Yamaha Fazer FZ6-S Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-17

6

“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
(60 mi) after installing a new tire.

●

The tires must be warmed up
before a high-speed run.

●

Always adjust the tire air pres-
sure according to the operating
conditions.

EAU21960

Cast wheels

To 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 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 replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

●

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.

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).

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

5VXE1.book Page 17 Monday, February 9, 2004 5:39 PM

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Summary of Contents for Fazer FZ6-S

Page 1: ...5VX 28199 E1 FZ6 S OWNER S MANUAL ...

Page 2: ...R TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 2000 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue Aug 1st 2002 Kind of equipment IMMOBILIZER Address 1450 6 Mori Mori Machi Shuchi gun Shizuoka 437 0292 Japan Company MORIC CO LTD Kazuji Kawai representative name and signature 5VXE1 book Page 1 Monday February 9 2004 5 39 P...

Page 3: ... to enjoy all advantages of your FZ6 S 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 deal...

Page 4: ... your motorcycle and this manual If 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 The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motor cycle operator a ...

Page 5: ...ANUAL 2003 by Yamaha Motor Co Ltd 1st edition July 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan 5VXE1 book Page 2 Monday February 9 2004 5 39 PM ...

Page 6: ...d installing panels 6 5 Checking the spark plugs 6 6 Engine oil and oil filter cartridge 6 7 Coolant 6 10 Replacing the air filter element 6 11 Adjusting the engine idling speed 6 13 Adjusting the throttle cable free play 6 14 Adjusting the valve clearance 6 14 Tires 6 14 Cast wheels 6 17 Adjusting the clutch lever free play 6 17 Adjusting the brake pedal position 6 18 Adjusting the rear brake lig...

Page 7: ...xiliary light bulb 6 32 Front wheel 6 33 Rear wheel 6 34 Troubleshooting 6 36 Troubleshooting charts 6 37 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 5VXE1 book Page 2 Monday February 9 2004 5 39 PM ...

Page 8: ...ents 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 m...

Page 9: ...hield 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 ...

Page 10: ... 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 clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle...

Page 11: ...cle 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 fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting...

Page 12: ...er element page 6 11 4 Throttle stop screw page 6 13 5 Shock absorber assembly spring preload adjusting ring page 3 15 6 Owner s tool kit page 6 1 7 Shift pedal page 3 10 8 Engine oil drain bolt page 6 7 9 Engine oil filter cartridge page 6 7 5VXE1 book Page 1 Monday February 9 2004 5 39 PM ...

Page 13: ...t view 1 Fuse box page 6 28 2 Rear brake fluid reservoir page 6 20 3 Engine oil filler cap page 6 7 4 Front brake fluid reservoir page 6 20 5 Dipstick page 6 7 6 Brake pedal page 3 11 5VXE1 book Page 2 Monday February 9 2004 5 39 PM ...

Page 14: ... 3 10 2 Left handlebar switches page 3 9 3 LCD tachometer page 3 5 4 Multi function display page 3 6 5 Right handlebar switches page 3 9 6 Brake lever page 3 11 7 Throttle grip page 6 14 8 Main switch steering lock page 3 2 5VXE1 book Page 3 Monday February 9 2004 5 39 PM ...

Page 15: ...T 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 code re regis ...

Page 16: ...ighting 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 stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are of...

Page 17: ...lectrical systems are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11001 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left o...

Page 18: ... diagnosis system See page 3 6 for an explanation of the self diagnosis de vice The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit EAU27020 Immobilizer system indicator light The electrical circuit of the indicator light can be checked by turning th...

Page 19: ...r and have the stan dard keys re registered EAU32922 LCD tachometer The LCD tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON all of the display segments of the LCD ta chometer will appear one after the oth er across the r min range and then disappear in order to test the electrical circuit NOTE The first segment of the ta...

Page 20: ...ast two seconds Odometer tripmeter and digital ta chometer modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 TRIP F and the tachometer E in the following or der ODO TRIP 1 TRIP 2 TRIP F E ODO When the fuel amount in the fuel tank decreases to 3 6 L 0 95 US gal 0 79 Imp gal the bottom segment of the fuel meter will start fla...

