Yamaha Fazer Owner'S Manual Download

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TABLE OF CONTENTS

Air filter ........................................................... 6-10

Carburetor adjustment ................................. 6-11
Idle speed adjustment ................................. 6-12

Throttle cable free play adjustment ............. 6-12
Valve clearance adjustment ......................... 6-13

Tyres .............................................................. 6-13
Wheels .......................................................... 6-15

Clutch lever free play adjustment ................ 6-16
Rear brake adjustment ................................ 6-17

Brake light switch adjustment ..................... 6-17
Checking front & rear brake shoes .............. 6-18

Checking brake fluid level ............................ 6-18
Drive chain slack check ................................ 6-19

Drive chain slack adjustment ...................... 6-20
Drive chain lubrication .................................. 6-22

Cable inspection and lubrication ................. 6-22
Throttle cable and grip lubrication ............... 6-22

Brake and shift pedal lubrication ................. 6-23
Brake and clutch lever lubrication ................ 6-23

Center and sidestand lubrication ................ 6-23
Front fork inspection ..................................... 6-24

Steering inspection ....................................... 6-24
Wheel bearings ............................................ 6-25

Battery ........................................................... 6-25
Fuse replacement ........................................ 6-27

Headlight bulb replacement ........................ 6-28

Turn signal and taillight bulb
replacement .................................................. 6-29

Front wheel removal ..................................... 6-29
Front wheel installation ................................ 6-30

Rear wheel removal ..................................... 6-31
Rear wheel installation ................................ 6-33

Troubleshooting ........................................... 6-33
Troubleshooting chart .................................. 6-34

CLEANING & STORAGE ................................. 7-1
A. Cleaning ................................................... 7-1

B. Storage ...................................................... 7-2

SPECIFICATIONS ........................................... 8-1

CUSTOMER INFORMATION ........................... 9-1

Key identification number ............................. 9-1

Frame serial number ................................... 9-1
Engine serial number .................................. 9-1

DETACHMENTS

Pre-delivery inspection .............................. 10-1
Installation ................................................. 10-5

GREEN BOOK

fazer5p41.pmd

10/1/2005, 12:57 PM

Summary of Contents for Fazer

Page 1: ...fe intenance Cost haust Smoke Wear and Tear OTOR OIL PRINTED IN INDIA 5P41 FAZER 2Y16 OM 01 234 10 05 Starter Motor Disc Brake Starter Motor Disc Brake OWNER S MANUAL 5P4 E8199 E0 Starter Motor Disc Brake 5P41 ...

Page 2: ...MANUAL YAMAHA MOTOR INDIA PVT LIMITED All rights reserved Any reprinting or unauthorised use without the written permission of YAMAHA MOTOR LIMITED is expressly prohibited INDIA PVT WARNING PLEASEREADTHISMANUALCAREFULLYANDCOMPLETELYBEFOREOPERATINGTHISMOTORCYCLE ...

Page 3: ...ance please take due care and ensure proper maintenance of your Motorcycle as recommended in this Owner s Manual Always demand only YAMAHA Genuine Spare Parts and Yamalube oil If you have any queries regarding the operation or maintenance of your Motorcycle please consult your YAMAHA DEALER who will be too happy to help you This Owner s Manual also includes the GREEN BOOK containing Guidelines DO ...

Page 4: ...e A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this Motorcycle and should remain with it even if the Motorcycle is subsequently sold YAMAHA continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may...

Page 5: ...er 3 7 Kick starter 3 8 Seat 3 8 Storage compartment 3 9 Rear shock absorber adjustment 3 9 Handle Seat Stay Lock 3 10 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 2 Tips for reducing fuel consumption 5 3 Running in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR...

