Yamaha FZ-07 2016 Owner'S Manual Download Page 70 | Manualshive

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background image

Perio

d

ic maintenance an

d

a

d

justment

7-20

7

EAU33893

A

d

justin

g

the clutch lever free

play

Measure the clutch lever free play as
shown.

Periodically check the clutch lever free
play and, if necessary, adjust it as fol-
lows.
To increase the clutch lever free play,
turn the clutch lever free play adjusting
bolt at the clutch lever in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).

TIP

If the specified clutch lever free play
cannot be obtained as described
above, proceed as follows.

1. Fully turn the adjusting bolt at the

clutch lever in direction (a) to loos-
en the clutch cable.

2. Loosen the locknut at the crank-

case.

3. To increase the clutch lever free

play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free
play, turn the adjusting nut in di-
rection (b).

4. Tighten the locknut.

EAU37914

Checkin

g

the

b

rake lever free

play

There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.

WARNING

EWA14212

A soft or spon

g

y feelin

g

in the

b

rake

lever can in

d

icate the presence of

air in the hy

d

raulic system. If there is

air in the hy

d

raulic system, have a

Yamaha

d

ealer

b

lee

d

the system

b

e-

fore operatin

g

the vehicle. Air in the

hy

d

raulic system will

d

iminish the

1. Clutch lever free play adjusting bolt
2. Clutch lever free play

Clutch lever free play:

5.0–10.0 mm (0.20–0.39 in)

2

1

(b)

(a)

1. Locknut
2. Clutch lever free play adjusting nut

1

2

(a)

(b)

1. No brake lever free play

1

UBU270E0.book Page 20 Monday, November 14, 2016 8:53 AM

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Summary of Contents for FZ-07 2016

Page 1: ...DIC183 FZ07H FZ07AH OWNER S MANUAL Read this manual carefully before operating this vehicle BU2 28199 70 English E...

Page 2: ...EAU46093 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UBU270E0 book Page 1 Monday November 14 2016 8 53 AM...

Page 3: ...high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually...

Page 4: ...ial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or s...

Page 5: ...NUAL 2016 by Yamaha Motor Co Ltd 1st edition October 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed i...

Page 6: ...for the emission control system 7 3 General maintenance and lubrication chart 7 4 Checking the spark plugs 7 9 Engine oil and oil filter cartridge 7 10 Coolant 7 13 Replacing the air filter element an...

Page 7: ...S models 7 38 Rear wheel for non ABS models 7 40 Troubleshooting 7 42 Troubleshooting charts 7 43 Motorcycle care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 Specifications 9 1 Consum...

Page 8: ...y contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is availab...

Page 9: ...e 3JJ 28446 B1 1 5 kg 3 lb 3SA 24877 B1 CHARGE LIMITE 1 5 kg 3 lbs 3SA 24877 A0 LOAD LIMIT TIRE INFORMATION Cold tire normal pressure should be set as follows FRONT REAR 225 kPa 2 25 kgf cm 33 psi 250...

Page 10: ...8 10 INFORMATION SUR LES PNEUS AVERTISSEMENT LIRE LE MANUEL DU PROPRIETAIRE AINSI QUE TOUTES LES ETIQUETTES AVANT D UTILISER CE VEHICULE TOUJOURS PORTER UN CASQUE DE MOTOCYCLISTE APPROUVE des lunettes...

Page 11: ...Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibilit...

Page 12: ...main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry...

Page 13: ...d To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along...

Page 14: ...ange any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep...

Page 15: ...truc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leak...

Page 16: ...t page 4 19 3 Owner s tool kit page 7 2 4 Shift pedal page 4 12 5 Engine oil filler cap page 7 10 6 Engine oil drain bolt page 7 10 7 Engine oil level check window page 7 10 8 Engine oil filter cartri...

Page 17: ...Shock absorber assembly spring preload adjusting ring page 4 20 4 Fuel tank cap page 4 14 5 Headlight page 7 34 6 Coolant drain bolt page 7 14 7 Brake pedal page 4 12 8 Rear brake light switch page 7...

