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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

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 ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.

WARNING

EWA10720

Damage to the outer sheath may in-
terfere with proper cable operation
and will 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.

Recommended lubricant:

Engine oil

U1B322E0.book Page 21 Monday, August 8, 2005 1:49 PM

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Summary of Contents for FZ6-NV

Page 1: ...1B3 28199 22 FZ6 NV FZ6 NSV OWNER S MANUAL ProCarManuals com ...

Page 2: ...U1B322E0 book Page 2 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 3: ... all advantages of your FZ6 NV FZ6 NSV 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 deale...

Page 4: ...ave 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 ...

Page 5: ...2005 by Yamaha Motor Co Ltd 1st edition August 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1B322E0 book Page 2 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 6: ...ving 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 Checking the throttle cable free play 6 13 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 6 17 Checking the front and rear bra...

Page 7: ...porting 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 Motorcycle noise regulation for Australia 9 2 U1B322E0 book Page 2 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 8: ...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 motorists c...

Page 9: ...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 exhaust s...

Page 10: ...eme 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 limi...

Page 11: ...entilation 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...

Page 12: ... INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U1B322E0 book Page 5 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 13: ...are 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 U1B322E0 book Page 6 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 14: ... adjusting screw page 6 12 5 Shock absorber assembly spring preload adjusting ring page 3 14 6 Owner s tool kit page 6 1 7 Storage compartment page 3 13 8 Shift pedal page 3 10 9 Engine oil drain bolt page 6 6 10 Engine oil filter cartridge page 6 6 U1B322E0 book Page 1 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 15: ...7 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 10 U1B322E0 book Page 2 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 16: ...ft 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 U1B322E0 book Page 3 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 17: ...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 tering key...

Page 18: ...aillight 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 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...

Page 19: ... 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 the left or right E...

Page 20: ...ne trouble warning light This warning light comes on or flashes when 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 th...

Page 21: ... 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 EAU33712 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 speed 1 L...

Page 22: ... 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 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 displa...

Page 23: ... 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 those circuits are defective the engine trouble warning light will come on and then the multi function display will indicate a two digit error code e g 12...

Page 24: ...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 EAU12344 Handlebar switches Left Right EAU12350 Pass switch Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand t...

Page 25: ...this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10061 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever The c...

Page 26: ...pped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake pre...

Page 27: ...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 sure that the fuel tank cap is properly closed before riding EAU13220 Fuel Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler tube as s...

Page 28: ...and reduce maintenance costs EAU13431 Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasol...

Page 29: ...the key NOTE Make sure that the seat is properly se cured before riding EAU14451 Storage compartment The storage compartment is located under the seat See page 3 13 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 When storing the owner s manual or other documents in the storage com partment be ...

Page 30: ...uspension turn the adjusting ring in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting ring in direction b NOTE Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment 3 Install the seat WARNING EWA10220 This shock absorber con...

Page 31: ...er 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 or if the side stand cannot be properly moved up or does not stay up o...

Page 32: ...h 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 EWA10250 If a malfunction is noted have a Yamaha ...

Page 33: ...gine 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...

Page 34: ...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 working p...

Page 35: ...ongy 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 reservoir If ne...

Page 36: ...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 22 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 Tighten if nec...

Page 37: ...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 warning light...

Page 38: ...position press 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 ...

Page 39: ...e 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 1600 km 600...

Page 40: ... 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 U1B322E0 book Page 4 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 41: ...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 torque w...

Page 42: ... 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 operation...

Page 43: ...g 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 leakag...

Page 44: ...e 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 system if nec...

Page 45: ...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 all spark p...

Page 46: ...ap 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 lubricati...

Page 47: ... 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 is not bei...

Page 48: ...e 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 oil is lea...

Page 49: ...evel 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 coolant shoul...

Page 50: ...o 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 for further...

Page 51: ...t 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 EWA12462 Before placing the fuel tank in the original position make s...

Page 52: ...ment 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...

Page 53: ...in the periodic maintenance and lubrication chart EAU21780 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 e when the temp...

Page 54: ...tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced WARNING EWA10470 Have a Yamaha 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 relate...

Page 55: ...per high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively ...

Page 56: ... 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 EAU22080 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch lever free ...

Page 57: ...ovided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure...

Page 58: ...id reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower ...

Page 59: ...side stand NOTE When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU34361 To adjust the drive c...

Page 60: ...als specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows CAUTION ECA10581 The drive chain must be lubricated after washing 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 no...

Page 61: ... is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will 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 ...

Page 62: ...pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation 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 U1B322E0 book Page 22 Monday August 8 2005 1 49 PM ProCarManuals co...

Page 63: ... does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium...

Page 64: ...if 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 char...

Page 65: ...cated under the fuel tank See page 6 11 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 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 equip...

Page 66: ...ALL BATTER IES OUT OF THE REACH OF CHILDREN 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 installation make sure that...

Page 67: ...possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 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 Fuel injection system fus...

Page 68: ...le 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 ...

Page 69: ...b by turning it counter clockwise WARNING EWA12301 Do not touch the muffler bracket un til the exhaust system has cooled 3 Remove the defective bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket 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 seat 1 Do not touch the glass...

Page 70: ...en 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 socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by i...

Page 71: ... 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 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 th...

Page 72: ... Pull the wheel axle out and then remove the wheel EAU24860 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground 4 Install the brake calipers by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the bra...

Page 73: ...port 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 on page 6 31 3 Remove the axle nut 4 Loosen the locknut and drive chain adjusting nut on each side of the swingarm 5 Push the wheel forward and then remove the drive chain from the rear sprocket 1 Axle nut 2 Drive chain slack adjusting nut 3 Lockn...

Page 74: ...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 Make sure that there is enough space between the brake pads be fore installing the wheel 2 Install the drive chain onto the rear sprocket 3 Install the axle nut and then...

Page 75: ...hooting 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...

Page 76: ...n 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 The engin...

Page 77: ...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 the coolin...

Page 78: ...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 plastic p...

Page 79: ...ome 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 moved th...

Page 80: ...ing 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 of engine...

Page 81: ...n 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 battery see ...

Page 82: ... 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 Unleaded gasoline only Fuel tank capacity 19 4 L 5 13 US gal 4 27 Imp gal Fuel reserve amount...

Page 83: ...5 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 hand ope...

Page 84: ... V 10 0 W 2 Auxiliary light 12 V 5 0 W 1 License 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 Parking l...

Page 85: ...on 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 cycl...

Page 86: ...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 87: ...icator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 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 Noise regulation for Australia 9 2 O Oil level warning light 3 4 P Panel removing and installing 6 5 Parking 5 4 Part locations 2...

Page 88: ...nal switch 3 8 V Valve clearance 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 25 Wheel front 6 32 Wheel rear 6 33 Wheels 6 16 U1B322E0 book Page 2 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 89: ...U1B322E0 book Page 3 Monday August 8 2005 1 49 PM ProCarManuals com ...

Page 90: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2005 08 0 3 1 CR E ProCarManuals com ...

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