Page 6: ...nd shift pedal lubrication 6 23 Brake and clutch lever lubrication 6 23 Center and sidestand lubrication 6 23 Front fork inspection 6 24 Steering inspection 6 24 Wheel bearings 6 25 Battery 6 25 Fuse replacement 6 27 Headlight bulb replacement 6 28 Turn signal and taillight bulb replacement 6 29 Front wheel removal 6 29 Front wheel installation 6 30 Rear wheel removal 6 31 Rear wheel installation ...

Page 7: ...to know its capabilities and limitations 5 Right thoughtfully planning your route well in advance 6 Give proper Signals and use Horn and Headlights judiciously 7 Don t ride in another motorist s blind spot 8 Always make pre ride safety checks before you start the Engine SAFE BRAKING Use the basic methods of braking effectively 1 Engine Brake When the Throttle is released compression backs up and a...

Page 8: ...hain free play check window page 6 19 9 Side panel L H lock page 6 5 10 Shift pedal page 3 4 1 Fuel cock page 3 6 2 Starter Lever page 3 7 3 Fuse page 6 27 4 Battery page 6 25 5 Storage Compartment page 3 9 STANDARD VEHICLE 2 6 5 4 3 7 8 9 1 10 fazer5p41 pmd 10 1 2005 12 57 PM 6 ...

Page 9: ...Rear shock absorber page 3 9 12 Air filter page 6 10 13 Kick starter page 3 8 14 Seat page 3 8 15 Engine oil filler cap page 6 8 16 Rear brake pedal page 3 5 6 17 15 STANDARD VEHICLE 11 12 13 14 16 fazer5p41 pmd 10 1 2005 12 57 PM 7 ...

Page 10: ...g Lock Page 3 1 21 Tachometer page 3 2 22 Front Brake Lever page 3 4 6 16 23 Throttle Grip page6 12 24 Fuel Tank Cap page 3 5 25 Turn Indicator Switch page 3 2 26 Starter Kill Switch page 3 3 17 18 19 20 21 23 24 25 Controls Instruments DESCRIPTION 22 STANDARD VEHICLE 2 3 26 fazer5p41 pmd 10 1 2005 12 57 PM 8 ...

Page 11: ...CK The steering is locked in this position and all electrical circuits are switched off The key can be removed in this position To lock the steering turn the handle bars all the way to the left or right With the key at OFF push it into the main switch and release it turn it counter clockwise to LOCK and remove it To release the lock turn the key to OFF INSTRUMENT AND CONTROL FUNCTIONS WARNING Neve...

Page 12: ...e left or right This indicator comes on when the transmission is in neutral This indicator comes on when the headlight high beam is used 1 Speedometer 2 Odometer Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer 1 Tachometer Tachometer The Tachometer Indicates Engine Speed RPM and is Pulse Operated 1 1 2 1 2 3 2 D Chapt3 cdr Saturday October01 20051 01 01...

Page 13: ... 3 3 1 PassSwitch 2 Dimmer Switch 3 Light switch 4 Turn signal cum cancellation switch 5 Horn switch Handlebar switches Dimmer switch Turn the switch to for the high beam and to for the low beam Pass switch Press the switch to operate the Passing Light 1 2 3 4 5 Press ON OFF 1 Starter Switch 2 Kill Switch Starter Switch Press the button to start the bike Vehicle should be in 1 Neutral Position 2 I...

Page 14: ... lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 1 1 1 Clutch lever Clutch lever The clutch lever is located on the left handlebar Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation 1 4 D Chap...

Page 15: ...sition with the key inserted To remove the key turn it counterclockwise to the original position Ensure the arrow on fuel tank is towards the Front of the bike when inserting Fuel Tank Cap in Fuel Tank 1 This tank cap cannot be closed unless the key is in the lock The key cannot be removed if the cap is not locked properly Be sure the cap is properly installed and locked in place before riding the...

Page 16: ...inted surfaces or plastic parts Recommended Fuel Fuel tank capacity Regular gasoline Petrol Total 13 0 L Reserve 1 2 L CAUTION IT IS A GOOD PRACTICE TO RETURN THE FUEL COCK LEVER TO Off POSITION WHEN ENGINE IS NOT RUNNING OFF 1 1 Filler tube 2 Fuel level Fuel Make sure there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustration WARNING 1 2 ...