Page 18: ...1 2 Left handlebar switches page 4 10 3 Multi function meter unit page 4 4 4 Main switch steering lock page 4 1 5 Front brake fluid reservoir page 7 22 6 Right handlebar switches page 4 10 7 Throttle...

Page 19: ...ntil the key is turned to OFF even if the engine stalls EAU10662 OFF All electrical systems are off The key can be removed WARNING EWA10062 Never turn the key to OFF or LOCK while the vehicle is movin...

Page 20: ...light comes on when the high beam of the headlight is switched on EAU59962 Oil pressure warning light This warning light comes on if the en gine oil pressure is low The electrical circuit of the warni...

Page 21: ...ontinue to operate the en gine if it is overheating TIP For radiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If...

Page 22: ...the brake system re verts to conventional braking If ei ther of the above occurs or if the warning light does not come on at all use extra caution to avoid possi ble wheel lock during emergency braki...

Page 23: ...tachometer allows the rider to monitor the engine speed and keep it within the ideal power range NOTICE ECA10032 Do not operate the engine in the ta chometer red zone Red zone 10000 r min and above Cl...

Page 24: ...ng indicator will flash repeatedly If this occurs have a Yamaha dealer check the vehicle Eco indicator The eco indicator comes on when the vehicle is being operated in an environ mentally friendly fue...

Page 25: ...omatically while the brightness control mode is accessed sepa rately Odometer and tripmeters The odometer shows the total distance traveled by the vehicle The tripmeters show the distance trav eled si...

Page 26: ...ton for one second TIP If traveling at speeds under 20 km h 12 mi h _ _ _ is displayed Average fuel consumption This function calculates the average fuel consumption since it was last re set The avera...

Page 27: ...the temperature reading may be affected by engine heat when riding slowly under 20 km h 12 mi h or when stopped at traffic signals etc Self diagnosis mode This model is equipped with a self di agnosis...

Page 28: ...t Right EAU12352 Pass switch Press this switch to flash the headlight TIP When the dimmer switch is set to the passing switch has no ef fect EAU12401 Dimmer switch Set this switch to for the high beam...

Page 29: ...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...

Page 30: ...a brake lever position adjusting dial To adjust the distance between the brake lever and the throttle grip turn the ad justing dial while holding the lever pushed away from the throttle grip Make sur...

Page 31: ...ECU which will revert the system to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and t...

Page 32: ...el is a fire hazard EAU13222 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10882 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce t...

Page 33: ...valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane nu...

Page 34: ...ust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place wh...

Page 35: ...eat into the seat holders as shown and then push the rear of the seat down to lock it in place 2 Remove the key Rider seat To remove the rider seat 1 Remove the passenger seat and then remove the hexa...

Page 36: ...met to the vehicle To secure a helmet with the helmet holding cable 1 Remove the passenger seat See page 4 17 2 Remove the screwdriver from its holders on the passenger seat and then remove the helmet...

Page 37: ...the cable loops over the screwdriver install the screw driver in its original position and then hook the helmet holding ca ble over the hook on the bottom of the passenger seat 4 Install the passenge...

Page 38: ...crease the spring preload and there by soften the suspension turn the ad justing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorbe...

Page 39: ...r worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service EAU38963 Luggage strap holders There are six luggage strap holders four on the bottom o...

Page 40: ...ff system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair...

Page 41: ...0 Move the sidestand up 11 Keep the clutch lever pulled 12 Slide the switch toward Does the engine start The system is OK The motorcycle can be ridden YES NO YES NO YES NO The neutral switch may not b...

Page 42: ...functions 4 24 4 EAU70641 Auxiliary DC connector This vehicle is equipped with an auxil iary DC connector Consult your Yamaha dealer before installing any accessories UBU270E0 book Page 24 Monday Nov...

Page 43: ...nts ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather hose and overflow hose for obstructions cracks or damage and check hose...

Page 44: ...e grip free play and lubricate ca ble and grip housing 7 16 7 27 Control cables Make sure that operation is smooth Lubricate if necessary 7 26 Drive chain Check chain slack Adjust if necessary Check c...

Page 45: ...ghtened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working c...

Page 46: ...an engine auto stop system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU61932 Starting the engine In order fo...

