Yamaha FAZER FZS1000 Owner'S Manual Download Page 92 | Manualshive

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INDEX

Throttle grip and cable, checking and

lubricating ........................................... 6-26

Tires ...................................................... 6-17
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-38
Troubleshooting charts ......................... 6-39
Turn signal indicator lights ...................... 3-2
Turn signal light bulb, replacing ............ 6-34
Turn signal switch ................................... 3-6

V

Valve clearance .................................... 6-17
Vehicle identification number .................. 9-1

W

Wheel bearings, checking..................... 6-29
Wheel (front) ......................................... 6-35
Wheel (rear) .......................................... 6-36
Wheels .................................................. 6-20

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Summary of Contents for FAZER FZS1000

Page 1: ...1C2 28199 EA FZS1000 FZS1000S OWNER S MANUAL ...

Page 2: ...U1C2E1E0 book Page 2 Wednesday August 4 2004 11 57 AM ...

Page 3: ...to enjoy all advantages of your FZS1000 FZS1000S 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 Ya...

Page 4: ...our 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 motorcycle operator a bys...

Page 5: ...S MANUAL 2004 by Yamaha Motor Co Ltd 1st edition July 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1C2E1E0 book Page 2 Wednesday August 4 2004 11 57 AM ...

Page 6: ...n 5 4 Engine break in 5 4 Parking 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 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 Cleaning the air filter element 6 14 Adjusting the carburetors 6 16 Adjusting the engine idling speed 6 16 Checking the throttle cable ...

Page 7: ... Replacing a tail brake light bulb 6 33 Replacing a turn signal light bulb 6 34 Replacing an auxiliary light bulb 6 34 Front wheel 6 35 Rear wheel 6 36 Troubleshooting 6 38 Troubleshooting charts 6 39 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U1C2E1E0 book Page 2 Wednesday August 4 2004 11 57 AM ...

Page 8: ...s 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 moto...

Page 9: ...eld 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 ex...

Page 10: ...se 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 clearan...

Page 11: ...entilation 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 fall over...

Page 12: ...page 6 14 5 Main fuse page 6 31 6 Fuse box page 6 31 7 Storage compartment page 3 12 8 Grab bar 9 Seat lock helmet holder page 3 11 page 3 12 10 Shock absorber assembly compression damping force adjusting screw page 3 15 11 Shock absorber assembly spring preload adjusting ring page 3 15 12 Shock absorber assembly rebound damping force adjusting knob page 3 15 13 Shift pedal page 3 8 U1C2E1E0 book ...

Page 13: ...servoir page 6 22 3 Battery page 6 29 4 Front brake fluid reservoir page 6 22 5 Radiator cap page 6 11 6 Engine oil filter cartridge page 6 8 7 Engine oil level check window page 6 8 8 Brake pedal page 3 8 9 Coolant reservoir page 6 11 U1C2E1E0 book Page 2 Wednesday August 4 2004 11 57 AM ...

Page 14: ...ches page 3 6 3 Starter choke lever page 3 11 4 Speedometer unit page 3 3 5 Main switch steering lock page 3 1 6 Tachometer unit page 3 4 7 Fuel gauge page 3 5 8 Right handlebar switches page 3 6 9 Brake lever page 3 8 10 Throttle grip page 6 17 U1C2E1E0 book Page 3 Wednesday August 4 2004 11 57 AM ...

Page 15: ...l systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it WARN...

Page 16: ...n the neutral position EAU11080 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU11120 Oil level warning light This warning light comes on when the engine oil level is low 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 d...

Page 17: ... and allow the engine to cool 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 cir cuit CAUTION ECA10020 Do not operate the engine if it is overheated EAU11810 Speedometer unit The speedometer unit is equipped with the following an odometer two tripmeters...

Page 18: ...and keep it within the ideal power range CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 11500 r min and above This tachometer unit is equipped with a clock To set the clock 1 Push both the SELECT and RE SET buttons for at least two sec onds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button to change the minutes 4 ...

Page 19: ...er ror code the vehicle should be checked as soon as possible in or der to avoid engine damage EAU12110 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E approximately 4 1 L 1 08 US gal 0 90 Imp gal of fuel remain in the fuel tank If this occurs refuel as soon as possible NOTE Do not allow ...