Page 17: ...t the fuel cock to this position Fill the tank at the first opportunity Be sure to set the fuel cock back to ON after refueling 1 Starter lever Starter lever Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move the Starter Lever in Direction a toTurn on the Starter Move the Starter Lever in Direction b toTurn Off the Starter RES 1 a b 7 D ...

Page 18: ...ft and right hand side of the seat ALWAYS USE A HELMET WHILE RIDING FOR YOUR SAFETY 1 2 1 Kick starter Kick starter Raise the right Pillion footrest and rotate the kick starter away from the engine Push the starter down lightly with your foot Kick until the gears engage then kick smoothly and forcefully to start the engine This model has a primary coupled kick starter so the engine can be started ...

Page 19: ...ng preload and in direction b to decrease spring preload Make sure that the appropriate notch in the adjusting ring is aligned with the position indicator on the rear shock absorber Always adjust each shock absorber to the same setting Uneven adjustment can cause poor handling and loss of stability INSTRUMENT AND CONTROL FUNCTIONS 3 9 WARNING Adjusting Position Soft 1 2 3 4 5 Hard Stan dard 1 1 2 ...

Page 20: ...D CONTROL FUNCTIONS 3 10 1 HandleSeat 1 1 1 Stay Lock on Saree Guard Stay Lock For mounting Helmet Lock 10 D Chapt3 cdr Saturday October01 20051 01 06PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscreen ...

Page 21: ...essary Check tyre pressure wear damage and spoke tightness Tighten spokes if necessary Adjust if necessary 6 13 6 15 6 19 6 20 Check oil level Fill with oil if necessary Check chain slack and condition Check operation condition and free play Adjust if necessary Lubricate if necessary Check for smooth operation Adjust if necessary Check operation condition and free play Adjust if necessary Check op...

Page 22: ... bolts and screws are properly tightened Tighten if necessary Check fuel level Fill with fuel if necessary Fill with distilled water if necessary Check fluid level Check for proper operation 6 25 6 26 3 3 6 28 6 29 3 5 3 6 Lubricate if necessary Check for smooth operation Lubricate if necessary Check for smooth operation ITEM CHECKS 6 23 PAGE 6 23 Brake and shift pedal shafts Control and meter cab...

Page 23: ...uel cock to ON 2 Turn the main switch to ON 3 Shift the transmission into neutral When the transmission is in neutral the neutral indicator light should be on If the light does not come on ask a YMI dealer to inspect it 4 Fully open the Starter Lever and completely close the throttle grip 5 Kick the kick starter to start the engine 6 After starting the Engine turn back the Starter Lever to the War...

Page 24: ...ift into neutral depress the shift pedal repeatedly until it reaches the end of its travel then raise the pedal slightly Do not ride downhill with Ignition Switch in OFF Position in Neutral Gear Always ride motor cycle with Ignition Switch in ON Position in Neutral Gear Always use the clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced...

Page 25: ... Motorcycle 7 Plan your route in advance Running in There is never a more important period in the life of your Motorcycle than the period between zero and 1 000 km For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first 1 000 km The various parts in the engine wear and polish themselves to the corr...

Page 26: ...ark the Motorcycle in a place where pedestrians or children are not likely to touch the Motorcycle Do not park the Motorcycle on a slope or soft ground the Motorcycle may overturn IT IS NOT RECOMMENDED TO RIDE THE MOTORCYCLE WITH CONSTANT THROTTLE OPENING FOR VERY LONG DISTANCE 5 4 WARNING 6 CHAPT4_5_6 cdr Saturday October01 20051 02 23PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscre...