Page 21: ...k The display seg ments of the fuel meter disappear to wards E Empty as the fuel level decreases When only one segment is left near E refuel as soon as possible NOTE This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective the display segments will flash If this occurs have a Yamaha dealer check the electrical circuit Coolant temperature meter With the key in...

Page 22: ...y ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the multi funct...

Page 23: ... switch 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 CA...

Page 24: ...r 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 which is part of the igni tion circuit cut off system See page 3 17 EAU12870 Shift pedal The shift pedal ...

Page 25: ...The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13070 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 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 ...

Page 26: ...ION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts 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 ga...

Page 27: ...his model is equipped with a catalytic converter in the exhaust chamber WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 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 dam...

Page 28: ...OTE Make sure that the seat is properly se cured before riding EAU14421 Storage compartment This storage compartment is designed to hold a genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage compartment securely fasten it with the straps When the U LOCK is not in the storage com partment be sure to secure the straps to prevent losing them WARNING EWA10961 Do not exce...

Page 29: ...reby soften the suspension turn the adjust ing ring in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible fo...

Page 30: ...ion circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of cont...

Page 31: ...the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have ...

Page 32: ...ter 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 ...

Page 33: ...equences 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 ...

Page 34: ...ha dealer bleed hydraulic system Check lever free play Adjust if necessary 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 19 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 fl...

Page 35: ... 6 14 6 17 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 24 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightene...

Page 36: ...d 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 17 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA12741 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warn...

Page 37: ...ravel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the e...

Page 38: ...AU16841 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 the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During t...

Page 39: ...ng the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17211 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 CA...

Page 40: ...liar with mainte nance work have a Yamaha dealer do it for you EAU17520 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 14 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 ...

Page 41: ...R READING 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 ...

Page 42: ...all nuts bolts and screws are properly tightened 15 Sidestand centerstand Check operation Lubricate 16 Sidestand switch Check operation 17 Front fork Check operation and for oil leakage 18 Shock absorber assem bly Check operation and shock absorber for oil leakage 19 Electronic fuel injection Adjust engine idling speed and synchronization 20 Engine oil Change Check oil level and vehicle for oil le...

Page 43: ...cate Every 800 km and after washing the motorcycle or riding in the rain 24 Front and rear brake switches Check operation 25 Moving parts and ca bles Lubricate 26 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 27 Air induction system Check the air cut off valve reed valve and hose for dam ...

Page 44: ...2861 Panels A and B To remove one of the panels Remove the bolts and the quick fasten er and then pull the panel off as shown To install the panel Place the panel in the original position install the quick fastener and the bolts EAU33020 Panel C To remove the panel 1 Remove the seat See page 3 14 2 Remove the bolt and then pull the panel off as shown 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Bolt ...

Page 45: ... when the vehicle is 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 defective Do not attempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced ...

Page 46: ...nd oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up whe...

Page 47: ...off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 10 if the oil filter cartridge is not being replaced 4 Remove the oil filter 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 oi...

Page 48: ... then let it idle for several minutes 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 ve...

Page 49: ...e page 3 14 3 Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum level marks 4 If the coolant is at or below the minimum level mark open the coolant reservoir cap 5 Add coolant or distilled water to raise the coolant to the specified level close the coolant reservoir cap and then install the seat CAUTION ECA10470 If coolant is not available...

Page 50: ...ructions EAU33030 Changing the 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 EAU32881 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maint...

Page 51: ...uel tank in the original position and install the bolts WARNING EWA11330 Before installing the fuel tank make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose and t...

Page 52: ...The engine is warm when it quickly re sponds to the throttle Check the engine idling speed and if necessary adjust it to specification by turning the throttle stop screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer mak...

Page 53: ...ervals specified in the periodic maintenance and lubrication chart EAU21771 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires ...

Page 54: ...ard to the load Check the tire condition and air pressure before each ride 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 sidewall is cracked have a Yamaha dealer re place the tire immediately NOTE The tire tread depth limits may differ from country to country Always comply w...

Page 55: ...r this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the spe...

Page 56: ...eel A deformed 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 Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU220...

Page 57: ...e foot rest bracket as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer ad just it WARNING EWA10690 A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydraulic system will diminish the bra...

