E0E0 book Page 5 Wednesday October 11 2006 11 04 AM ...

Page 53: ...d and installed EAU40030 Panels A and B To remove one of the panels Remove the bolts and the screws and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screws and the bolts EAU19272 Panel C To remove the panel Remove the screw and then pull out ward on the areas shown 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Screw 3 Bolt U5D0E0E0...

Page 54: ...s ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before i...

Page 55: ...eplaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the ...

Page 56: ...cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt 1 Oil filter wrench 2...

Page 57: ...es while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 10 Turn the engine off and th...

Page 58: ... NOTE The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove pan el C See page 6 6 4 Remove the reservoir cap add coolant to the maximum level mark and then install the reservoir cap CAUTION ECA10471 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmf...

Page 59: ...coolant WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant EAU40051 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Re...

Page 60: ... to allow foreign objects to drop into the air intake manifold 7 Pull the air filter element out 8 Insert a new air filter element into the air filter case CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively wor...

Page 61: ...lts 12 Install the panels 13 Install the rider seat EAU34300 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly re sponds to the throttle Check the engine idling speed...

Page 62: ...check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Idle adjusting screw Engine i...

Page 63: ...EVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the motorcyc...

Page 64: ...es should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below...

Page 65: ...tion of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or...

Page 66: ... the adjusting bolt in direction b NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU36501 Rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necess...

Page 67: ... If a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EAU43110 Checking the brake ...

Page 68: ...areful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock and dirt may clog the ABS hydraulic unit valves Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go ...

Page 69: ...bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine a...

Page 70: ...iding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for th...

Page 71: ... and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and sh...

Page 72: ...er The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease U5D0E0E0 book Page 25 Wednesday October 11 2006 11 04 AM ...

Page 73: ...cified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the hand...

Page 74: ...upport the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If ...

Page 75: ...TTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then...

Page 76: ...eplace it as follows NOTE Include steps 2 and 6 only for the fuel injection system fuse 1 Turn the key to OFF and turn off the electrical circuit in question 1 Main fuse 2 Fuse box 3 Fuel injection system fuse 4 Fuel injection system spare fuse 1 Ignition fuse 2 Signaling system fuse 3 Taillight fuse 4 Backup fuse for odometer clock and immo bilizer system 5 Right radiator fan fuse 6 Left radiator...

Page 77: ...tion to check if the device operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 Install the battery cover and then hook the battery band onto the holder 1 Battery band 2 Battery cover 1 Fuel injection system fuse 2 Fuel injection system spare fuse Specified fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A F...

Page 78: ...hen secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with ...

Page 79: ...socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the passenger seat EAU24202 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn i...

Page 80: ...7011 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove panel B if replacing the left auxiliary light bulb or panel A if replacing the right auxiliary light bulb See page 6 6 2 Remove the auxiliary light socket together with the bulb by turning the socket counterclockwise 3 Remove the defective bul...

Page 81: ...le can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation...

Page 82: ...here is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starte...

Page 83: ... press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leak...

Page 84: ...fler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles ...

Page 85: ... if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into ...

Page 86: ...eat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26180 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it wi...

Page 87: ...ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from...

Page 88: ...lter cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 25 L 2 38 US qt 1 98 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve a...

Page 89: ... 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 184 kg 198 406 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT6 00 Front brake Type Dual disc brake Operation Right hand...

Page 90: ...License plate light 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 25 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ig...

Page 91: ...fication number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your moto...

Page 92: ...is affixed to the frame under the rider seat See page 3 18 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5D0E0E0 book Page 2 Wednesday October 11 2006 11 04 AM ...

Page 93: ...p 3 16 Fuses replacing 6 29 H Handlebar switches 3 13 Hazard switch 3 14 Headlight bulb replacing 6 31 High beam indicator light 3 4 Horn switch 3 13 I Identification numbers 9 1 Ignition circuit cut off system 3 25 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 4 K Key identification number 9 1 L License plate light bulb replacing 6 33 Luggage strap h...

Page 94: ...arts 6 35 Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 32 Turn signal switch 3 13 V Valve clearance 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheels 6 18 U5D0E0E0 book Page 2 Wednesday October 11 2006 11 04 AM ...

Page 95: ...U5D0E0E0 book Page 3 Wednesday October 11 2006 11 04 AM ...

Page 96: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 10 0 3 1 CR E ...

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