Page 27: ...ALS TO MATCH THE ENVIRONMENT The most impor tant points of Motorcycle inspection adjustment and lubrication are explained in the following pages If you are not familiar with Motorcycle service this work should be done by a YAMAHA dealer 1 Tool kit Tool kit The service information included in this manual is intended to provide you the owner with the necessary information for completing some of your...

Page 28: ... operation take your Motorcycle to a YAMAHA dealer for service Modifications to this Motorcycle not approved by YAMAHA may cause loss of performance and render it unsafe for use Consult a YA M A H A d e a l e r b e f o r e attempting any changes 6 2 8 CHAPT4_5_6 cdr Saturday October01 20051 02 24PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscreen ...

Page 29: ...GINE OIL 7 ENGLINE OIL FILTER SCREEN 8 BRAKE REAR 9 BRAKE FLUID LEVEL 11 BRAKE SHOES REAR 10 Check for wear replace if necessary Check Level Refill if necessary 1 TPS Throttle Position Sensor 2 BS Butterfly Slide Valve Screws CAUTION 1 Do not Tamper Adjust with TPS fig 1 2 Do not Open BS Butterfly slide Valve Screws fig 2 BRAKE DISC 12 Check for scoring marks on disc Face and Run out BRAKE PADS 13...

Page 30: ...eck operation and lubricate if necessary 25 Check electrolyte level and top it up if necessary Check specific gravity and charge if required Check breather pipe for blockage and routing 26 BATTERY CONTROL CABLES THROTTLE CLUTCH FRONT BRAKE 27 Readjust or replace as required Check operation free play cable damage EVERY MONTH EVERY 10 000 KMS WHEEL BEARING 19 Check Bearing assembly for looseness dam...

Page 31: ...ed or reinstalled 2 Panel B PERIODIC MAINTENANCE AND MINOR REPAIR 6 5 1 Lug 2 Panel A 3 Lug Removal of Panel A Unlock the panel Pull the lug 1 towards you to remove it from the fuel tank Slide the panel A towards the Front of the motorcycle for removing the lug 3 to free the panel 1 2 2 3 1 1 CHAPT6_A cdr Saturday October01 20051 03 40PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscree...

Page 32: ...orcycle for inserting the lug 2 in the slot given in the frame Insert and push the lug 1 in the fuel tank ensuring proper seating After proper seating of the panel A lock it 1 Lug 2 Lug 3 Lug Installation of Panel B Follow the same procedure as given for installation of panel A and tighten the screw for locking 2 1 1 2 1 2 3 3 2 CHAPT6_A cdr Saturday October01 20051 03 40PM Colorprofile GenericCMY...

Page 33: ...you should replace the spark plug with the specified plug Specified spark plug CR7HSA NGK Before installing the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification as necessary PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 A Spark plug gap 0 6 0 7 mm When installing the plug always clean the gasket surface and use a new gasket Wipe off any grime from the th...

Page 34: ...imum level 2 Minimum level Wait a few minutes until the oil level settles before checking B Unscrew the dipstick and rest it on the threads of the oil filler hole The oil level should be between the minimum and maximum mark on the dip stick If the level is low add oil to raise it to the specified level PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 NOTE 1 Dipstick 2 Engine oil replacement a Warm up the...

Page 35: ...nd install the dipstick Recommended oil YAMALUBE 4 stroke motor oil 20W40 type SG Oil quantity Total amount 1 2 L Periodic oil change 1 0 L PERIODIC MAINTENANCE AND MINOR REPAIR 6 9 f Start the engine and warm up for a few minutes While warming up check for oil leak age If oil leakage is found stop the engine immediately and check for the cause 1 5 CHAPT6_A cdr Saturday October01 20051 03 41PM Col...

Page 36: ...filter element 2 Frame PERIODIC MAINTENANCE AND MINOR REPAIR 6 10 3 Remove the air filter from the case 4 Unlock the spring wire 5 Remove the air filter elements from the frame and clean them with solvent kerosene After cleaning remove the remaining solvent kerosene by squeezing the elements 6 Apply recommended oil to the entire surface of the each element and squeeze out the excess oil They shoul...

