Yamaha FZ6RY Owner'S Manual Download Page 85

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-40

3. Remove the brake caliper (togeth-

er with the reflector) on each side
by removing the bolts.

NOTICE:

Do not apply the brake after the
brake calipers have been re-
moved, otherwise the brake
pads will be forced shut.

[ECA11051]

4. Pull the wheel axle out, and then

remove the wheel.

EAU43101

To install the front wheel

1. Lift the wheel up between the fork

legs.

2. Insert the wheel axle.

3. Install the brake caliper (together

with the reflector) on each side by
installing the bolts.

TIP

Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.

4. Lower the front wheel so that it is

on the ground, and then put the
sidestand down.

5. Tighten the wheel axle, the front

wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.

6. Push down hard on the handlebar

several times to check for proper
fork operation.

EAU25080

Rear wheel

EAU34414

To remove the rear wheel

WARNING

EWA10821

To avoid injury, securely support the
vehicle so there is no danger of it
falling over.

1. Loosen the locknut and drive chain

slack adjusting nut on each side of
the swingarm.

2. Loosen the axle nut.

1. Reflector
2. Brake caliper bolt

3. Brake caliper

Tightening torques:

Wheel axle:

65 Nm (6.5 m·kgf, 47 ft·lbf)

Front wheel axle pinch bolt:

19 Nm (1.9 m·kgf, 13 ft·lbf)

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

1. Axle nut

2. Drive chain slack adjusting nut

3. Locknut

U36P10E0.book Page 40 Thursday, November 13, 2008 4:45 PM

Summary of Contents for FZ6RY

Page 1: ...DIC183 36P 28199 10 FZ6RY C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 22 77 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U36P10E0 book Page 1 Thursday November 13 2008 4 45 PM ...

Page 3: ...ain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancies ...

Page 4: ... all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U36P10E0 book Page 1 Thu...

Page 5: ...or Corporation U S A 1st edition October 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 22 77 U36P10E0 book Page 2 Thursday November 13 2008 4 45 PM ...

Page 6: ...em 7 3 General maintenance and lubrication chart 7 4 Removing and installing cowlings and panels 7 9 Checking the spark plugs 7 12 Canister for California only 7 13 Engine oil and oil filter cartridge 7 13 Coolant 7 16 Replacing the air filter element 7 19 Checking the engine idling speed 7 21 Checking the throttle cable free play 7 21 Valve clearance 7 21 Tires 7 22 Cast wheels 7 24 Adjusting the...

Page 7: ...shooting 7 42 Troubleshooting charts 7 43 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YAMAHA EXTENDED SERVICE Y E S 10 9 U36P...

Page 8: ...hey contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 4 5 6 7 8 9 U36P10E0 book Page 1 Thursday November 13 2008 4 45 PM ...

Page 9: ...kaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 NOTICE 4B5 2815K 00 U36P10E0 book Page 2 Thursday November 13 2008 4 45 PM ...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 California only 8 California only 9 California only 7 U36P10E0 book Page 3 Thursday November 13 2008 4 45 PM ...

Page 11: ...ssenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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 y...

Page 12: ...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 Always wear protective clothing that covers your legs ankles and feet The engin...

Page 13: ... evenly as possi ble on both sides of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres s...

Page 14: ...k area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become...

Page 15: ...2 Passenger seat lock page 4 13 3 Main fuse page 7 35 4 Fuse box page 7 35 5 Storage compartment page 4 17 6 Owner s tool kit page 7 2 7 Shift pedal page 4 10 8 Engine oil filter cartridge page 7 13 9 Engine oil drain bolt page 7 13 U36P10E0 book Page 1 Thursday November 13 2008 4 45 PM ...

Page 16: ...uid reservoir page 7 26 4 Engine oil filler cap page 7 13 5 Radiator cap page 7 16 6 Coolant reservoir page 7 16 7 Coolant drain bolt page 7 18 8 Engine oil dipstick page 7 13 9 Brake pedal page 4 10 10 Shock absorber assembly spring preload adjusting ring page 4 19 U36P10E0 book Page 2 Thursday November 13 2008 4 45 PM ...

