Yamaha FZ6-N Owner'S Manual Download Page 58 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

6

4. If the drive chain slack is incorrect,

adjust it as follows.

EAU34361

To adjust the drive chain slack

1. Loosen the axle nut, then loosen

the locknut at each end of the
swingarm.

2. To tighten the drive chain, turn the

adjusting nut at each end of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing nut at each end 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 adjusting nuts are in the same po-
sition 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, and then

tighten the axle nut to the specified
torque.

1. Drive chain slack

1. Axle nut

2. Drive chain slack adjusting nut
3. Locknut

4. Alignment marks

Tightening torques:

Locknut:

16 Nm (1.6 m·kgf, 11 ft·lbf)

Axle nut:

120 Nm (12.0 m·kgf, 87 ft·lbf)

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Summary of Contents for FZ6-N

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 07 0 4 2 CR E 1B3 28199 E1 FZ6 N OWNER S MANUAL ...

Page 2: ... TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 2000 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue Aug 1st 2002 Kind of equipment IMMOBILIZER Address 1450 6 Mori Mori Machi Shuchi gun Shizuoka 437 0292 Japan Company MORIC CO LTD Kazuji Kawai representative name and signature U1B3E1E0 book Page 1 Thursday July 8 2004 11 49 ...

Page 3: ...to enjoy all advantages of your FZ6 N 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 oth ers 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 deale...

Page 4: ... your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 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 motorcycle operator a b...

Page 5: ...NUAL 2004 by Yamaha Motor Co Ltd 1st edition June 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1B3E1E0 book Page 2 Thursday July 8 2004 11 49 AM ...

Page 6: ...cation chart 6 2 Removing and installing the panel 6 5 Checking the spark plugs 6 5 Engine oil and oil filter cartridge 6 6 Coolant 6 9 Replacing the air filter element 6 11 Adjusting the engine idling speed 6 12 Adjusting the throttle cable free play 6 13 Adjusting the valve clearance 6 13 Tires 6 13 Cast wheels 6 16 Adjusting the clutch lever free play 6 16 Adjusting the rear brake light switch ...

Page 7: ...n auxiliary light bulb 6 31 Supporting the motorcycle 6 31 Front wheel 6 32 Rear wheel 6 33 Troubleshooting 6 35 Troubleshooting charts 6 36 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U1B3E1E0 book Page 2 Thursday July 8 2004 11 49 AM ...

Page 8: ...nts have been 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 mo...

Page 9: ...ield or goggles 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 e...

Page 10: ... Use extreme 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 clear...

Page 11: ... equate ventilation 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 ...

Page 12: ...11 4 Idle adjusting screw page 6 12 5 Shock absorber assembly spring preload adjusting ring page 3 15 6 Owner s tool kit page 6 1 7 Storage compartment page 3 14 8 Shift pedal page 3 10 9 Engine oil drain bolt page 6 6 10 Engine oil filter cartridge page 6 6 U1B3E1E0 book Page 1 Thursday July 8 2004 11 49 AM ...

Page 13: ... page 6 27 2 Rear brake fluid reservoir page 6 18 3 Coolant reservoir cap page 6 9 4 Engine oil filler cap page 6 6 5 Front brake fluid reservoir page 6 18 6 Dipstick page 6 6 7 Brake pedal page 3 11 U1B3E1E0 book Page 2 Thursday July 8 2004 11 49 AM ...

Page 14: ...3 10 2 Left handlebar switches page 3 8 3 LCD tachometer page 3 5 4 Multi function display page 3 5 5 Right handlebar switches page 3 8 6 Brake lever page 3 10 7 Throttle grip page 6 13 8 Main switch steering lock page 3 2 U1B3E1E0 book Page 3 Thursday July 8 2004 11 49 AM ...

Page 15: ...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 regis te...

Page 16: ...ting taillight li cense plate light and auxiliary light 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 or the sidestand is moved down EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are ...

Page 17: ...ectrical 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 EAU11002 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or...

Page 18: ...n an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system See page 3 5 for an explanation of the self diagnosis de vice The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit EAU2687...

Page 19: ...mperature has reached 60 C 140 F so this is not a malfunction CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 14000 r min and above EAU32976 Multi function display WARNING EWA12311 Be sure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following a speedometer which shows the riding ...

Page 20: ...l start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT button switches the display between the vari ous tripmeter and odometer modes in the following order TRIP F E ODO TRIP 1 TRIP 2 TRIP F To reset a tripmeter select it by push ing the SELECT button and t...

Page 21: ...r and then disappear in order to test the electrical circuit The coolant temperature varies with changes in the weather and engine load If the top seg ment flashes stop the vehicle and let the engine cool See page 6 36 CAUTION ECA10020 Do not operate the engine if it is overheated Self diagnosis devices This model is equipped with a self diag nosis device for various electrical cir cuits If any of...

Page 22: ...ey and both standard keys to a Yamaha dealer and have the stan dard keys re registered If the multi function display indicates any error code 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 EAU12330 Anti theft alarm optional This model can b...

Page 23: ... 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 EAU12731 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ar...

Page 24: ...er when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU26822 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial whil...

Page 25: ... tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sur...

Page 26: ... 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 signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel wil...

Page 27: ...ork CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages 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 EAU32980 Seat To remove the seat 1 Inser...

Page 28: ...may not fit When placing a U LOCK in the storage compartment securely fasten it with the straps When the U LOCK is not in the storage com partment be sure to secure the straps to prevent losing them WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do not exceed the maximum load of 196 kg 432 lb for the ve hicle 1 Projection 2 Seat holder 1 U LOCK bar optional...

