Yamaha FZ8 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-21

7

EAU22081

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 in direction (a). To decrease the
clutch lever free play, turn the adjusting
bolt in direction (b).

TIP

If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.

EAU37913

Checking the brake lever free
play

There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.

WARNING

EWA14211

A soft or spongy 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

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

1. No brake lever free play

1

U39P10E0.book Page 21 Thursday, October 7, 2010 5:12 PM

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Summary of Contents for FZ8

Page 1: ...DIC183 39P 28199 10 FZ8NA C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 24 07 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U39P10E0 book Page 1 Thursday October 7 2010 5 12 PM ...

Page 3: ...tain 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: ...y 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 U39P10E0 book Page 1 Th...

Page 5: ...or Corporation U S A 1st edition September 2010 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 24 07 U39P10E0 book Page 2 Thursday October 7 2010 5 12 PM ...

Page 6: ...tenance and lubrication chart 7 5 Removing and installing the panel 7 9 Checking the spark plugs 7 9 Canister for California only 7 10 Engine oil and oil filter cartridge 7 11 Coolant 7 13 Replacing the air filter element 7 15 Checking the engine idling speed 7 17 Checking the throttle grip free play 7 17 Valve clearance 7 18 Tires 7 18 Cast wheels 7 20 Adjusting the clutch lever free play 7 21 Ch...

Page 7: ...oubleshooting charts 7 42 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 U39P10E0 book Page 2...

Page 8: ...le 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 6 2 3 4 5 U39P10E0 book Page 1 Thursday October 7 2010 5 12 PM ...

Page 9: ...kgf cm 36 psi 290 kPa 2 90 kgf cm 42 psi 90kg 198 lbs maximum load FRONT REAR 250 kPa 2 50 kgf cm 36 psi 290 kPa 2 90 kgf cm 42 psi 14B 21668 00 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 80 EMISSION HOSE ROUTING 39P 21686 00 FUEL TANK THROTTLE BODY CHARCOAL CANISTER ATMOSPH...

Page 10: ...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 11: ... 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 engi...

Page 12: ...s 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 ...

Page 13: ...anges 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 un stable in cross winds These ac cessories may also cause instability when passing...

Page 14: ...e downs or suitable straps that are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or parts that could break Choose the lo cation for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs ...

Page 15: ...fuse page 7 32 4 Fuel injection system fuse page 7 32 5 Storage compartment page 4 15 6 Owner s tool kit page 7 2 7 Shock absorber assembly spring preload adjusting ring page 4 16 8 Shift pedal page 4 9 9 Engine oil drain bolt page 7 11 10 Engine oil filter cartridge page 7 11 U39P10E0 book Page 1 Thursday October 7 2010 5 12 PM ...

Page 16: ...se box page 7 32 3 Battery page 7 30 4 Rear brake fluid reservoir page 7 23 5 Coolant reservoir page 7 13 6 Engine oil filler cap page 7 11 7 Engine oil level check window page 7 11 8 Brake pedal page 4 10 9 Rear brake light switch page 7 22 U39P10E0 book Page 2 Thursday October 7 2010 5 12 PM ...

Page 17: ... 9 2 Left handlebar switches page 4 8 3 Multi function meter unit page 4 5 4 Main switch steering lock page 4 1 5 Front brake fluid reservoir page 7 23 6 Right handlebar switches page 4 8 7 Throttle grip page 7 17 8 Brake lever page 4 10 U39P10E0 book Page 3 Thursday October 7 2010 5 12 PM ...

Page 18: ...ine 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 19: ...ing 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 acceleratio...

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 equi...

Page 21: ...head with riding 117 134 C 243 274 F Coolant temperature 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 42 Above 135 C Above 275 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 7 42 U39P10E0 book Page 4 Thursday October 7 2010 5 12 P...

Page 22: ...anges 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 t...

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 odom...

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: ...mer 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 th...

Page 26: ... 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 18 EAU12871 Shift pedal The shift pedal is located on the left side of the motorcycle and is use...

Page 27: ... 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 inserted ...

Page 28: ...nition 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 ...

Page 29: ... 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 EAU48790 Fuel tank breather overflow hose TIP For California See page 7 10 for breather hose information Before operating the motorcycle C...

Page 30: ...hicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the 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 unle...

Page 31: ... seat holders as shown and then push the rear of the seat down to lock it in place 2 Remove the key Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the bolts and then pull the seat off To install the rider seat Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original po sition and then install the bol...

Page 32: ...documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do not exceed the maximum load of FZ8NA 198 kg 437 lb FZ8NAC 197 kg 434 lb for the vehicle 1 Storage compartment 1 U39P...

Page 33: ...ol 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 to e...

Page 34: ...t TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 18 for an explanation of the ignition circuit cut off system WARNING EWA10241 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distr...

Page 35: ...nctions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off s...

Page 36: ...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 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 37: ...g points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather overflow hose for obstructions cracks or damage and check 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 11 Coolant Check coolant level in reservoir If necessary add ...

Page 38: ...ttle grip free play and lubricate cable and grip housing 7 17 7 27 Control cables Make sure that operation is smooth Lubricate if necessary 7 27 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 24 7 26 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 18 7 20 Brake and shift pedals Make s...

Page 39: ...ightened 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 17 ITEM CHECKS PAGE U39P10E0 book Page 3 Thursday October 7 2010 5 12 PM ...

Page 40: ...ne auto stop system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU40199 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 is in gear with the clutch lever pulled and th...

Page 41: ... 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 Inad...

Page 42: ...ed 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 43: ...e 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 o...

Page 44: ... performing maintenance unless otherwise specified A running 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 WARNING EWA15460 Brake discs calipers d...

