Yamaha FZ1-SW Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-22

6

5. If the drive chain slack is incorrect,

adjust it as follows.

EAU34311

To adjust the drive chain slack

1. Loosen the axle nut and the lock-

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 wheel alignment.

CAUTION:

ECA10570

Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.

3. Tighten the locknuts, then the axle

nut to their specified torques.

Drive chain slack:

25.0–35.0 mm (0.98–1.38 in)

1. Axle nut
2. Locknut

3. Drive chain slack adjusting bolt

4. Alignment marks

Tightening torques:

Locknut:

16 Nm (1.6 m·kgf, 11 ft·lbf)

Axle nut:

150 Nm (15.0 m·kgf, 110 ft·lbf)

U3C321E0.book Page 22 Friday, September 29, 2006 4:57 PM

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Summary of Contents for FZ1-SW

Page 1: ...3C3 28199 21 FZ1 SW OWNER S MANUAL ProCarManuals com ...

Page 2: ...U3C321E0 book Page 2 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 3: ...ll advantages of your FZ1 SW 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 U3C321E0 book Page 2 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 6: ...ing and installing panels 6 6 Checking the spark plugs 6 7 Engine oil and oil filter cartridge 6 8 Coolant 6 11 Replacing the air filter element 6 12 Adjusting the engine idling speed 6 14 Checking the throttle cable free play 6 15 Valve clearance 6 15 Tires 6 16 Cast wheels 6 18 Adjusting the clutch lever free play 6 18 Adjusting the rear brake light switch 6 19 Checking the front and rear brake ...

Page 7: ...ting 6 36 Troubleshooting charts 6 37 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 U3C321E0 book Page 2 Friday September 29 2006 4 57 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: ...ggles 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 sys...

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 U3C321E0 book Page 5 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 13: ...le 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 00 290 kPa 2 90 kgf cm2 42psi 5VY 21668 00 U3C321E0 book Page 6 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 14: ...stem fuse page 6 29 6 Storage compartment page 3 18 7 Passenger seat lock page 3 16 8 Shock absorber assembly spring preload adjusting ring page 3 20 9 Shock absorber assembly rebound damping force adjusting screw page 3 20 10 Shift pedal page 3 13 11 Idle adjusting screw page 6 14 12 Engine oil drain bolt page 6 8 13 Engine oil filter cartridge page 6 8 U3C321E0 book Page 1 Friday September 29 20...

Page 15: ...id reservoir page 6 20 6 Engine oil filler cap page 6 8 7 Front brake fluid reservoir page 6 20 8 Front fork rebound damping force adjusting screw page 3 18 9 Engine oil level check window page 6 8 10 Brake pedal page 3 14 11 Coolant reservoir page 6 11 12 Luggage strap holder page 3 22 U3C321E0 book Page 2 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 16: ...3 13 2 Left handlebar switches page 3 12 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 7 5 Right handlebar switches page 3 12 6 Throttle grip page 6 15 7 Brake lever page 3 14 U3C321E0 book Page 3 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 17: ...F IT IS LOST If 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 reg...

Page 18: ...p it in a safe place and only use it for code re registering EAU10550 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stalls EAU10...

Page 19: ...which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU10941 Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key ...

Page 20: ...ation 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 Coolant t...

Page 21: ...INSTRUMENT AND CONTROL FUNCTIONS 3 5 3 CAUTION ECA10020 Do not operate the engine if it is overheated U3C321E0 book Page 5 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 22: ... 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 37 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 37 U3C321E0 book Page 6 Friday September 29 2006 4 57 PM P...

Page 23: ...ck 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 7 for an explana tio...

Page 24: ... 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 25: ...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 26: ...ake 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 disp...

Page 27: ... 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 ...

Page 28: ...witch 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 EAU417...

Page 29: ... 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 23 EAU12870 Shift pedal The shift p...

Page 30: ...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 31: ...illing 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 d...

Page 32: ...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 33: ...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 U3C321E0 book Page 17 Friday September 29 2006 4 57 PM ...

Page 34: ... 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 adju...

Page 35: ...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 36: ...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 37: ...WA10220 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 38: ...and is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down...

Page 39: ...ch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10260 The vehicle must be placed on the cente...

Page 40: ...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 41: ...erefore 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 pro...