Page 47: ...o the neutral position The neutral indi cator light should come on If not ask a Yamaha dealer to check the electrical circuit 3 Start the engine by sliding the switch toward If the engine fails to sta...

Page 48: ...clutch lever 7 Follow the same procedure when shifting to the next higher gear TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU58270 To decelerate 1 Releas...

Page 49: ...result in engine overheating must be avoided EAU17094 0 1000 km 0 600 mi Avoid prolonged operation above 5000 r min NOTICE After 1000 km 600 mi of operation the engine oil must be changed and the oil...

Page 50: ...exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn...

Page 51: ...rforming maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while...

Page 52: ...nual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be n...

Page 53: ...DINGS 1000 km 600 mi or 1 month 7000 km 4000 mi or 6 months 13000 km 8000 mi or 12 months 19000 km 12000 mi or 18 months 25000 km 16000 mi or 24 months 31000 km 20000 mi or 30 months 1 Fuel line Check...

Page 54: ...Check the error codes 2 Air filter element Replace Every 37000 km 24000 mi 3 Air filter check hose Clean 4 Clutch Check operation Adjust or replace cable 5 Front brake Check operation fluid level and...

Page 55: ...chain lubricant thoroughly Every 800 km 500 mi and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing assemblies for looseness Moderately repack...

Page 56: ...ck operation and for oil leak age Replace if necessary 23 Shock absorber as sembly Check operation and for oil leak age Replace if necessary 24 Rear suspension link pivots Apply lithium soap based gre...

Page 57: ...t 28 Front and rear brake switches Check operation 29 Control cables Apply Yamaha cable lubricant or other suitable cable lubricant thoroughly 30 Throttle grip Check operation Check throttle grip free...

Page 58: ...s change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the...

Page 59: ...cessive 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...

Page 60: ...the bottom left side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommend...

Page 61: ...w oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 8 Install the engine oil drain bolt and its new gasket and then tighten the bolt to th...

Page 62: ...ler cap 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause TIP After the engine is...

Page 63: ...nimum and maximum level marks 3 If the coolant is at or below the mi nimum level mark remove the res ervoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the ra diator cap...

Page 64: ...ove the coolant reservoir cov er by removing the bolt and quick fastener and then remove the coolant reservoir 5 Remove the coolant reservoir cap 6 Drain the coolant from the coolant reservoir by turn...

Page 65: ...coolant until it reaches the top of the radi ator and then install the radiator cap and radiator cap retaining bolt 16 Check the coolant level in the res ervoir If necessary remove the coolant reservo...

Page 66: ...ilter check hose can be easily reached and should be frequently checked and cleaned if necessary To clean the air filter check hose 1 Remove the air filter check hose under the air filter case 2 Clean...

Page 67: ...essure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The t...

Page 68: ...o has the necessary professional knowl edge and experience to do so Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal character...

Page 69: ...0 km 60 mi after installing a new tire The tires must be warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions EAU21963 Cast wheels To maximize t...

Page 70: ...h lever free play turn the clutch lever free play adjusting nut in direction a To decrease the clutch lever free play turn the adjusting nut in di rection b 4 Tighten the locknut EAU37914 Checking the...

Page 71: ...a Yamaha dealer Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To mak...

Page 72: ...maha dealer replace the brake pads as a set EAU46292 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassem...

Page 73: ...r or dust does not enter the brake fluid reservoir when refilling Water will significantly lower the boil ing point of the fluid and may re sult in vapor lock and dirt may clog the ABS hydraulic unit...

Page 74: ...nd TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neutral position 3 Push down on the drive chain un der the end of...

Page 75: ...ward TIP Using the alignment marks on each side of the swingarm make sure that both drive chain slack adjusting plates are in the same position for proper wheel alignment 3 Tighten the axle nut and th...

Page 76: ...ive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that...

Page 77: ...lled Even though the cover is installed correctly it does not completely protect the cable from wa ter entry Therefore use care not to pour water directly onto the cover or cable when washing the vehi...

Page 78: ...should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10732 If the sidestand does not move up and down smoothly ha...

Page 79: ...fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakag...