Page 37: ... cleaned and lubricated more frequently every 1000 kms if Motorcycle is operated in very dusty e g unpaved dust laden roads conditions Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisti cated adjustments Most adjust ments should be left to a YAMAHA dealer who has the professional knowledge and experience to do so However the following may be serviced by t...

Page 38: ...e engine speed Standard idle speed 1 300 1 500 r min If the specified idle speed cannot be obtained by performing the above adjustment consult a dealer YAMAHA Throttle cable free play adjustment Before checking the throttle cable free play the engine idling speed should be adjusted Adjust the throttle cable by turning the adjusting nut so that specified free play at the throttle grip is obtained F...

Page 39: ...er fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a YAMAHA dealer 1 Tread depth 2 Side wall Tyres To ensure maximum performance long service and safe operation note the following 1 Tyre air pressure Always check and adjust the tyre pressure before operating the Motorcycle PERIODIC MAINTENANCE AND MINOR REPAIR...

Page 40: ...ose to the center of the Motorcy cle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pressure of your tyres NEVER O V E R L O A D Y O U R MOTORCYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc approved for this model does not exceed the maximum load of the Motorcycle Opera...

Page 41: ...lt a YAMAHA dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced 2 Tyres and wheels should be balanced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse handling characteristics and shortened tyre life 3 Ride at moderate speeds after changing a tyre since the tyre surface must fi...

Page 42: ... bolt at the clutch lever in direction b to increase free play or in direction a to decrease free play 3 Tighten the locknut If proper adjustment cannot be obtained or the clutch does not work correctly ask a dealer to inspect the internal clutch mechanism YAMAHA PERIODIC MAINTENANCE AND MINOR REPAIR 6 16 NOTE a b 1 2 3 3 Chapt6_b cdr Saturday October01 20051 04 44PM Colorprofile GenericCMYKprinte...

Page 43: ... light switch adjustment The rear brake light switch is acti vated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect To adjust the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the adjusting nut in direction a to make the brake light come on earlier Turn the adjusting nut in direction...

Page 44: ...e brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to thepoint that the wear indicator reaches the wear limit line have a YAMAHA dealer replace the brake shoes as a set 1 Minimum Level Mark Checking the brake fluid level Insufficient brake fluid may allow air to enter th brake system possibly causing it to become ineffective Before riding c...

Page 45: ...k Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and l e a d t o p o o r b r a k i n g performance or the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have YAMAHAde...

Page 46: ...n the chain adjusting locknuts on each chain puller To tighten the chain turn the chain adjusting nut in direction b to loosen the chain turn the chain adjusting nut in direction a and push the wheel forward Turn each chain adjusting nut exactly the same amount to maintain correct axle alignment There are marks on each chain puller Use these marks to align the rear wheel PERIODIC MAINTENANCE AND M...

Page 47: ...b 9 05 m kg 1 Cotter pin 6 Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown If the notch in the axle nut and the cotter pin hole do not match tighten the nut slightly to align them Always use a new cotter pin on the axle nut 7 Adjust the free play in the brake pedal Check the operation of the brake light after adjusting the rear brake PERIODIC MAINTENANCE AND M...

Page 48: ...ousing of cables may lead to internal rusting and interfere with the cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Lubricate the cables with anti corrosive oil at cable ends If a cable does not operate smoothly ask a YAMAHA dealer to replace it Recommended lubricant YAMALUBE 20W40Type SG Throttle cable and grip lubrication The throttle twist grip assembly s...

Page 49: ...destand lubrication Lubricate the pivoting and mating joints Check to see that the center and sidestand move up and down smoothly If the center and or sidestand does not move smoothly consult a YAMAHAdealer PERIODIC MAINTENANCE AND MINOR REPAIR 6 23 WARNING 10 Chapt6_b cdr Saturday October01 20051 04 48PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscreen ...