Page 20: ...s this switch to flash the head lights 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 PASS 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard switch 1 Engine stop switch...

Page 21: ...he ON or posi tion use this switch to turn on the haz ard light simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10060 Do not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU12820 Clutch lever The clutch leve...

Page 22: ...ipped 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 arrow mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear br...

Page 23: ...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 not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not overfi...

Page 24: ...ng 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 EAU13410 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 breathe...

Page 25: ...ire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU13590 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke EAU13940 Seat To remove the seat 1 Insert the key in...

Page 26: ...0 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EAU14411 Storage compartment This storage compartment is designed to hold an optional genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage com partment securely fasten it with the straps When the U LOCK is not in the storage compa...

Page 27: ...ual ly otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE Align the appropriate groove on the ad justing mechanism with the top of...

Page 28: ...ettings NOTE Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always 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 specifi...

Page 29: ...e adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting knob in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in di rectio...

Page 30: ...NING 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 open the gas cylinder Do not subject the shock ab sorber to an open...

Page 31: ...e of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition 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 b...

Page 32: ...vents 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 EWA10260 The vehicle must be placed on the centerstand during this in spectio...

Page 33: ... 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 sho...

Page 34: ...uences 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 wo...

Page 35: ...t 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 reservoi...

Page 36: ... 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 26 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 37: ...he 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 18 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11430 The oil level warning light coolant temperature warning light and fuel level warning light should come o...

Page 38: ...en the key is turned to ON the warn ing light does not come on for a few seconds then go off or if it does not go off after starting with sufficient coolant have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If when ...

Page 39: ...n press 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 transmi...

Page 40: ...low 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 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 ab...

Page 41: ... 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 U1C2E1E0 book Page 5 Wednesday August 4 2004 11 57 AM ...

Page 42: ...r 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 11 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 t...

Page 43: ...ECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage...

Page 44: ...ry 1000 km and after washing the motorcycle or riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand centerstand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for o...

Page 45: ...t and rear brake switches Check operation 27 Moving parts and ca bles Lubricate 28 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 29 Air induction system Check the air cut off valve reed valve and hose for dam age Replace the entire air induction system if necessary 30 Muffler and exhaust ...

Page 46: ...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 U1C2E1E0 book Page 5 Wednesday August 4 2004 11 57 AM ...

Page 47: ... to this section each time a panel needs to be removed and installed EAU19292 Panels A and C To remove one of the panels Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screw 1 Panel A 2 Panel B 1 Panel C 2 Panel D 1 Panel A 2 Screw 1 Panel C 2 Screw U1C2E1E0 book Page 6 Wednesday August 4 2004 11 57 AM ...

Page 48: ... the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that...

Page 49: ...ssible 4 Install the spark plug cap EAU19890 Engine oil and 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 the center stand NOTE Make sure that the vehicle is posit...

Page 50: ...e engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter car tridge is not being replaced When draining the engine oil use a funnel or similar device to keep the oil away from the exhaust pipe 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...

Page 51: ... a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and 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 1 O ring 1 Torque wrench Tighten...

Page 52: ... 1 Place the vehicle on the center stand NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum lev...

Page 53: ...WA10380 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 radia tor If the engine overheats see page 6 39 for further instructions EAU20431 To change the coolant 1 Place the vehicle on the center stand and let the engine cool if necessary 2 Remove panels A and B See page 6 6 3 Place ...

Page 54: ...ced 9 Install the radiator cap start the engine let it idle for several min utes and then turn it off 10 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 11 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximu...

Page 55: ...t dis connect the fuel hoses WARNING EWA10410 Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage 4 Remove panels A and C See page 6 6 5 Pull the rubber cover off its hold ers 6 Remove the air filter case cover by removing the screws 7 Pull the air filter element out 8 Lightly tap the air f...

Page 56: ...rubber cover in the origi nal position 12 Install the panels 13 Install the fuel tank by installing the bolts WARNING EWA11290 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 pinc...

Page 57: ... of or damage to the engine EAU21320 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 and if necessary adjust...

Page 58: ...cified 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 t...

Page 59: ... 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 with...

Page 60: ...l 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 specified repl...

Page 61: ...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 fr...

Page 62: ...s on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22321 Checking the front and rear brake pads Front brake Rear brake 1 Rear br...

