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Yamaha FZ6-SA Owner'S Manual Download Page 47

PERIODIC MAINTENANCE AND MINOR REPAIR

6-6

6

EAU18771

Removing and installing 
panels 

The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.

EAU32863

Panels A and B

To remove one of the panels
Remove the bolts and the quick fasten-
er screw, and then pull the panel off as
shown.

To install the panel
Place the panel in the original position,
and then install the quick fastener
screw and the bolts.

1. Panel A

2. Panel B

1. Panel C

1. Panel A
2. Bolt

3. Quick fastener screw

U4P5E0E0.book  Page 6  Wednesday, December 14, 2005  11:15 AM

Summary of Contents for FZ6-SA

Page 1: ...4P5 28199 EA FZ6 SA OWNER S MANUAL ...

Page 2: ...6 EN60950 2000 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue 1 Aug 2002 Revolution record No Contents Date To change contact person and integrate type designation 9 Jun 2005 General manager of quality assurance div representative name and signature MORIC CO LTD 1450 6 Mori machi Shuchi gun Shizuoka 437 0292 JAPAN Telephone 81 538 85 ...

Page 3: ...enjoy all advantages of your FZ6 SA 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 dealer ...

Page 4: ... 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 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 t...

Page 5: ... 2005 by Yamaha Motor Co Ltd 1st edition December 2005 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U4P5E0E0 book Page 2 Wednesday December 14 2005 11 15 AM ...

Page 6: ...g 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 15 Adjusting the engine idling speed 6 16 Checking the throttle cable free play 6 17 Valve clearance 6 17 Tires 6 17 Cast wheels 6 20 Adjusting the clutch lever free play 6 20 Adjusting the rear brake light switch 6 21 Checking the front and rear brake pa...

Page 7: ...placing an auxiliary light bulb 6 36 Troubleshooting 6 36 Troubleshooting charts 6 37 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U4P5E0E0 book Page 2 Wednesday December 14 2005 11 15 AM ...

Page 8: ... 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 motor...

Page 9: ...d 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 exha...

Page 10: ...e 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 clearanc...

Page 11: ...uate 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 fal...

Page 12: ...r filter element page 6 15 5 Idle adjusting screw page 6 16 6 Shock absorber assembly spring preload adjusting ring page 3 17 7 Owner s tool kit page 6 1 8 Shift pedal page 3 12 9 Engine oil drain bolt page 6 8 10 Engine oil filter cartridge page 6 8 U4P5E0E0 book Page 1 Wednesday December 14 2005 11 15 AM ...

Page 13: ...eservoir page 6 22 4 Engine oil filler cap page 6 8 5 Front brake fluid reservoir page 6 22 6 Radiator cap page 6 11 7 Coolant reservoir page 6 11 8 Coolant reservoir cap page 6 11 9 Coolant drain bolt page 6 12 10 Dipstick page 6 8 11 Brake pedal page 3 12 U4P5E0E0 book Page 2 Wednesday December 14 2005 11 15 AM ...

Page 14: ... 2 Left handlebar switches page 3 10 3 LCD tachometer page 3 5 4 Multi function display page 3 6 5 Right handlebar switches page 3 10 6 Brake lever page 3 12 7 Throttle grip page 6 17 8 Main switch steering lock page 3 2 U4P5E0E0 book Page 3 Wednesday December 14 2005 11 15 AM ...

Page 15: ...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 terin...

Page 16: ...ing 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 EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off Th...

Page 17: ...ems 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 EAU11020 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right EAU11060 Neutral indicato...

Page 18: ...ve a Yamaha dealer check the self diagnosis system See page 3 6 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 EAU39500 ABS warning light If this warning light comes on or flashes while riding the...

Page 19: ...ometer The LCD tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON all of the display segments of the LCD ta chometer will appear one after the oth er across the r min range and then disappear in order to test the electrical circuit NOTE The first segment of the tachometer will flash while idling or riding until the cool ant...

Page 20: ...uttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least two seconds Odometer tripmeter and digital ta chometer modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 TRIP F and the tachometer E in the following or der ODO TRIP 1 TRIP 2 T...

Page 21: ...nd then push the RESET button for at least two seconds NOTE The clock is automatically displayed when the key is turned to OFF To set the clock 1 Push the SELECT button and RESET button together for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the m...

Page 22: ...in the ON position the coolant temperature meter indicates the temperature of the coolant When the key is turned to ON all of the dis play segments of the coolant tempera ture meter will appear one after the other 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...

Page 23: ...e fol lowing 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If ...

Page 24: ...s 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 turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard switch 1 Engine stop switch 2 Star...

Page 25: ... use 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 ...

Page 26: ... equipped 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 brak...

Page 27: ...sating action may be felt at the brake lever or brake pedal but this does not indicate a mal function This ABS has a test mode which allows the owner to experience the pulsating at the brake lever or brake pedal when the ABS is oper ating However special tools are required so please consult your Yamaha dealer when performing this test EAU13070 Fuel tank cap To open the fuel tank cap Open the fuel ...

Page 28: ... spilling 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 EAU13320 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 bee...

Page 29: ... 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 gasoline The use of leaded gasoline will cause unrepairable damage to the ca...

Page 30: ...Make sure that the seat is properly se cured before riding EAU14421 Storage compartment This storage compartment is designed to hold a genuine Yamaha U LOCK Other locks 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 t...

