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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

6

EAU22390

Checking the front and rear
brake pads

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

EAU36890

Front brake pads

Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn to

the point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.

EAU22500

Rear brake pads

Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.

EAU22571

Checking the brake fluid level

Front brake

Rear brake

Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.

1. Brake pad wear indicator

1. Lining thickness

1. Minimum level mark

1. Minimum level mark

U2D121E0.book Page 19 Tuesday, September 19, 2006 1:30 PM

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Summary of Contents for FZ1-NW

Page 1: ...2D1 28199 21 FZ1 NW OWNER S MANUAL ProCarManuals com ...

Page 2: ...U2D121E0 book Page 2 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 3: ...ll advantages of your FZ1 NW The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yama...

Page 4: ...e any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the mo...

Page 5: ...Yamaha Motor Co Ltd 1st edition September 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2D121E0 book Page 2 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 6: ...lubrication chart 6 2 Removing and installing the panel 6 6 Checking the spark plugs 6 6 Engine oil and oil filter cartridge 6 7 Coolant 6 10 Replacing the air filter element 6 12 Adjusting the engine idling speed 6 14 Checking the throttle cable free play 6 14 Valve clearance 6 15 Tires 6 15 Cast wheels 6 17 Adjusting the clutch lever free play 6 18 Adjusting the rear brake light switch 6 18 Chec...

Page 7: ...heel 6 34 Rear wheel 6 35 Troubleshooting 6 37 Troubleshooting charts 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U2D121E0 book Page 2 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 8: ...en 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 motorists can...

Page 9: ...gles 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 exhaust syst...

Page 10: ...e 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 clearance limit ...

Page 11: ...tilation 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 D...

Page 12: ...NFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2D121E0 book Page 5 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 13: ... 90 kgf cm2 42 psi 5VY 21668 00 TIRE INFORMATION 2 1 3 Before you operate this vehicle read the owner s manual Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5PA 21568 00 U2D121E0 book Page 6 Tuesday...

Page 14: ...stem fuse page 6 28 6 Storage compartment page 3 17 7 Passenger seat lock page 3 15 8 Shock absorber assembly spring preload adjusting ring page 3 19 9 Shock absorber assembly rebound damping force adjusting screw page 3 19 10 Shift pedal page 3 12 11 Idle adjusting screw page 6 14 12 Engine oil drain bolt page 6 7 13 Engine oil filter cartridge page 6 7 U2D121E0 book Page 1 Tuesday September 19 2...

Page 15: ...ttery page 6 27 6 Rear brake fluid reservoir page 6 19 7 Engine oil filler cap page 6 7 8 Front brake fluid reservoir page 6 19 9 Front fork rebound damping force adjusting screw page 3 17 10 Engine oil level check window page 6 7 11 Brake pedal page 3 13 12 Coolant reservoir page 6 10 U2D121E0 book Page 2 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 16: ...3 12 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 6 5 Right handlebar switches page 3 11 6 Throttle grip page 6 14 7 Brake lever page 3 13 U2D121E0 book Page 3 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 17: ...the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re regis tering key in...

Page 18: ...light li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key c...

Page 19: ...l other electrical systems are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to t...

Page 20: ...eleration but this is not a malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11423 Coola...

Page 21: ... with riding 117 139 C 243 283 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 38 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 38 U2D121E0 book Page 5 Tuesday September 19 2006 1 30 PM ...

Page 22: ...k the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer system is still enabled This model is also equipped with a self diagnosis device for the immobilizer system See page 3 6 for an explana tion...

Page 23: ... engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 12000 r min and above Clock The clock displays when the key is turned to ON In addition the clock can b...

Page 24: ...order F TRIP TRIP A TRIP B ODO F TRIP To reset a tripmeter select it by push ing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter The fuel meter indicates the amount of fuel in the fuel ta...

Page 25: ...ke temperature is set to be displayed the coolant temperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed for one second and then the air in take temperature is displ...

Page 26: ...re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle CAUTION ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage LCD and tachometer brightness control mode This f...

Page 27: ...itch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU4170...

Page 28: ...lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 22 EAU12870 Shift pedal The shift pe...

Page 29: ...dal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13072 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in ...

Page 30: ...lling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13330 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de...

Page 31: ...mages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU39322 Seats Passenger seat To remove the passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 Pull the ...

Page 32: ...n and then pull the seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock it in place 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Rider seat lock lever 1 Projection 2 Seat holder U2D121E0 book Page 16 Tuesday September 19 2006 1 30 PM...

Page 33: ...with a com pression damping force adjusting screw WARNING EWA14670 Always adjust the spring preload on both fork legs equally 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 adjus...

Page 34: ...com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b NOTE Be sure to perform this adjustment on the left front fork leg CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload setting Minimum soft 8 Standard 5 5 Maximum hard 0 1 Rebound damping force adjusting screw Rebound damping ...

Page 35: ...ing ring and a rebound damping force adjusting screw CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE Align the approp...

Page 36: ...A10220 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 flame ...

Page 37: ...l is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor CAUTION ECA15610 The EXUP system has been set and extensively tested at the Yamaha factory Changing these settin...

Page 38: ...n sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission ...

Page 39: ...ne 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 should not b...

Page 40: ...refore 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 working prop...

Page 41: ...gy 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 19 6 19 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 reservoir If nece...

Page 42: ... 6 17 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 23 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if neces...

Page 43: ...ed and the 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 22 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15400 The following warning lights and in dicator light should come on for a few seconds then go off O...

Page 44: ...Yamaha dealer check the cause The immobilizer system indica tor light should come on when the key is turned to ON and then go off after a few seconds If the indicator light does not come on or does not go off or if it flashes and the display indi cates a two digit error code have a Yamaha dealer check the electrical circuit CAUTION ECA11040 For maximum engine life never ac celerate hard when the e...