Page 63: ...system possibly caus ing it to become ineffective Before riding check that the 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 su...

Page 64: ...e 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 checked...

Page 65: ...arks 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 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 and then t...

Page 66: ... 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 ride and ...

Page 67: ...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 EAU23140 Checking and lubricating the brake and clutch levers 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 al...

Page 68: ...er check or re pair it EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart EAU23250 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap ba...

Page 69: ... check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubricati...

Page 70: ...heck the wheel bearings EAU33650 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when 1 Ne...

Page 71: ...e 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 place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 Aft...

Page 72: ... extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Main fuse 2 Headlight fuse 3 Radiator fan fuse 4 Ignition fuse 5 Signaling system fuse 6 Backup fuse for odometer and clock 7 Turn signal light and ...

Page 73: ...as cooled down 4 Place a new headlight bulb into po sition and then 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 f...

Page 74: ...e light bulb cover 3 Remove the socket together with the bulb by turning it counter clockwise 4 Remove the defective bulb by pushing it in and turning it counter clockwise 5 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the bulb cover 8 Install the seat 1 Tail brake light bulb co...

Page 75: ...liary 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 D if replacing the left auxiliary light bulb or panel B if replacing the right auxiliary light bulb See page 6 6 2 Remove the auxiliary light socket together with the coupler by turn ing the socket counterclockwise 3 Remove the defective bulb by pull ing it o...

Page 76: ...e wheel axle out and then remove the wheel EAU25020 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 brake hose ...

Page 77: ...ake caliper bolts 2 Place the motorcycle on the cen terstand 3 Disconnect the brake torque rod from the brake caliper by removing the nut and the bolt 4 Remove the axle nut then the brake caliper by removing the bolts CAUTION ECA11300 Do not apply the brake after the brake caliper has been removed otherwise the brake pads will be forced shut 5 Loosen the locknut on each side of the swingarm 1 Axle...

Page 78: ... 3 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 23 4 Connect the brake torque rod to the brake caliper bracket by install ing the bolt and the nut 5 Install the brake caliper by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc 6 Take the motorcycle off t...

Page 79: ...roubleshooting 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 80: ...pression 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 Th...

Page 81: ...issing 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 the...

Page 82: ...irt 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 pl...

Page 83: ...n 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 re moved through polishing 4 To prevent corrosion it is recom m...

Page 84: ...chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Pe...

Page 85: ...els are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 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 ...

Page 86: ...t With oil filter cartridge replacement 3 00 L 3 17 US qt 2 64 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt Radiator capacity including all routes 2 40 L 2 54 US qt 2 11 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 21 0 L 5 55 US gal 4 62 Imp gal Fuel reserve a...

Page 87: ...condition 90 189 kg 198 417 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 MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Si...

Page 88: ...ary light 12 V 5 0 W 2 Meter lighting 12 V 2 0 W 3 Neutral indicator light 14 V 1 4 W 1 High beam indicator light 14 V 1 4 W 1 Oil level warning light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 4 W 2 Fuel level warning light 12 V 2 0 W 1 Coolant temperature warning light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Signaling system fuse 20 0 A Ignition fuse 20 0 A Radiator fan fuse 10 0 A...

Page 89: ...ification number The key identification 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 ma...

Page 90: ...bel is affixed to the frame under the seat See page 3 11 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 U1C2E1E0 book Page 2 Wednesday August 4 2004 11 57 AM ...

Page 91: ... tank breather hose 3 10 Fuel tank cap 3 9 Fuses replacing 6 31 H Handlebar switches 3 6 Hazard switch 3 7 Headlight bulb replacing 6 32 Helmet holder 3 12 High beam indicator light 3 2 Horn switch 3 7 I Identification numbers 9 1 Ignition circuit cut off system 3 18 Indicator and warning lights 3 2 K Key identification number 9 1 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator...

Page 92: ...roubleshooting charts 6 39 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 34 Turn signal switch 3 6 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 29 Wheel front 6 35 Wheel rear 6 36 Wheels 6 20 U1C2E1E0 book Page 2 Wednesday August 4 2004 11 57 AM ...

Page 93: ...U1C2E1E0 book Page 3 Wednesday August 4 2004 11 57 AM ...

Page 94: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 08 0 3 1 CR E ...

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