Page 17: ...9 2 Left handlebar switches page 4 8 3 Main switch steering lock page 4 1 4 Multi function meter unit page 4 5 5 Front brake fluid reservoir page 7 26 6 Right handlebar switches page 4 8 7 Throttle grip page 7 21 8 Brake lever page 4 10 U36P10E0 book Page 3 Thursday November 13 2008 4 45 PM ...

Page 18: ...gine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10681 LOCK The steering is locked and all electrical systems...

Page 19: ... light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit TIP Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration o...

Page 20: ...circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit NOTICE ECA10021 Do not continue to operate the en gine if it is overheating TIP For radiator fan equip...

Page 21: ... Go ahead with riding 117 139 C 243 283 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 7 43 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 7 43 U36P10E0 book Page 4 Thursday November 13 2008...

Page 22: ...nges to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident The multi function meter unit is equipped with the following a speedometer a tachometer an odometer two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled since the left segment of th...

Page 23: ...button and RESET button together for at least two seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock Odometer and tripmeter modes Push the SELECT button to switch the display between the odome...

Page 24: ... of fuel in the fuel tank The display seg ments of the fuel meter disappear to wards E Empty as the fuel level decreases When the last segment on the left starts flashing refuel as soon as possible TIP This fuel meter is equipped with a self diagnosis system If a problem is de tected in the electrical circuit the follow ing cycle is repeated until the malfunction is corrected fuel level seg ments ...

Page 25: ... also detects problems in the immobilizer system cir cuits If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle NOTICE ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EAU12348 Handlebar switches Left Right 1 Error code display 1 1 Dimmer switch 2 Turn signal sw...

Page 26: ...he vehicle overturns or when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch lever The clutch lever is...

Page 27: ...ped with a brake lever position adjusting dial To adjust the distance 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 ...

Page 28: ...fuel is a fire hazard EAU13221 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi ci...

Page 29: ...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 pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenan...

Page 30: ...e hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10701 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU47360 Seats Passenger seat To remove the passenger seat 1 Insert...

Page 31: ...hen pull the rider seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original position and then tighten the bolts 2 Install the passenger seat TIP Make sure that the seats are prop erly secured before riding The rider seat height can be ad justed to change the riding posi tion See page 4 15 1 Projection 2 S...

Page 32: ...Install the rider seat height position adjuster so that its bolt holes marked H are aligned with the bolt holes of the adjuster brackets and then install the adjuster bolts 4 Insert the projection on the front of the rider seat into seat holder B as shown 5 Align the lower bolt holes in the rid er seat with the bolt holes in the seat brackets and then install the bolts 1 Low position 2 High positi...

Page 33: ... bolt holes of the adjuster brackets and then install the adjuster bolts 4 Insert the projection on the front of the rider seat into seat holder A as shown 5 Align the upper bolt holes in the rider seat with the bolt holes in the seat brackets and then install the bolts 6 Install the passenger seat TIP Make sure that the seats are properly secured before riding 1 Bolt 1 1 Rider seat height positio...

Page 34: ... and possibly an accident EWA10161 To release the helmet from the hel met holder Remove the passenger seat remove the helmet holding cable from the hel met holder and the helmet and then in stall the passenger seat EAU14462 Storage compartment The storage compartment is located under the passenger seat See page 4 13 WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com par...

Page 35: ...a Yamaha dealer adjust the position of the handlebars EAU47260 Rear view mirrors The rear view mirrors of this vehicle can be folded forward for parking in narrow spaces Fold the mirrors back to their original position before riding WARNING EWA14371 Be sure to fold the rear view mirrors back to their original position before riding 1 Handlebar 1 1 Riding position 2 Parking position 1 2 1 2 U36P10E...

Page 36: ...s tool kit to make the adjustment WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due ...

Page 37: ... designed to assist the operator in fulfilling 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 EAU44892 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowin...

Page 38: ...ove 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 The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch ...

Page 39: ...dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 11 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 13 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling ...

Page 40: ... free play and lubricate cable and grip housing 7 21 7 30 Control cables Make sure that operation is smooth Lubricate if necessary 7 30 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 28 7 29 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 22 7 24 Brake and shift pedals Make sure that ...

Page 41: ...ghtened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 4 20 ITEM CHECKS PAGE U36P10E0 book Page 3 Thursday November 13 2008 4 45 PM ...