Page 58: ...vals spec ified in the periodic maintenance and lubrication chart EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Y...

Page 59: ...the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid ...

Page 60: ...rstand 2 Shift the transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measure the drive chain slack as shown 5 If the drive chain slack is incorrect adjust it as follows EAU22930 To adjust the drive chain slack 1 Loosen the axle nut then loosen the locknut at each end of the swingarm 2 To tighten the drive chain turn the ...

Page 61: ... tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows CAUTION ECA10580 The drive chain must be lubricated after washing the motorcycle or riding 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 press...

Page 62: ...ble is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked befo...

Page 63: ...he pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever 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 5VXE1 book Page 24 Monday February 9 2004 5 39 PM ...

Page 64: ... as follows at the intervals specified 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 ...

Page 65: ...g must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support 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 Yam...

Page 66: ...it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention...

Page 67: ...ttery charg er have a Yamaha dealer charge your battery EAU32840 Replacing the fuses The main fuse box is located under the fuel tank The fuse box is located behind panel C See page 6 5 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Spare fuse ...

Page 68: ...dlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb WARNING EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 3 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10650 Take care not to dam...

Page 69: ...ght lens Do not use a headlight bulb of a wattage higher than specified 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU32820 Replacing the tail brake light bulb 1 Remove the seat See page 3 14 WARNING EWA12300 Do not touch the bracket until the ex haust system has cooled 2 Remove the socket together with the bulb by ...

Page 70: ...lb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together ...

Page 71: ...ights 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 5 2 Remove the auxiliary light socket together with the coupler by pull ing it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the auxiliary light socket to get...

Page 72: ...t 5 Pull the wheel axle out and then remove the wheel EAU24860 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground 4 Install the brake calipers by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the ...

Page 73: ...ice the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the axle nut 2 Place the motorcycle on the cen terstand 3 Remove the axle nut 4 Loosen the locknut and drive chain adjusting nut on each side of the swingarm 5 Push the wheel forward and then remove the drive chain from the rear sprocket 1 Axle nut 2 Drive chain slack adjusting nut 3 Locknut 5VXE1...

Page 74: ... the brake cal iper bracket by inserting the wheel axle from the right hand side NOTE Make sure that the retainer on the swingarm is inserted into the slot in the brake caliper bracket Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 21 3 Install the axle nut an...

Page 75: ... 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 parts may look like Yamaha parts but they are often infer...

Page 76: ...ompression 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 starter 4 Battery ...

Page 77: ...e hissing sound has stopped 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 ...

Page 78: ...e dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on...

Page 79: ...luding chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be r...

Page 80: ...efore storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful...

Page 81: ...ry month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the ba...

Page 82: ...h oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 27 L 0 29 US qt 0 24 Imp qt Radiator capacity including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 19 4 L 5 13 US gal 4 27 Imp gal Fuel r...

Page 83: ...3 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 190 kg 198 419 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 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 MT5 50 Front brake Type Dual disc brake Operation Right...

Page 84: ...turn signal light 12 V 10 0 W 2 Auxiliary light 12 V 5 0 W 2 Licence plate light 12 V 5 0 W 2 Meter lighting EL LCD backlight Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition f...

Page 85: ...entification 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 ...

Page 86: ...label is affixed to the frame under the seat See page 3 14 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 5VXE1 book Page 2 Monday February 9 2004 5 39 PM ...

Page 87: ...t bulb replacing 6 29 High beam indicator light 3 4 Horn switch 3 9 I Identification numbers 9 1 Ignition circuit cut off system 3 17 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L LCD tachometer 3 5 License plate light bulb replacing 6 31 M Main switch steering lock 3 2 Model label 9 2 Multi function display 3 6 N N...

Page 88: ... replacing 6 31 Turn signal switch 3 9 V Valve clearance adjusting 6 14 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 33 Wheel rear 6 34 Wheels 6 17 5VXE1 book Page 2 Monday February 9 2004 5 39 PM ...

Page 89: ...5VXE1 book Page 3 Monday February 9 2004 5 39 PM ...

Page 90: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 07 1 2 4 CR E ...

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