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Yamaha FZ6RZ(C), Owner'S Manual

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Summary of Contents for FZ6RZ(C)

Page 1: ...DIC183 36P 28199 11 FZ6RZ C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 23 69 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U36P11E0 book Page 1 Tuesday September 29 2009 5 12 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 U36P11E0 book Page 1 Tue...

Page 5: ...r Corporation U S A 1st edition September 2009 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 23 69 U36P11E0 book Page 2 Tuesday September 29 2009 5 12 PM ...

Page 6: ...tenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 5 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 20 Checking the throttle cable free play 7 21 Valve clearance 7 2...

Page 7: ... wheel 7 40 Rear wheel 7 41 Troubleshooting 7 42 Troubleshooting charts 7 44 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 YAMA...

Page 8: ...They 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 U36P11E0 book Page 1 Tuesday September 29 2009 5 12 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 U36P11E0 book Page 2 Tuesday September 29 2009 5 12 PM ...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 7 California only 8 California only U36P11E0 book Page 3 Tuesday September 29 2009 5 12 PM ...

Page 11: ...LOCATION OF IMPORTANT LABELS 1 4 1 1 U36P11E0 book Page 4 Tuesday September 29 2009 5 12 PM ...

Page 12: ...LOCATION OF IMPORTANT LABELS 1 5 1 1 California only U36P11E0 book Page 5 Tuesday September 29 2009 5 12 PM ...

Page 13: ...senger 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 yo...

Page 14: ...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 15: ... 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 16: ...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 17: ... 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 9 8 Engine oil filter cartridge page 7 13 9 Engine oil drain bolt page 7 13 U36P11E0 book Page 1 Tuesday September 29 2009 5 12 PM ...

Page 18: ...uid reservoir page 7 27 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 17 8 Engine oil dipstick page 7 13 9 Brake pedal page 4 10 10 Shock absorber assembly spring preload adjusting ring page 4 19 U36P11E0 book Page 2 Tuesday September 29 2009 5 12 PM ...

Page 19: ...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 27 6 Right handlebar switches page 4 8 7 Throttle grip page 7 21 8 Brake lever page 4 10 U36P11E0 book Page 3 Tuesday September 29 2009 5 12 PM ...

Page 20: ...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 EAU10683 LOCK The steering is locked and all electrical systems...

Page 21: ... 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 22: ...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 23: ... Go ahead with riding 117 134 C 243 274 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 44 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 7 44 U36P11E0 book Page 4 Tuesday September 29 2009...

Page 24: ...ehicle before making any setting changes 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 t...

Page 25: ...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 26: ... 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 27: ...mmer 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 position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound t...

Page 28: ...p To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 4 20 EAU12870 Shift pedal The shift pedal is located on the left side of the engine and is used i...

Page 29: ... The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13074 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key...

Page 30: ...ion such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ately NOT...

Page 31: ...so hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAU48760 Fuel tank breather overflow hose TIP For California See page 7 13 for breather hose information Before operating...

Page 32: ...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 33: ...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 34: ...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 35: ... 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 36: ... 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 37: ...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 U36P11E...

Page 38: ...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 39: ...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 lowing...

Page 40: ...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 41: ...nts ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check the fuel tank breather overflow hose for obstructions cracks or damage and check the hose connection 4 11 4 12 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 a...

Page 42: ... 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 21 7 24 Brake and shift pedals Make sure that ...

Page 43: ...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 U36P11E0 book Page 3 Tuesday September 29 2009 5 12 PM ...

Page 44: ... 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 EAU40198 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 the neutral position The transmission ...

Page 45: ...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 46: ...commended 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 p...

Page 47: ... 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 48: ...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 49: ...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 U36P11E0 book Page 2 Tuesday September...

Page 50: ...nths 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check 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 syst...

Page 51: ... tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 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 U36P11E0 book Page 4 Tuesday September 29 2009 5 12 PM ...

Page 52: ...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 53: ...epack with 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 light...

Page 54: ...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 55: ...quired 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 26 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Lights signals and switches Check operation ...

Page 56: ... 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 57: ...nal 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 1 1 Turn signal light lead 2 Guide 3 Turn signal light lead...

Page 58: ...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 U36P11E0 book Page 11 Tuesday September 29 2009 5 12 PM ...

Page 59: ...ally 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 s...

Page 60: ...nd 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 side can result in a false reading 2 St...

Page 61: ...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 the engine oil drain bolt and its gasket 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 wrench 1 Engine oil dipstick 2 ...

Page 62: ...n 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 addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial e...

Page 63: ...n 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 A See page 7 9 TIP 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 stra...