Page 42: ...system The engine stops automatically if left idling for 20 minutes In this case the multi function display indicates error code 70 but this is not a mal function Push the start switch to clear the error code and to restart the engine EAU40197 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in t...

Page 43: ...shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE 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...

Page 44: ...d shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully 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 ...

Page 45: ... EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or...

Page 46: ...ning engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17302 Emission controls not only function to ensure cleaner air but are also vital to proper...

Page 47: ...he owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit 1 U36P10E0 book Page 2 Thursday November...

Page 48: ...ck condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and synchronization 6 Exhaust system Check for leakage Tighten if nec...

Page 49: ...k operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam age Replace if...

Page 50: ... lithium soap based grease Every 12000 mi 19000 km 12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake lever pivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply lithium soap based grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease lightly No ITEM...

Page 51: ...g 22 Engine oil filter car tridge Replace 23 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 24 Front and rear brake switches Check operation 25 Control cables Apply Yamaha chain and cable lube or engine oil thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6...

Page 52: ...isassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid 26 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the t...

Page 53: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 8 7 Replace the brake hoses every four years and if cracked or damaged U36P10E0 book Page 8 Thursday November 13 2008 4 45 PM ...

Page 54: ... panel needs to be re moved and installed EAU46740 Cowling A To remove the cowling Remove the bolts and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU47380 Cowlings B and C To remove one of the cowlings 1 Remove cowling A 1 Cowling A 2 Cowling B 2 1 1 Cowling C 2 Panel A 1 Panel B 2 Panel C 2 1 1 2 1 Cowling A 2 Bolt 1 2 ...

Page 55: ...al light cou pler and then route the turn signal light lead through the guide 2 Place the cowling in the original position and then install the bolts and the quick fastener 3 Install cowling A EAU46770 Panel A To remove the panel Remove the bolt and the quick fasten er and then take the panel off 1 Cowling B 2 Quick fastener 3 Bolt 3 3 2 2 1 1 Turn signal light lead 2 Guide 3 Turn signal light lea...

Page 56: ...f the panels 1 Remove the quick fastener and the bolt 2 Slide the panel backward and then lift up the rear of the panel slightly 3 Pull the panel backward to remove it To install the panel 1 Fit the projections on the panel into the slots and slide it forward 1 Panel A 2 Bolt 3 Quick fastener 1 2 3 1 Panel B 2 Quick fastener 3 Bolt 1 3 2 U36P10E0 book Page 11 Thursday November 13 2008 4 45 PM ...

Page 57: ...lly and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a sp...

Page 58: ...it if necessary EAU46720 Engine oil and oil filter car tridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion A slight tilt to the si...

Page 59: ...ter cartridge replace ment 1 Remove cowling B See page 7 9 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wr...

Page 60: ...n install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE ECA11620 In order to prevent clutch slip page 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 1 O ring 1 Torque wrenc...

Page 61: ...ff and then check the oil level and correct it if necessary 12 Install the cowling EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU47330 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 Remove cowling ...

Page 62: ...ater since it is harmful to the engine If water has been used instead of coolant replace it with coolant as soon as possi ble otherwise the cooling sys tem will not be protected against frost and corrosion If water has been 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 ECA10472 7 ...

Page 63: ...nd coolant reservoir by remov ing the bolts 7 Drain the coolant from the coolant reservoir by turning it upside down 8 Remove the coolant drain bolt to drain the cooling system 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant drain bolt and then tighten it to the specified torque TIP Check the washer for damage and re place ...

Page 64: ...r coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 20 Install the cowlings EAU47460 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the rider seat See pa...

Page 65: ...Make sure that the fuel hoses are properly connected and routed and are not pinched Be sure to place the hoses in their original position WARNING Be fore placing the fuel tank in the original position make sure that all hoses i e fuel hose fuel tank breather hose fuel tank overflow hose are not dam aged that they are properly con nected and routed and that they are not pinched If any hose is damag...

Page 66: ...rip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Engine idling ...

Page 67: ...load your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum 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 Tire air pressure measured on cold tires 0 90 kg 0 ...

Page 68: ...e leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd 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 specified rep...

Page 69: ...heel 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 EAU47390 Adjusting the clutch lev...

