Yamaha FZ07HC 2016 Owner'S Manual Download Page 59

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Perio

ic maintenance an

justment

7-8



Hydraulic brake service

• After disassembling the brake master cylinders and calipers, always 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 brake

fluid.

• Replace the brake hoses every four years and if cracked or damaged.

UBU210E0.book Page 8 Thursday, November 3, 2016 1:02 PM

Summary of Contents for FZ07HC 2016

Page 1: ...DIC183 BU2 28199 10 FZ07H FZ07HC FZ07AH FZ07AHC OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 30 56...

Page 2: ...EAU10043 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UBU210E0 book Page 1 Thursday November 3 2016 1 02 PM...

Page 3: ...To maintain these 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 Y...

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: ...amaha Motor Corporation U S A 1st edition October 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P...

Page 6: ...t for the emission control system 7 3 General maintenance and lubrication chart 7 4 Checking the spark plugs 7 9 Canister for California 7 10 Engine oil and oil filter cartridge 7 10 Coolant 7 13 Repl...

Page 7: ...ooting 7 42 Troubleshooting charts 7 44 Motorcycle care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 Specifications 9 1 Consumer information 10 1 Identification numbers 10 1 Diagnostic...

Page 8: ...They 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 avai...

Page 9: ...CUUM HOSE ROUTING 34B 21684 00 INTAKE MANIFOLD PRESS SENSOR WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and...

Page 10: ...s Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 80 TIRE INFORMATION Cold tire normal pressure should be set as follows FRONT REAR 22...

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: ...ain 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 a...

Page 13: ...id 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 with th...

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 20 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: ...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 23 6 Right handlebar switches page 4 10 7 Throttle g...

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: ...ight 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 warnin...

Page 21: ...ntinue 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 t...

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: ...vehicle s traveling speed Tachometer The 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 r...

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: ...on au tomatically 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...

Page 26: ...button 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 a...

Page 27: ...he 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: ...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: ...he 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 h...

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: ...l 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 th...

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: ...is model is equipped with a catalytic converter in the exhaust system WARNING EWA10863 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possibl...

Page 35: ...ey in that posi tion lift the rear of the passenger seat and pull it backward To install the passenger seat 1 Insert the projections on the front of the passenger seat into the seat holders as shown a...

Page 36: ...ll the passenger seat TIP Make sure that the seats are properly secured before riding EAU59981 Helmet holding cable A helmet holding cable is located on the bottom of the passenger seat Use this cable...

Page 37: ...5 Install the passenger seat WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident EWA10162 To release a hel...

Page 38: ...AU47001 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring NOTICE ECA10102 To avoid damaging the mechanism do not attempt to turn beyo...

Page 39: ...way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any servic...

Page 40: ...certain situa tions See the following section for an explanation of the ignition circuit cut off system WARNING EWA10242 The vehicle must not be ridden with the sidestand down or if the side stand can...

Page 41: ...ion is in gear and the sidestand is up but the clutch le ver is not pulled It prevents starting when the transmission is in gear and the clutch lever is pulled but the side stand is still down It cuts...

Page 42: ...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 43: ...functions 4 25 4 EAU70641 Auxiliary DC connector This vehicle is equipped with an auxil iary DC connector Consult your Yamaha dealer before installing any accessories UBU210E0 book Page 25 Thursday N...

Page 44: ...ts 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 45: ...e grip free play and lubricate ca ble and grip housing 7 17 7 27 Control cables Make sure that operation is smooth Lubricate if necessary 7 27 Drive chain Check chain slack Adjust if necessary Check c...

Page 46: ...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 47: ...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 for...

Page 48: ...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 49: ...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 Release...

Page 50: ...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 51: ...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 52: ...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 53: ...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 54: ...hs 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 S...

Page 55: ...Check the error codes 2 Air filter element Replace Every 24000 mi 37000 km 3 Air filter check hose Clean 4 Clutch Check operation Adjust or replace cable 5 Front brake Check operation fluid level and...

Page 56: ...chain lubricant thoroughly Every 500 mi 800 km 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 57: ...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 58: ...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 59: ...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 b...

Page 60: ...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 61: ...e and lubrication chart To check the engine oil level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the en...

Page 62: ...7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 6 Apply a thin coat of clean en...

Page 63: ...gher Make sure that no foreign mate rial enters the crankcase 10 Check the O ring for damage and replace it if necessary 11 Install and tighten the engine oil filler cap 12 Start the engine and then l...

Page 64: ...l 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion TIP The coolant level must be checked on a cold engine since the level varies with engine tem perature Make sure that the...