Page 64: ...on as possible otherwise the effectiveness of the coolant will be reduced ECA10472 7 Route the coolant reservoir breath er hose through the guide as shown 8 Install the cowlings EAU47321 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove cowlings A and C See page 7 9 3 Place a container under the engine to collect the used coolant 4 Remove ...

Page 65: ...or and reservoir 13 Install the radiator cap 14 Install the coolant reservoir cap 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 1 Coolant reservoir cap 2 Coolant reservoir breather hose 3 Guide 1 Bolt 2 Coolant reservoir cover 3 Coolant reservoir 3 1 2 2 3 1 1 Coola...

Page 66: ...ld 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 page 4 13 2 Remove panels B and C See page 7 9 3 Remove the fuel tank bolts and then lift the fuel tank away from the air filter case 4 Remove the air filter case cover by removing ...

Page 67: ...e 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 damaged have a Yamaha dealer replace the hose before starting the engine otherwise fuel may leak creating a ...

Page 68: ...ion chart EAU21752 Tires To maximize the performance durabil ity and safe operation of your motorcy cle 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 EWA10501 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air...

Page 69: ... related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi FZ6RZ 90 189 kg 198 417 lb FZ6RZC 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 spee...

Page 70: ...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 for appro...

Page 71: ...90 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 play turn the clutch lever free play adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in direction ...

Page 72: ...ngy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the braking performance which may re sult in loss of control and an acci dent 1 Locknut clutch cable 2 Clutch lever free play adjusting nut clutch cable 1 2 a b 1...

Page 73: ...r at the intervals spec ified in the periodic maintenance and lubrication chart EAU22420 Front brake pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the 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 p...

Page 74: ...uid 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 75: ...e 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 EAU47032 To adjust the drive chain slack 1 Loosen the locknut at each end of the s...

Page 76: ... out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10583 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 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 sol...

Page 77: ... or replace it WARNING Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU23112 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 by a ...

Page 78: ...re each ride and the pedal pivots should be lu bricated if necessary EAU23142 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 U36P11E0 book Page 31 Tuesday September 29 2009 5 12 PM ...

Page 79: ...or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAUM1651 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Rec...

Page 80: ...t fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23283 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a ...

Page 81: ...ns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefo...

Page 82: ... is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 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 the battery leads are properly con nected to the battery terminals NOTICE ECA16530 Always keep...

Page 83: ...TICE 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 with al cohol or thinner Headlight lens Do ...

Page 84: ...ect the coupler 6 Install the cowlings 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU47400 Replacing the tail 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 1 Do not touch the glass part of the bulb 1 Headlight bulb c...

Page 85: ...Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11191 EAU24313 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the license plate light bulb socket together with the bulb by pulling it out...

Page 86: ...e 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 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...

Page 87: ...he 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 a...

Page 88: ...e wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain does not need to be disassembled in order to re move and install the rear wheel 6 While supporting the brake caliper and slightly lifting the wheel pull the wheel axle out TIP A rubber mallet may be useful to tap the wheel axle out 7 Remove the wheel NOTICE Do not apply the bra...

Page 89: ... 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 to a Yamaha dealer whose skilled technicians have the necessary tools e...

Page 90: ...ODIC MAINTENANCE AND ADJUSTMENT 7 43 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U36P11E0 book Page 43 Tuesday September 29 2009 5 12 PM ...

Page 91: ...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 92: ...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 93: ...tlet 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 ...

Page 94: ...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 95: ...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 96: ...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 97: ...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 98: ... 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition FZ6RZ 90 189 kg 198 417 lb FZ6RZC 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 99: ...ht 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 Radiat...

Page 100: ...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 101: ...ordering spare parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 1 Vehicle Emission Control Information label 1 U36P11E0 book Page 2 Tues...

Page 102: ...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 103: ...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 104: ...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 105: ...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 U36P11E0 book Page 6 Tuesday September 29 2009 5 12 PM ...

Page 106: ...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 107: ...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 108: ... 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 109: ...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 U36P11E0 book Page 10 Tuesday September 29 2009 5 12 PM ...

Page 110: ... 7 36 Helmet holder 4 17 High beam indicator light 4 2 Horn switch 4 8 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 5 Maintenance emission control system 7 3 Maintenance record 10...

Page 111: ...acing 7 38 Turn signal switch 4 8 V Valve clearance 7 21 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 34 Wheel front 7 40 Wheel rear 7 41 Wheels 7 24 U36P11E0 book Page 2 Tuesday September 29 2009 5 12 PM ...

Page 112: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 113: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 114: ...PRINTED IN JAPAN 2009 10 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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