Page 70: ...en the locknut 6 Install the cowlings EAU22272 Adjusting the rear brake light switch The rear brake light which is activated by the brake pedal should come on just before braking takes effect If neces sary adjust the rear brake light switch as follows Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the ...

Page 71: ... 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 the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 5 mm 0 06 in have a Yamaha dealer replace the brake pads as a set EAU39371 Checking the brake fluid level Front bra...

Page 72: ...raking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake...

Page 73: ...n loosen the axle nut 2 To tighten the drive chain turn the drive chain slack adjusting nut at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting nut at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can lead to chain slipp...

Page 74: ...hing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lub...

Page 75: ...th cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 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 EAU44271 Checking and lubricating the brake and shift pedals Th...

Page 76: ... 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 Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U36P10E0 book Page 31 Thursday November 13 2008 4 45 PM ...

Page 77: ...maintenance and lubrication chart EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition 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 p...

Page 78: ... the ground See page 7 39 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 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 chec...

Page 79: ...tion when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520 To charge a VRLA Valve Regulated Lead Acid ...

Page 80: ...ed under the rider seat See page 4 13 TIP To access the main fuse remove the starter relay cover as shown 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 WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age...

Page 81: ...nosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove cowlings A and C See page 7 9 2 Disconnect the headlight c...

Page 82: ...ail brake light bulb 1 Remove the passenger seat See page 4 13 2 Remove the owner s tool kit 3 Remove the socket together with the bulb by turning it counter clockwise 4 Remove the burnt out bulb by pull ing it out 5 Insert a new bulb into the socket 6 Install the socket together with the bulb by turning it clockwise 7 Install the owner s tool kit 8 Install the passenger seat 1 Headlight bulb hold...

Page 83: ... the lens may break ECA11191 EAU24312 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 burnt out 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 installing the ...

Page 84: ... jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel EAU47420 To r...

Page 85: ... wheel so that it is on the ground and then put the sidestand down 5 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 6 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU34414 To remove the rear wheel WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of...

Page 86: ...may be useful to tap the wheel axle out 7 Remove the wheel NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU34431 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 TIP Make sure that the retainer on the swingarm is ins...

Page 87: ...se vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARN...

Page 88: ...maha 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 engine turns over quickly The engin...

Page 89: ...d press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leak...

Page 90: ...let with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always r...

Page 91: ...d detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosiv...

Page 92: ...ic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26181 Storage Short term Always st...

Page 93: ...k plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires fr...

Page 94: ...th 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 25 L 0 26 US qt 0 22 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 17 3 L 4 57 US gal 3 81 Imp gal Fuel reserve ...

Page 95: ... 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition FZ6RY 90 188 kg 198 414 lb FZ6RYC 90 187 kg 198 412 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT4 50 Fron...

Page 96: ... light 12 V 21 W 5 0 W 2 Rear turn signal light 12 V 21 0 W 2 License plate light 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Ra...

Page 97: ...ification number The key identification 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 TIP The vehicle identification number is used to identify your motorcycle and may...

Page 98: ...affixed to the frame under the passenger seat See page 4 13 Record the information on this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 U36P10E0 book Page 2 Thursday November 13 2008 4 45 PM ...

Page 99: ...nd if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Sevent...

Page 100: ...le for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exh...

Page 101: ...der that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or...

Page 102: ...ATION 10 6 10 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U36P10E0 book Page 6 Thursday November 13 2008 4 45 PM ...

Page 103: ...warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha mo...

Page 104: ...later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires warra...

Page 105: ... repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing p...

Page 106: ...d protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U36P10E0 book Page 10 Thursday November 13 2008 4 45 PM ...

Page 107: ... I Identification numbers 10 1 Ignition circuit cut off system 4 20 Indicator and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 38 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color caution 8 1 Model label 10 2 Multi function meter unit ...

Page 108: ...n signal light bulb replacing 7 38 Turn signal switch 4 9 V Valve clearance 7 21 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 33 Wheel front 7 39 Wheel rear 7 40 Wheels 7 24 U36P10E0 book Page 2 Thursday November 13 2008 4 45 PM ...

Page 109: ...U36P10E0 book Page 3 Thursday November 13 2008 4 45 PM ...

Page 110: ...PRINTED IN JAPAN 2008 11 4 2 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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