Page 42: ...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 20 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 43: ...Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten i...

Page 44: ...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 23 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 45: ...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 46: ...ine 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 follo...

Page 47: ...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 48: ...iar 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 16 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 49: ...000 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 f...

Page 50: ...ium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand centerstand 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 point...

Page 51: ...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 52: ... 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 U3C321E0 book Page 5 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 53: ...stalled EAU40030 Panels A and B To remove one of the panels Remove the bolts and the screws and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screws and the bolts EAU19272 Panel C To remove the panel Remove the screw and then pull out ward on the areas shown 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Screw 3 Bolt U3C321E0 book Pa...

Page 54: ... normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installin...

Page 55: ...at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set ...

Page 56: ...e 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 NOTE Make sure that the O ring is properly seated 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt 1 Oil filter wrench 2 Oil fil...

Page 57: ... checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 10 Turn the engine off and then check...

Page 58: ...e coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove pan el C See page 6 6 4 Remove the reservoir cap add coolant to the maximum level mark and then install the reservoir cap CAUTION ECA10471 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to th...

Page 59: ...WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant EAU40051 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace th...

Page 60: ...w foreign objects to drop into the air intake manifold 7 Pull the air filter element out 8 Insert a new air filter element into the air filter case CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 Inst...

Page 61: ...nstall the panels 13 Install the rider seat EAU34300 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly re sponds to the throttle Check the engine idling speed and if ...

Page 62: ...e throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Idle adjusting screw Engine idling sp...

Page 63: ...ely pack your heavi est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum ...

Page 64: ...nformation This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the valve caps are secu...

Page 65: ...hecked 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 repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a sho...

Page 66: ...t come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 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 a...

Page 67: ...nd replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage NOTE The rear brake fluid reservoir is located behind panel C See page 6 6 Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is l...

Page 68: ...ls specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before e...

Page 69: ...he swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 3 Tighten the locknuts then the axle nut to their speci...

Page 70: ...pe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain as they may contain substances that could damage the O rings EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the...

Page 71: ...e lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U3C321E0 book Page 24 Friday September 29 2006 4 57 PM ProCarM...

Page 72: ...d and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10740 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant L...

Page 73: ... the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart ...

Page 74: ... bearings EAU33650 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when 1 Positive battery...

Page 75: ... if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After instal...

Page 76: ...question 2 Unhook the battery band and then remove the battery cover 3 Remove the blown fuse and then install a new fuse of the specified amperage 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 immo bilizer system 6 Right radiator fan fuse 7 Left radiator...

Page 77: ...ok the battery band onto the holder EAU23930 Replacing a headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb Specified fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 10 0 A Ignit...

Page 78: ...otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and 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 not use a headlight bulb of a wattage higher than specified 4 Install the head...

Page 79: ...nal 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 clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate lig...

Page 80: ...ut replace it as follows 1 Remove panel B if replacing the left auxiliary light bulb or panel A if replacing the right auxiliary light bulb See page 6 6 2 Remove the auxiliary light socket together with the bulb by turning the socket counterclockwise 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the auxiliary light socket to gether with the bulb by pu...

Page 81: ... pads will be forced shut 5 Pull the wheel axle out and then remove the wheel EAU40070 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Install the brake caliper on each side by installing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 4 Install the brake hose holder...

Page 82: ...fully in direction a and push the wheel forward 6 Remove the drive chain from the rear sprocket NOTE If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel Tighte...

Page 83: ... speci fied torque EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing 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 procedures for checking these vital systems your self How...

Page 84: ...no 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 Batt...

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: ...area 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 tar...

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 ...

Page 91: ...f cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 190 kg 198 419 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 25 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: ...BITED 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 ele...

Page 95: ...eam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 23 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 32 Luggage strap holders 3 22 M Main switch steering lock 3 2 Matte color caution 7 1 Model label 9 2 Mu...

Page 96: ... Turn signal light bulb replacing 6 32 Turn signal switch 3 12 V Valve clearance 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 34 Wheel rear 6 35 Wheels 6 18 U3C321E0 book Page 2 Friday September 29 2006 4 57 PM ProCarManuals com ...

Page 97: ...U3C321E0 book Page 3 Friday September 29 2006 4 57 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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