Page 80: ...und See page 7 38 WARNING To avoid injury se curely support the vehicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward and...

Page 81: ...osed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that...

Page 82: ...the fuses The main fuse and the fuse boxes which contain the fuses for the individ ual circuits are located under the rider seat See page 4 17 TIP To access the main fuse remove the starter relay cov...

Page 83: ...tely blows again have a Yamaha dealer check the electrical system 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Backup fuse 2 for ECU 5 Backup fuse for clock 6 Radiator fan motor fuse 7 A...

Page 84: ...hly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do...

Page 85: ...aha dealer adjust the headlight beam if necessary EAU46405 Replacing the auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit See page 7 34 2 R...

Page 86: ...ed with an LED type brake tail light If the brake tail light does not come on have a Yamaha dealer check it EAU43006 Replacing a turn signal light bulb 1 Remove the turn signal light unit by removing...

Page 87: ...ens may break ECA11192 EAU59890 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the nuts washers and collars and then remove the license plate light bulb socke...

Page 88: ...ance that requires the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance EAU44792 Front wheel for non ABS models WARNING EWA14841...

Page 89: ...wheel so that it is on the ground and then put the sidestand down 4 Install the brake calipers and the reflectors by installing the bolts TIP Make sure that there is enough space between the brake pa...

Page 90: ...e locknut and drive chain slack adjusting nut on each side of the swingarm 2 Loosen the axle nut 3 Lift the rear wheel off the ground according to the procedure on page 7 38 4 Remove the axle nut wash...

Page 91: ...the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the rear wheel 1 Install the wheel the brake caliper bracket and the drive c...

Page 92: ...t 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 e...

Page 93: ...ve a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yam...

Page 94: ...ss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is c...

Page 95: ...let with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark plug caps are tightly in stalled 3...

Page 96: ...d detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area i...

Page 97: ...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 TIP Consult a Yamaha dealer for ad vice on what pr...

Page 98: ...e engine over EWA10952 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers a...

Page 99: ...e SG type or higher JASO standard MA Engine oil quantity Oil change 2 30 L 2 43 US qt 2 02 Imp qt With oil filter removal 2 60 L 2 75 US qt 2 29 Imp qt Coolant quantity Coolant reservoir up to the max...

Page 100: ...al weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Front wheel Wheel type Cast wheel Rim size...

Page 101: ...m indicator light LED Oil pressure warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light LED FZ07AH Fuse s Main fus...

Page 102: ...NUMBER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION KEY IDENTIFICATION NUMBER EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record thi...

Page 103: ...is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU48271 Vehicle Emission Control Informa tion label The Vehicle Emission Control...

Page 104: ...Consumer information 10 3 10 EAU69910 Diagnostic connector The diagnostic connector is located as shown 1 Diagnostic connector 1 UBU270E0 book Page 3 Monday November 14 2016 8 53 AM...

Page 105: ...der that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 1000 km 600 mi or 1 month 70...

Page 106: ...ation 10 5 10 55000 km 36000 mi or 54 months 61000 km 40000 mi or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks UBU270E0 book Page 5 Monday November...

Page 107: ...transfer MUST be done by contacting the DEALER who will forward the following information to YAMAHA Section B Subsequent Owner The MOTORCYCLE has been fully assembled and set to the MANUFACTURER s ope...

Page 108: ...ble for special incidental or consequential damages howsoever caused whether by negligence or otherwise resulting directly or indirectly from the use of the MOTORCYCLE or the MOTORCYCLE having replace...

Page 109: ...rflow hose 4 16 Fuel tank cap 4 14 Fuses replacing 7 32 H Handlebar switches 4 10 Hazard switch 4 11 Headlight bulb replacing 7 34 Helmet holding cable 4 18 High beam indicator light 4 2 Horn switch 4...

Page 110: ...Turn signal indicator lights 4 2 Turn signal light bulb replacing 7 36 Turn signal switch 4 10 V Valve clearance 7 17 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1...

Page 111: ...right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha enginee...

Page 112: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2016 11 0 5 1 CR E UBU270E0 book Page 1 Monday November 14 2016 8 53 AM...

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