Page 50: ...or unsmooth movement is found with the front fork consult aYAMAHAdealer Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be danger ous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward If any free play can be felt ask a YAMAHA dealer to ...

Page 51: ... mark Battery 1 Battery is located inside the L H side panel for removal installation of L H side panel please refer page 6 5 2 Open the lid 3 Check the level of the battery electrolyte and make sure that the terminals are tight Top up with distilled water if the electrolyte level is low PERIODIC MAINTENANCE AND MINOR REPAIR 6 25 WARNING 1 2 MAX MIN 1 Chapt6_c cdr Saturday October01 20051 05 28PM ...

Page 52: ...g or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Replenishing the battery fluid Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water Take care not to spill battery fluid on the chain Battery fluid may weaken the chain causing shorter chain life and possibly result in an accident...

Page 53: ...aged or obstructed 1 Main fuse Fuse replacement The fuse is located behind panel A See page 6 6 for panel removal and installation procedures If the fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of proper amperage Turn on the switches and see if the electrical device operates If the fuse immediately blows again consult a YAMAHA dealer Do not us...

Page 54: ...hever is fused 1 Bulb 2 Nos LH RH Keep flammable products and your hands away from the bulb while it is on as it is hot Do not touch the bulb until it cools down 5 Put a new bulb into position and secure it in place with the bulb holder 6 Install the Head LightAssy 7 If the headlight beam adjustment is necessary ask a YAMAHA dealer to make adjustment PERIODIC MAINTENANCE AND MINOR REPAIR 6 28 WARN...

Page 55: ...l the lense and the screw 1 Integral Tail lamp Screws Nos Do not over tighten the screws as the lense may break 2 with Indicators Front wheel removal It is advisable to have a YAMAHA dealer service the wheel S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over PERIODIC MAINTENANCE AND MINOR REPAIR 6 29 WARNING CAUTION 1 1 1 5 Chapt6_c cdr Saturday October01 20051...

Page 56: ... Wheel 1 Cotter Pin 2 Axle Nut 3 Remove the cotter pin 1 and axle nut 2 4 Remove theAxle 5 Remove the wheel make sure the Motorcycle is properly supported 6 Remove the Front Wheel PERIODIC MAINTENANCE AND MINOR REPAIR 6 30 1 1 2 2 1 6 Chapt6_c cdr Saturday October01 20051 05 31PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscreen ...

Page 57: ...nut is properly torqued and a new cotter pin is installed Always use a new cotter pin Axle nut torque 33 ft lb 4 55 m kg PERIODIC MAINTENANCE AND MINOR REPAIR 6 31 WARNING Rear wheel removal It is advisable to have a YAMAHA dealer service the wheel S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over WARNING 1 7 Chapt6_c cdr Saturday October01 20051 05 32PM Color...

Page 58: ...ake adjusting nut 3 Remove the brake adjusting nut and brake rod from the brake cam lever 4 Remove the axle nut cotter pin and the axle nut 1 Rear axle 5 Pull out the rear axle 6 Remove the wheel assembly PERIODIC MAINTENANCE AND MINOR REPAIR 6 32 ALWAYS USE YAMAHA GENUINE SPARE PARTS 1 2 3 4 8 Chapt6_c cdr Saturday October01 20051 05 33PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscr...

Page 59: ...hooting Although YAMAHA Motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your Motorcycle requires any repair bring it to a YAMAHA dealer The skilled technicians at ...

Page 60: ...in the fuel tank Check if there is fuel Supply fuel Open the throttle half way and start the engine or replace spark plug WARNING Never Check the fuel system while smoking or in the vicinity of an open flame PERIODIC MAINTENANCE AND MINOR REPAIR 6 34 Ask YAMAHA dealer to inspect Troubleshooting chart For Starting 1 Fuel 2 Compression 3 Ignition If Engine does not start Contact YAMAHA dealer 10 Cha...

