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

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

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.

EAU22390

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.

EAU36890

Front brake pads

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

1. Rear brake light switch

2. Rear brake light switch adjusting nut

1. Brake pad wear indicator

U4S8E0E0.book Page 21 Tuesday, August 1, 2006 3:16 PM

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Summary of Contents for Fazer FZ6-SHG

Page 1: ...4S8 28199 EA FZ6 SHG OWNER S MANUAL ...

Page 2: ...ee 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 ...

Page 3: ... to enjoy all advantages of your FZ6 SHG 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 others 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 dea...

Page 4: ... 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 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 deat...

Page 5: ...ANUAL 2006 by Yamaha Motor Co Ltd 1st edition July 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U4S8E0E0 book Page 2 Tuesday August 1 2006 3 16 PM ...

Page 6: ...Removing and installing panels 6 6 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Coolant 6 11 Replacing the air filter element 6 15 Adjusting the engine idling speed 6 16 Checking the throttle cable free play 6 17 Valve clearance 6 17 Tires 6 17 Cast wheels 6 20 Adjusting the clutch lever free play 6 20 Rear brake light switch 6 21 Checking the front and rear brake pads 6 21...

Page 7: ... bulb 6 35 Front wheel 6 36 Rear wheel 6 37 Troubleshooting 6 39 Troubleshooting charts 6 40 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 U4S8E0E0 book Page 2 Tuesday August 1 2006 3 16 PM ...

Page 8: ...nts 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 mo...

Page 9: ...ield 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 e...

Page 10: ... Use 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 clear...

Page 11: ... equate 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 ...

Page 12: ... 6 15 4 Idle adjusting screw page 6 16 5 Shock absorber assembly spring preload adjusting ring page 3 18 6 Owner s tool kit page 6 1 7 Helmet holder page 3 17 8 Shift pedal page 3 13 9 Engine oil drain bolt page 6 9 10 Engine oil filter cartridge page 6 9 U4S8E0E0 book Page 1 Tuesday August 1 2006 3 16 PM ...

Page 13: ...Rear brake fluid reservoir page 6 22 4 Engine oil filler cap page 6 9 5 Front brake fluid reservoir page 6 22 6 Radiator cap page 6 11 7 Coolant reservoir cap page 6 11 8 Coolant drain bolt page 6 12 9 Dipstick page 6 9 10 Brake pedal page 3 13 U4S8E0E0 book Page 2 Tuesday August 1 2006 3 16 PM ...

Page 14: ... lever page 3 12 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 2 4 Multi function display page 3 6 5 Right handlebar switches page 3 11 6 Brake lever page 3 13 7 Throttle grip page 6 17 U4S8E0E0 book Page 3 Tuesday August 1 2006 3 16 PM ...

Page 15: ...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 te...

Page 16: ...ghting 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 off...

Page 17: ...d on but all other electrical 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 EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is ...

Page 18: ...tion or deceleration but this is 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 EAU...

Page 19: ...OK 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 40 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 40 U4S8E0E0 book Page 5 Tuesday August 1 2006 3...

Page 20: ...r check the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer system is still enabled This model is also equipped with a self diagnosis device for the immobilizer system See page 3 6 for an explan...

Page 21: ...or 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 ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 14000 r min an...

Page 22: ... following order F TRIP TRIP A TRIP B ODO F TRIP To reset a tripmeter select it by push ing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter The fuel meter indicates the amount of fuel in ...

Page 23: ...he air intake temperature is set to be displayed the coolant temperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed for one second and then the air in take temperatu...

Page 24: ...e the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle CAUTION ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage LCD and tachometer brightness control ...

Page 25: ...ress this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard switch 1 Engine stop switch 2 S...

Page 26: ...indicate a malfunction EAU12733 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10061 Do not use the hazard lights for an extended length of time with th...

Page 27: ... is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear b...

Page 28: ...osed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13220 Fuel Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler t...

Page 29: ...ing or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13411 Fuel tank breather hose Before operating the motorcycle Check the fuel tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breath...

Page 30: ...tic 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 EAU32980 Seat To remove the seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the rear of the seat up and then pull the seat off To install the seat 1 Insert the projection...

Page 31: ...2 Storage compartment This storage compartment is designed to hold a genuine Yamaha CYCLELOK Other locks may not fit When placing a CYCLELOK in the stor age compartment securely fasten it with the straps When the CYCLELOK is not in the storage compartment be sure to secure the straps to prevent los ing them WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do ...

Page 32: ... owner s tool kit to make the ad justment 3 Install the seat 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 for property damage or personal injury that may result from improper handling Do not tamper with or attempt to ope...

Page 33: ...e sidestand 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 ...

Page 34: ...er 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 s...

Page 35: ...quences 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 w...

Page 36: ...oft 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 21 6 22 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 reserv...

Page 37: ...6 17 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 27 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened...

Page 38: ... 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 19 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 warni...

Page 39: ... the shift pedal down repeatedly until it reaches the end of its travel 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 A...

Page 40: ...ully 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 this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17091 0 1000 km 0 600 mi Avoid prolonged operation above 7000 r min 1000 16...

Page 41: ...e 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 CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U4S8E0E0 book Page 4 Tuesday August 1 2006 3 16 PM ...

Page 42: ...iar 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 16 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...

Page 43: ... 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 o...

Page 44: ...ing bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand centerstand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber ...

Page 45: ...ge Change Every 3 years 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 age Replace the entire air induction system if ne...

Page 46: ... 5 6 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 U4S8E0E0 book Page 5 Tuesday August 1 2006 3 16 PM ...