Page 45: ...ne while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow...

Page 46: ...e break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the 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 ECA103...

Page 47: ...ar with mainte nance work have a Yamaha dealer do it for you EAU17541 Owner s tool kit The owner s tool kit is located under the passenger seat See page 3 15 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 torque wrench may be ...

Page 48: ...00 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fl...

Page 49: ...h lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Chec...

Page 50: ...very 3 years 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 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 28 Air induction system Check the air cut off valve reed valve and hose for dam age Replace the entire air induction system if necessary 29 ...

Page 51: ...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 U2D121E0 book Page 5 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 52: ...ly erode they should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine sho...

Page 53: ...ist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU19902 Engine oil and oil filter car tridge 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 ve...

Page 54: ...engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 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 to the O ring of the new oil filter car tridge 1 Engine oil f...

Page 55: ... 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 Tightening torqu...

Page 56: ...heck the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 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...

Page 57: ...nt will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 38 for further instructions EAU33030 Changing the coolant WARNING EWA10380 Never attempt to remove the radiator cap when the engine...

Page 58: ...ont of the fuel tank and then tilt it back and away from the air filter case Do not disconnect 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 5 Remove the air filter case cover by removing the screws CAUTION ECA12880 When removing the air filter case cov...

Page 59: ...WA11360 Before placing the fuel tank in the original position make sure that the fuel hoses are not dam aged If any fuel hose is dam aged do not start the engine but have a Yamaha dealer replace the hose otherwise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose and the fuel tank overflow hose in the original...

Page 60: ...e adjusting screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle gri...

Page 61: ...mperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your ...

Page 62: ...aha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control 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 knowl edge and experience NOTE The tire tread depth limits may differ from country ...

Page 63: ...adjust the tire air pres sure according to the operating conditions EAU21960 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repa...

Page 64: ...Yamaha dealer check the internal clutch mechanism EAU22270 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary 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 ...

Page 65: ...ake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EAU22571 Checking the brake fluid le...

Page 66: ...erformance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid l...

Page 67: ...ck nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper whe...

Page 68: ...shing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or an...

Page 69: ...l cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift peda...

Page 70: ...eration 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 all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease U2D121E0 book Page 24 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 71: ...enance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check...

Page 72: ...he vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is...

Page 73: ... 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 the battery tends to discharge more 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 i...

Page 74: ...s follows NOTE Include steps 2 and 6 only for the fuel injection system fuse 1 Turn the key to OFF and turn off the electrical circuit in question 2 Unhook the battery band and then remove the battery cover 1 Main fuse 2 Fuse box 3 Fuel injection system fuse 4 Fuel injection system spare fuse 1 Fuse box 2 Ignition fuse 3 Signaling system fuse 4 Taillight fuse 5 Backup fuse for odometer clock and i...

Page 75: ... if the device operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 Install the battery cover and then hook the battery band onto the holder 1 Battery band 2 Battery cover 1 Fuel injection system fuse 2 Fuel injection system spare fuse Specified fuses Main fuse 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Fuel injection...

Page 76: ...products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off...

Page 77: ...ket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the passenger seat EAU24202 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it c...

Page 78: ...her with the bulb by pushing it in 6 Install the license plate light unit by installing the screws EAU39381 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove the headlight unit by re moving the bolts on each side 2 Remove the auxiliary light coupler bracket by removing the screws 1 Screw 2 License...

Page 79: ...rcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 ...

Page 80: ...e pinch bolt then the wheel axle and the brake caliper bolts 2 Lift the front wheel off the ground according to the procedure on page 6 33 3 Remove the brake hose holder on each side by removing the bolt and nut 4 Remove the brake caliper on each side by removing the bolts CAUTION ECA11050 Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shu...

Page 81: ... the wheel axle pinch bolt and the brake cali per bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU25311 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the axle nut Tighte...

Page 82: ...11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU39411 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the left hand side NOTE Make sure that the slot in the brake caliper bracket is fit over the retain er on the swingarm Make sure that there is en...

Page 83: ...ting 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 or have a ...

Page 84: ...o compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Batte...

Page 85: ...own 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 cooling system for leakage Have...

Page 86: ...let with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always r...

Page 87: ...rea is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 ...

Page 88: ...with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26180 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp...

Page 89: ...he spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becomin...

Page 90: ...cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 25 L 2 38 US qt 1 98 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve amount 3 4 L 0...

Page 91: ...f cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 196 kg 198 432 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 MT6 00 Front brake Type Dual disc brake Operation Right hand operati...

Page 92: ...uxiliary light 12 V 5 0 W 2 License plate light 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 10 0 A Signaling system fuse 10 ...

Page 93: ... number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle ...

Page 94: ...ITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or elem...

Page 95: ...rs 9 1 Ignition circuit cut off system 3 22 Immobilizer system 3 1 Immobilizer system indicator light 3 6 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 32 Luggage strap holders 3 21 M Main switch steering lock 3 2 Matte color caution 7 1 Model label 9 2 Multi function meter unit 3 6 N Neutral indicator light 3 4 Noise...

Page 96: ... Turn signal light bulb replacing 6 31 Turn signal switch 3 11 V Valve clearance 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 26 Wheel front 6 34 Wheel rear 6 35 Wheels 6 17 U2D121E0 book Page 2 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 97: ...U2D121E0 book Page 3 Tuesday September 19 2006 1 30 PM ProCarManuals com ...

Page 98: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 10 0 3 1 CR E ProCarManuals com ...

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