Page 65: ...wise the effectiveness of the coolant will be reduced ECA10473 EAU59863 To change the coolant 1 Place the vehicle on a level surfa ce and let the engine cool if neces sary 2 Place a container under th...

Page 66: ...t the engine let it idle for sev eral minutes and then turn it off 15 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of...

Page 67: ...ls specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the air filter element more frequently if you are riding in unusually wet or dusty areas However the air fil...

Page 68: ...on ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the...

Page 69: ...e lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional...

Page 70: ...ve been approved for this model by Yamaha WARNING EWA10601 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 o...

Page 71: ...dically 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...

Page 72: ...braking performance which may re sult in loss of control and an acci dent EAU57070 Brake light switches For non ABS models The brake light which is activated by the brake pedal and brake lever should...

Page 73: ...ich allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has wo...

Page 74: ...k age Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water or dust does not enter the brake fluid reservoir wh...

Page 75: ...damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU22762 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary...

Page 76: ...1 Loosen the locknut at each end of the swingarm and then loosen the axle nut 2 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc tion a To loos...

Page 77: ...e chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft bru...

Page 78: ...ked before each ride In addition the cable should be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make...

Page 79: ...ke and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Brake lever Clutch lever Recommended lubricant Lithium soap based grease Recommended lub...

Page 80: ...perator re sulting in a possible loss of control EAU23252 Lubricating the rear suspen sion The pivoting points of the rear suspen sion must be lubricated by a Yamaha dealer at the intervals specified...

Page 81: ...times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23285...

Page 82: ...s sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID...

Page 83: ...stored for more than two months check it at least once a month and fully char ge it if necessary 3 Fully charge the battery before installation NOTICE When in stalling the battery be sure to turn the...

Page 84: ...Parking lighting fuse 8 Auxiliary fuse 9 Spare fuse 7 8 1 2 3 4 5 6 9 9 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 f...

Page 85: ...b 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 oughl...

Page 86: ...osition then secure it with the bulb holder 5 Install the headlight bulb cover then connect the coupler 6 Install the headlight unit as shown and then install the washer and bolt on each side 7 Have a...

Page 87: ...terclockwise 3 Remove the burnt out bulb by pulling it out of the socket 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the headlight...

Page 88: ...e 3 Remove the burnt out bulb by pulling it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the turn signal light unit by installi...

Page 89: ...nstall the license plate light unit by installing the collars washers and nuts EAU67131 Supporting the motorcycle Since this model is not equipped with a centerstand use maintenance stands when removi...

Page 90: ...in the previous section Supporting the motorcycle 3 Remove the brake hose holder on the left side by removing the bolt 4 Remove the reflector and the brake caliper on each side by re moving the bolts...

Page 91: ...nch bolt to the specified torques 8 Push down hard on the handlebar several times to check for proper fork operation EAU44802 Rear wheel for non ABS models WARNING EWA14841 For the ABS model have a Ya...

Page 92: ...rting the brake caliper and slightly lifting the wheel pull the wheel axle out and remove the drive chain slack adjusting plate TIP A rubber mallet may be useful to tap the wheel axle out 7 Remove the...

Page 93: ...cur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedu...

Page 94: ...dic maintenance and adjustment 7 43 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage UBU210E0 book Page 43 Thursday November 3 2016 1...

Page 95: ...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 96: ...s 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 ch...

Page 97: ...et 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 R...

Page 98: ...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 is...

Page 99: ...o 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 pro...

Page 100: ...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 an...

Page 101: ...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 maxim...

Page 102: ...175 kg 386 lb FZ07H FZ07HC Total 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 W...

Page 103: ...ndicator 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 FZ07AHC Fuse s Mai...

Page 104: ...UMBER 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 this...

Page 105: ...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 106: ...Consumer information 10 3 10 EAU69910 Diagnostic connector The diagnostic connector is located as shown 1 Diagnostic connector 1 UBU210E0 book Page 3 Thursday November 3 2016 1 02 PM...

Page 107: ...finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor C...

Page 108: ...e for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or...

Page 109: ...er 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 600 mi 1000 km or 1 month 400...

Page 110: ...tion 10 7 10 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks UBU210E0 book Page 7 Thursday November...

Page 111: ...er s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be inspected and registered for warranty by...

Page 112: ...later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can...

Page 113: ...repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is includ...

Page 114: ...d protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help...

Page 115: ...overflow 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 swit...

Page 116: ...Turn signal indicator lights 4 2 Turn signal light bulb replacing 7 37 Turn signal switch 4 10 V Valve clearance 7 17 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1...

Page 117: ...ight 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 engineer...

Page 118: ...DIC183 PRINTED IN JAPAN 2016 11 1 7 1 CR E PRINTED ON RECYCLED PAPER...

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