Page 31: ...e 3 16 2 To increase the spring preload and thereby harden the suspension 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 just...

Page 32: ...estand 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 d...

Page 33: ...nts 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 centerstand during this in spection ...

Page 34: ...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 shou...

Page 35: ...nces 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 work...

Page 36: ... 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 21 6 22 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...

Page 37: ...7 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 27 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Ti...

Page 38: ...ARNING 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 19 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15450 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning light Eng...

Page 39: ...e 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 Alwa...

Page 40: ...y 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 1600 ...

Page 41: ...ngine 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 U4P5E0E0 book Page 4 Wednesday December 14 2005 11 15 AM ...

Page 42: ... 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 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 to...

Page 43: ...ADING 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 oper...

Page 44: ... 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 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...

Page 45: ...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 neces...

Page 46: ...6 Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U4P5E0E0 book Page 5 Wednesday December 14 2005 11 15 AM ...

Page 47: ... panel needs to be removed and installed EAU32863 Panels A and B To remove one of the panels Remove the bolts and the quick fasten er screw and then pull the panel off as shown To install the panel Place the panel in the original position and then install the quick fastener screw and the bolts 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Bolt 3 Quick fastener screw U4P5E0E0 book Page 6 Wednesday Dece...

Page 48: ...periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly differ...

Page 49: ... 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 lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when chec...

Page 50: ...ck 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 b...

Page 51: ...ce 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 oil i...

Page 52: ...ant level The coolant level should be checked as follows before each ride In addition the coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart 1 Place the vehicle on the center stand 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 check...

Page 53: ...ll 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 37 for further instructions EAU40132 To change the coolant 1 Place the vehicle on the center stand and let the engine cool if necessary 2 Remove panel A See p...

Page 54: ...ce it if necessary 12 Pour the specified amount of the recommended coolant into the ra diator and reservoir CAUTION ECA10470 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 the engine 1 Coolant reservoir cap 2 Coolant reservoir 1 Coolant reservoir cover 2 Bolt 1 Coolant drain bolt Tightening torque Coolant drain b...

Page 55: ...ng bolt 15 Start the engine let it idle for sev eral minutes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap radiator cap retainer and radi ator cap retaining bolt 17 Check the coolant level in the res ervoir If necessary remove the coolant rese...

Page 56: ...t 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 7 Install the air filter case cover by in stalling the screws 8 Place the fuel tank in the original position and install the bolts WARNING EWA12462 Before placing the fuel tank in the ...

Page 57: ...aking this adjustment 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 ab...

Page 58: ...ified 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 e when th...

Page 59: ...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 with ...

Page 60: ...is 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 specifi...

Page 61: ...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 EAU22080 A...

Page 62: ...necessary have a Yamaha dealer 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 disas...

Page 63: ... 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 Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and...

Page 64: ...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 each ride and adjusted if necessary ...

Page 65: ... 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 ...

Page 66: ...nts 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...

Page 67: ...hould be 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 U4P5E0E0 book Page 26 Wednesday December 14 2005 11 15 ...

Page 68: ...nterstand 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 lub...

Page 69: ...WA10750 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 CAUTION E...

Page 70: ...upport 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 If ...

Page 71: ... 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 one month...

Page 72: ...aler charge your battery EAU40140 Replacing the fuses The main fuse and fuse box 1 are locat ed under the fuel tank See page 6 15 Fuse box 2 is located behind panel C See page 6 6 1 Fuse box 1 2 Main fuse 3 Spare main fuse 1 ABS control unit fuse 2 ABS motor fuse 3 ABS motor spare fuse 1 Fuse box 2 U4P5E0E0 book Page 31 Wednesday December 14 2005 11 15 AM ...

Page 73: ...in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 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 fuse 7 Spare fuse 8 Parking lighting fuse Specified fuses Main fuse 30 0 A Headlight fuse 20 0 A Signaling syst...

Page 74: ... then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened wit...

Page 75: ...lb 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 Tail brake light bulb...

Page 76: ...tighten 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...

Page 77: ...maha 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 However should your motorcycle require any repair take it ...

Page 78: ...ession 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 ...

Page 79: ...ssing 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 ...

Page 80: ...rt 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 pla...

Page 81: ...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 82: ...e 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 of ...

Page 83: ...onth 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 batter...

Page 84: ...il 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 rese...

Page 85: ...i 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 185 kg 198 408 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 han...

Page 86: ...ry light 12 V 5 0 W 2 License plate light 12 V 5 0 W 1 Meter lighting EL backlight LCD Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Engine trouble warning light LED ABS 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 Parkin...

Page 87: ...fication 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 moto...

Page 88: ...l is affixed to the frame under the seat See page 3 16 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 U4P5E0E0 book Page 2 Wednesday December 14 2005 11 15 AM ...

Page 89: ...ht bulb replacing 6 33 High beam indicator light 3 4 Horn switch 3 11 I Identification numbers 9 1 Ignition circuit cut off system 3 19 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 35 M Main switch steering lock 3 2 Model label 9 2 Multi function display 3 6 N...

Page 90: ... light 3 3 Turn signal light bulb replacing 6 35 Turn signal switch 3 10 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 29 Wheels 6 20 U4P5E0E0 book Page 2 Wednesday December 14 2005 11 15 AM ...

Page 91: ...U4P5E0E0 book Page 3 Wednesday December 14 2005 11 15 AM ...

Page 92: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 01 0 4 1 CR E ...

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