Page 61: ...ading to its Deterioration CLEANING AND STORAGE 7 1 Improper cleaning can damage the 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 plastic parts Alaways use clean cloth or sponge for cleaning the Motorcycle CAUTION 4 After riding on salted roads wash the Motorcycle with cold wat...

Page 62: ...of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Kick the engine over several times with the ignition off to coat the cylinder wall with oil 4 Remove the drive chain Thoroughly clean the chain with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to frame for safe keeping 5 Lubricate all control cables 6 Block up the frame to raise b...

Page 63: ...ter Wet sump 3 10 8 BHP 7500 RPM 1 06 Kgfm 6500 RPM EngineOil Capacity Air filter Fuel Carburettor Type Periodic oil change 1 0 Total amount 1 2 Type Regular Gasoline Petrol Fuel tank capacity 13 0 Reserve amount Type BS25 Manufacturer M S UCAL Fuel System Be sure to use motor oils that do not contain antifriction modifiers Passenger car motor oils often labelled Energy conserving contain anti fri...

Page 64: ...eration Gear ratio 1st 2 750 2nd 1 688 27 16 3rd 1 200 24 20 4th 0 913 21 23 Frame type Diamond Type Caster angle 26 4 0 Wet multiple disc Left foot operation 33 12 Tyre with Tube Size Front Rear 3 00 Air pressure cold tyre Single Rider Front Rear 32 With Pillion and rider Front Rear 2 75 x18 4PR RIBBED X18 6PR UNIVERSAL 25 psi 1 75 Kgf cm psi 2 25Kgf cm 25 psi 1 75Kgf cm 32 psi 2 25 Kgf cm 2 2 2 ...

Page 65: ...ity Fuse Ignition system DC CDI Digitally Timing Generator system Type Standard output 12V Battery Type Voltage capacity Headlight Tail Brake light Front flasher light Rear flasher light Meter light Tacho Speedo Neutral indicator light High beam indicator light Turn indicator light Main Advanced Flywheel magneto Lead acid 12V 5 0 AH 12V 25W 25W x 2 12V 21W 5W x 1 12V 10 W x 2 12V 10 W x 2 In Built...

Page 66: ...ame serial number The frame serial number is stamped into the steering head pipe on right hand side Frame serial number 1 Engine serial number The engine serial number is stamped into the right hand crankcase Engine serial number 9 1 x x x x 1 CUSTOMER INFORMATION 6 CHAPT7_8_9 cdr Saturday October01 20051 06 36PM Colorprofile GenericCMYKprinterprofile CompositeDefaultscreen ...

Page 67: ...akes Rear Free Play at Rear Brake 20 30 mm b Clutch Free Play at Lever End 10 15 mm c Throttle Free Play at Throttle Grip 3 7 mm d Steering Check for Free Movement e Suspension Front Fork Check for any sticky movement Rear Shock Abs For Free Stroking Setting on both To be filled in by the Dealer on receipt of the Motorcycle from YMI Odo Meter Reading Date of Inspection Frame No Engine No Date of S...

Page 68: ... h Fasteners Specified Torque Ft Lb 1 Front Wheel Axle Nuts 25 40 2 Front Fork Crown Handle Inner Tube 13 20 2 Front Fork under Bracket Stem Nut 18 22 3 Handle Bar Mounting Bolts 13 20 4 Rear Shock Absorber Mounting Bolts 22 35 5 Rear Swing Arm Pivot Shaft Nut 32 52 6 Rear Wheel Axle Sprocket Shaft Nuts 60 70 B ENGINE a Engine Oil Oil Level For checking Refer Pg 6 8 Check for any Leakages 10 2 SER...

Page 69: ... Check for Overflow f Drive Chain Alignment Slackness 20 30 mm g Brake Fluid Fluid Level Refer Page 6 18 h Fasteners Specified Torque Ft Lb 1 Cylinder Head Bolts 14 17 2 Engine Mounting a Engine Mounting Front and Stay Front 25 29 b Stay Engine Front and Frame 25 29 c Engine Mounting Rear and Frame 25 29 d Engine Mounting Upper Stay Engine Upper 25 29 e Stay Engine Upper and Frame 25 29 3 Front an...