Page 29: ...r 3 Install the seat WARNING EWA10220 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 sh...

Page 30: ...g the respon 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 tra...

Page 31: ...er the engine 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 s...

Page 32: ...quences Therefore 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 w...

Page 33: ...ft or spongy 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 17 6 18 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 reservo...

Page 34: ...essary 6 13 6 16 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 22 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 23 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 23 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tight...

Page 35: ... 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 16 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA12741 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warni...

Page 36: ... the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission A...

Page 37: ...ully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17091 0 1000 km 0 600 mi Avoid prolonged operation above 7000 r min 1000 16...

Page 38: ...e 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 ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U1B3E1E0 book Page 4 Thursday July 8 2004 11 49 AM ...

Page 39: ...iar with mainte nance work have a Yamaha dealer do it for you EAU17520 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 13 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...

Page 40: ... READING 1000 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 o...

Page 41: ...ring bearings Check bearing play and steering for roughness Lubricate with 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 lea...

Page 42: ...nt leakage Change Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and ca bles Lubricate 26 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 27 Air induction system Check the air cut off valve reed valve and hose for dam age Replace the entire air induction syst...

Page 43: ...deposits will cause any spark plug to slowly 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 al...

Page 44: ... of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU32852 Engine oil and oil filter cartridge 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 ...

Page 45: ... dipstick and then install and tight en the oil filler cap To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the 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 i...

Page 46: ...since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel 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 oi...

Page 47: ...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 The cool...

Page 48: ...n added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 36 fo...

Page 49: ...e 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 6 Install the air filter case cover by in stalling the screws 7 Place the fuel tank in the original position and install the bolts WARNING EWA12461 Before placing the fuel tank in...

Page 50: ...t NOTE The engine is warm when it quickly re sponds to the throttle Check the engine idling speed and if necessary adjust it to specification by turning the idle 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 de...

Page 51: ...rvals specified in the periodic maintenance and lubrication chart EAU21771 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i...

Page 52: ...rd to the load Check the tire condition and air pressure before each ride Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re place the tire immediately NOTE The tire tread depth limits may differ from country to country Always comply wi...

Page 53: ... this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride WARNING EWA10600 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 only the spec...

Page 54: ...el 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 short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU2208...

Page 55: ... ad just the brake light switch 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 EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the ...

Page 56: ...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 under the fuel tank See page 6 11 Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir i...

Page 57: ...e 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 each ride and adjusted if necessary EAU22770 To check the drive chain slack 1 Place the motorcycle ...

Page 58: ...ks on each side of the swingarm make sure that both adjusting nuts are in the same po sition 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 and then ti...

Page 59: ...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 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...

Page 60: ...ld be lubricated or replaced 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 U1B3E1E0 book Page 22 Thursday July 8 2004 11 ...

Page 61: ... and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium so...

Page 62: ...G 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 if the front fork compresses and rebounds smoothly CAUTIO...

Page 63: ...y support the 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 ...

Page 64: ...y call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than o...

Page 65: ...panel A See page 6 5 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Spare fuse 1 Fuse box 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan fuse 5 Backup fuse for odometer clock and immo bilizer system 6 Electronic fuel in...

Page 66: ...uipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the bolts on each side 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb Specified fuses Main fuse 30 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Radia...

Page 67: ...and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the bolts 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU32822 Replacing the tail brake light bulb 1 Remove the seat See page 3 13 2 Remove the socket together with the bulb by turning i...

Page 68: ...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 light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the sock...

Page 69: ...ycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle 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 th...

Page 70: ...d according to the procedure on page 6 31 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 3 Remove the brake hose holder on each side by removing the bolts 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 shut 5 Pull the wh...

Page 71: ...o the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU34411 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 2 Lift the rear wheel off the ground according to the procedure...

Page 72: ...the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU34430 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the right hand side NOTE Make sure that the retainer on the swingarm is inserted into the slot in the brake caliper bracket ...

Page 73: ...ystems 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 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...

Page 74: ...mpression 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 Battery T...

Page 75: ... hissing sound has stopped press down 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 t...

Page 76: ... dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on ...

Page 77: ...uding chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re...

Page 78: ...fore storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful ...

Page 79: ...y month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the bat...

Page 80: ... oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 27 L 0 29 US qt 0 24 Imp qt Radiator capacity including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 19 4 L 5 13 US gal 4 27 Imp gal Fuel re...

Page 81: ... psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 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 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 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 MT5 50 Front brake Type Dual disc brake Operation Right ...

Page 82: ...light 12 V 10 0 W 2 Auxiliary light 12 V 5 0 W 1 Licence plate light 12 V 5 0 W 1 Meter lighting EL LCD backlight Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A P...

Page 83: ...ntification 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 m...

Page 84: ...abel is affixed to the frame under the seat See page 3 13 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U1B3E1E0 book Page 2 Thursday July 8 2004 11 49 AM ...

Page 85: ...off system 3 16 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L LCD tachometer 3 5 License plate light bulb replacing 6 30 M Main switch steering lock 3 2 Model label 9 2 Multi function display 3 5 N Neutral indicator light 3 3 O Oil level warning light 3 4 P Panel removing and installing 6 5 Parking 5 4 Part location...

Page 86: ... signal switch 3 9 V Valve clearance adjusting 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 25 Wheel front 6 32 Wheel rear 6 33 Wheels 6 16 U1B3E1E0 book Page 2 Thursday July 8 2004 11 49 AM ...

Page 87: ...U1B3E1E0 book Page 3 Thursday July 8 2004 11 49 AM ...

Page 88: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 07 0 4 2 CR E 1B3 28199 E1 FZ6 N OWNER S MANUAL ...

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