Page 47: ...eds to be removed and installed EAU42660 Panels A and B To remove one of the panels 1 Remove the bolts 2 Pull the front cowling away from the vehicle as shown and then re move the panel To install the panel Insert the tabs on the panel into the slots in the front cowling as shown and then install the bolts 1 Panel A 2 Panel B 3 Panel C 1 Panel D 1 Bolt 1 Front cowling 2 Panel A U4S8E0E0 book Page ...

Page 48: ... the original posi tion and then install the bolts 2 Install panels A and B EAU33020 Panel D To remove the panel 1 Remove the seat See page 3 16 2 Remove the bolt and then pull the panel off as shown To install the panel 1 Place the panel in the original posi tion and then install the bolt 2 Install the seat 1 Tab 2 Slot 1 Panel C 2 Bolt 1 Panel D 2 Bolt U4S8E0E0 book Page 7 Tuesday August 1 2006 ...

Page 49: ...gine 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 installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface...

Page 50: ...e it clean insert it back into the hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark remove the oil filler cap and then add sufficient oil of the recommended type to raise it to the correct level 6 Insert and tighten the engine oil dipstick a...

Page 51: ... oil filter wrench and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Engine oil drain bolt 1 Engine oil filter cartridge 2 Oil filter wr...

Page 52: ...e off and then check the oil level and correct it if necessary EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU40151 To check the coolant level The coolant level should be checked as follows before each ride In addition the coolant must be changed at the in...

Page 53: ...tected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the...

Page 54: ...ide down 7 Install the coolant reservoir and its reservoir cover by placing them in the original position and then in stalling the bolts 8 Remove the coolant drain bolt to drain the cooling system 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant drain bolt and then tighten it to the specified torque NOTE Check the washer for...

Page 55: ...ff 15 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap radiator cap retainer and radi ator cap retaining bolt 16 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 17 Sta...

Page 56: ...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 worn 7 Install the air filter case cover by in stalling the screws 8 Place the fuel tank in the original position and install the bolts WARNING EWA12462 Before placing the fuel tank in t...

Page 57: ...e making this adjustment NOTE 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 idle adjusting 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...

Page 58: ...pecified 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 i e when...

Page 59: ...rd 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 wi...

Page 60: ... 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 spec...

Page 61: ...el 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 EAU2208...

Page 62: ...ust the brake light switch EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU36890 Front brake pads 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 wea...

Page 63: ...he brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommend...

Page 64: ...the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be check...

Page 65: ...h 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 as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the locknuts then the axle nut to ...

Page 66: ...lvents 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 the drive chain as they may contain substances that could damage the O rings EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each r...

Page 67: ...e should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U4S8E0E0 book Page 26 Tuesday August 1 2006 3 16 PM ...

Page 68: ... centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10740 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Recommended lubricant Lithium soap based grease all pur pose grease Recommended ...

Page 69: ...NG 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 handlebars several times to check if the front fork compresses and rebounds smoothly CAUTI...

Page 70: ...y 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 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 ...

Page 71: ...y call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than o...

Page 72: ...hind panel D See page 6 6 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 1 Fuse box 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan fuse 5 Backup fuse for odometer clock and immo bilizer system 6 Fuel injectio...

Page 73: ...e headlight 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 t...

Page 74: ... 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 EAU32822 Replacing the tail brake light bulb 1 Remove the seat See page 3 16 2 Remove the socket together with the bulb by turning it counter clockwise WARNING EWA12301 Do not touch the muffler bracket un til t...

Page 75: ...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 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 sock...

Page 76: ...auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove panel C See page 6 6 2 Remove the auxiliary light socket together with the bulb by pulling 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 gether with the bulb by pushing it in 6 Install the panel 1 License plate light bulb 2 Licens...

Page 77: ...70 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 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 4 Take the vehicle off the center stand so that the front wheel is on the ground 5 Tighten the wheel axle the front wheel axle...

Page 78: ...e axle nut 4 Loosen the locknut and drive chain adjusting bolt on each side of the swingarm 5 While supporting the brake caliper and slightly lifting the wheel pull the wheel axle out NOTE A rubber mallet may be useful to tap the wheel axle out 6 Push the wheel forward and then remove the drive chain from the rear sprocket 1 Locknut 2 Drive chain slack adjusting bolt 3 Axle nut 1 Locknut 2 Drive c...

Page 79: ...y 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 23 3 Install the axle nut and then lower the rear wheel s...

Page 80: ...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 inferi...

Page 81: ... There 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 star...

Page 82: ... 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 t...

Page 83: ...uffler outlets with plas tic bags 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 axl...

Page 84: ...areas Stubborn dirt and insects will come off more easily 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 ...

Page 85: ...any excess Never apply oil or wax to any rubber and plastic parts but treat 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 EAU26201 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA108...

Page 86: ... 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 fro...

Page 87: ...il 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 25 L 0 26 US qt 0 22 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 rese...

Page 88: ... 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 89: ...al light 12 V 10 0 W 2 Auxiliary light 12 V 5 0 W 2 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 Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A S...

Page 90: ...ntification 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 m...

Page 91: ...abel is affixed to the frame under the seat See page 3 16 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 U4S8E0E0 book Page 2 Tuesday August 1 2006 3 16 PM ...

Page 92: ... bulb replacing 6 32 Helmet holder 3 17 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 19 Immobilizer system 3 1 Immobilizer system indicator light 3 6 Indicator and warning lights 3 3 K Key identification number 9 1 L License plate light bulb replacing 6 34 M Main switch steering lock 3 2 Matte color caution 7 1 Model label 9 2 Multi ...

Page 93: ...rn signal light bulb replacing 6 34 Turn signal switch 3 11 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 29 Wheel front 6 36 Wheel rear 6 37 Wheels 6 20 U4S8E0E0 book Page 2 Tuesday August 1 2006 3 16 PM ...

Page 94: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 95: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 96: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 09 0 3 2 CR E ...

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