Page 70: ...Specific Gravity Routing of Breather Pipe Fuse Routing of Positive Wire Red Below Breather Pipe e Starter Switch Kill Switch D ROAD TEST a Starting b Gear Shifting Operation c Clutch Operation d Application of Brakes Front and Rear e Speedo Odo Meter Operation f Tachometer Operation MAIN SELLING DLR S STAMP SIGN CODE EXPLAINED BY SIGNATURE NAME CUSTOMER S SIGN SERVICE2 PMD 10 1 2005 12 57 PM 4 ...

Page 71: ... pressed 9 Gear shifting pattern 10 Tyre inflation pressure Front 25 Psi Rear 32 Psi Solo 32 Psi Double 11 Never give sudden acceleration always accelerate gradually 12 Simultaneous use of Front and Rear Brakes 13 Checking of Brake Fluid at regular intervals 14 Never ride with your foot on Rear brake Pedal 15 Whenever parking the Motorcycle on the Side Stand ensure that the Fuel Cock Lever is in c...

Page 72: ...Engine Oil in Gear Box level checking and explaining the importance of replacing the Engine Oil after every 2000 KMS Always use YAMALUBE 4T OIL SG Grade 23 TFF oil to be replaced after every 10000 Kms 24 Running In Period Preventive Maintenance Schedule Instructions 25 Information of emission and safety norms 26 Importance and schedule of Free Services 27 Warranty Terms and Conditions INSTALLATION...

Page 73: ...NOTES NOTES IF REQUIRED pmd 10 1 2005 1 14 PM 3 ...

Page 74: ...NOTES NOTES IF REQUIRED pmd 10 1 2005 1 14 PM 2 ...

Page 75: ...CONTENTS DO S DON TS for the Motorcycle 2 3 Procedure for measurement of CO Emission Level 4 List of Components impacting Emission 5 greenbook PMD 10 1 2005 12 57 PM 1 ...

Page 76: ... serves you through a wide network of Authorised Dealers 5 Check the Following at every scheduled service a Spark Plug Check Reset Gap Replace as per the recommendations in this Owner s Manual page no 6 7 b Carburetor Cleaning Adjustment Every 4500 kms c Air Filter Clean every 2000 kms as per the environment conditions d Piston Rings Cylinder Check Clean Replace if necessary e Exhaust System Check...

Page 77: ...Get emission of your Motorcycle inspected at least once every 3 months 11 Please follow good driven habits in varying traffic conditions 12 Switch OFF the engine while waiting at signal point DON TS 1 Don t overload overspeed your Motorcycle 2 Don t after or modify you Motorcycle 3 Never drive with Ignition OFF while moving down a slope 4 Don t turn off the Engine or interrupt the Ignition when th...

Page 78: ...Gas Analyser inside the Exhaust Muffler of the Motorcycle 2 7 If the reading is within specified limits then it is acceptable If the reading exceeds the norm of 3 5 by volume have it adjusted by YAMAHA Authorised Dealer CO EMISSION LEVEL MEASUREMENT 4 MODEL IDLER P M 1300 1500 RPM FAZER 3 LIST OF COMPONENTS IMPACTING EMISSION a Air Filter b Carburetor c Cylinder d Piston Ring Piston e Cylinder Hea...

Page 79: ...Road Faridabad 121 006 INDIA Longer Engine Life Lower Maintenance Cost Lower Exhaust Smoke Reduces Wear and Tear SG 4 STROKE MOTOR OIL 20W40 4 Parts Accessories Always use PRINTED IN INDIA 5P41 FAZER 2Y16 OM 01 234 10 05 Starter Motor Disc Brake 5P41 ...

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