Page 45: ...the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque 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 U39P10E0 book Page 2 Thursday October...

Page 46: ...onths 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 sys...

Page 47: ...s 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 U39P10E0 book Page 4 Thursday October 7 2010 5 12 PM ...

Page 48: ...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 Check for correct routing and clamping Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and fo...

Page 49: ...s 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 17 Sidestand pivot Check operation Apply lithium soap based grease ...

Page 50: ...3 Engine oil filter car tridge Replace 24 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 25 Front and rear brake switches Check operation 26 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 mo...

Page 51: ... the reservoirs as required 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 27 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 28 Lights signals and switches Check operation Adjust headlight bea...

Page 52: ...slowly erode they should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine...

Page 53: ...damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in EAU19681 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before ope...

Page 54: ...P The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Place the vehicle on a level sur face 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil...

Page 55: ...to the specified torque with a torque wrench 8 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque 9 Refill with the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Oil filter wrench 2 Oil filter cartridge 1 2 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf ...

Page 56: ...ly turn the engine off and have a Yamaha dealer check the vehicle 11 Turn the engine off wait a few min utes until the oil settles and then check the oil level and correct it if necessary 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 EAU39087 To check the co...

Page 57: ... as soon as possible other wise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 5 Install the panel EAU33031 Changing the coolant The coolant must be changed at the in tervals specified ...

Page 58: ...ard on both sides then remove the cowling by moving it forward and then lifting it up 4 Remove the fuel tank bolt on both sides 5 Lift the front of the fuel tank and carefully tilt it back and away from the air filter case but do not dis connect the fuel hoses WARNING Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose w...

Page 59: ...0 Place the fuel tank in the original position Make sure that the fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose and the fuel tank overflow hose in the original position WARNING Before placing the fuel tank in the original position make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but have a ...

Page 60: ... Yamaha dealer EAU21384 Checking the throttle grip free play The throttle grip free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the inner edge of the throttle grip Periodi cally check the throttle grip free play and if necessary have a Yamaha deal er adjust it Engine idling speed 1150 1250 r min 1 Throttle grip free play 1 U39P10E0 book Page 17 Thursday October 7 2010 5 12 PM ...

Page 61: ...ntrol The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause...

Page 62: ...ry professional knowl edge and experience to do so Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This motorcycle is equipped with tube less tires tire air valves and cast wheels WARNING EWA10481 The front and rear tires should be of the same make and de sign otherwise the handling characte...

Page 63: ...warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions EAU21962 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or oth er damage before each ride If any damage is found have a Yamaha dealer re...

Page 64: ...ed above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU37913 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14211 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there...

Page 65: ...rn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22392 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 EAU36890 Front brake pads Each front brake pad is provided with wear indicators which allows you to check t...

Page 66: ...heck that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage TIP The rear brake fluid reservoir is located behind panel A See page 7 9 Observe these precautions When checking the fluid leve...

Page 67: ...fied in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses re placed at the intervals listed below or whenever they are damaged or leak ing 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 ...

Page 68: ...ide 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 slippage or breakage To prevent this from occurring keep the drive chain slack with in the specified limits ECA10571 TIP Using the alignment marks on each side of the swingarm make sure that both dr...

Page 69: ... 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 solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive c...

Page 70: ...d be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though the cover is installed correctly it does not completely protect the cable from water entry Therefore use care not to pour water directl...

Page 71: ...r 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 U39P10E0 book Page 28 Thursday October 7 2010 5 12 PM ...

Page 72: ... 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 posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Whi...

Page 73: ...g EAU23291 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 there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU50210 Battery The battery is located under the rider seat See page 4 14 This model is equipped with a VRLA Valv...

Page 74: ...16521 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then di...

Page 75: ...emove 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 to the electrical system and possibly a fire EWA15131 1 Main fuse 2 Fuse box 3 Fuel injection system fuse 4 Fuel injection system spare fuse 1 2 3 4 1 Fuse box 2 Headlight fuse 3 Ignition fuse 4 Signaling system fuse 5 ...

Page 76: ...he 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 the headlight unit top cov er by removing its bolts 2 Remove the head...

Page 77: ...light coupler then remove the headlight bulb cover 7 Unhook the headlight bulb holder then remove the burnt out bulb 8 Place a new headlight bulb into po sition then secure it with the bulb holder 1 Headlight unit side cover 2 Bolt 1 Bolt 1 1 2 2 1 1 Headlight unit bolt 1 Coupler 1 1 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder 2 Headlight bulb 1 2 1 2 U39P10E0 book Page 34 T...

Page 78: ...nal position and then install its bolts 15 Have a Yamaha dealer adjust the headlight beam if necessary EAU24115 Replacing the tail brake light bulb 1 Remove the passenger seat See page 4 14 2 Remove the tail brake light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket ...

Page 79: ...nstall the socket together with the bulb by turning it clockwise 6 Install the turn signal light unit by installing the screw 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 1 Turn signal light unit 2 Screw 1 2 1 Turn signal light bulb socket 1 Turn sig...

Page 80: ...re 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 whee...

Page 81: ...ith 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 5 Pull the wheel axle out and then remove the wheel EAU49841 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground and then put ...

Page 82: ...ff the ground according to the procedure on page 7 37 3 Remove the axle nut 4 Fully loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a and push the wheel forward 6 Remove the drive chain from the rear sprocket TIP If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the...

Page 83: ...otorcycles 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 to a Y...

Page 84: ...IODIC MAINTENANCE AND ADJUSTMENT 7 41 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U39P10E0 book Page 41 Thursday October 7 2010 5 12 PM ...

Page 85: ...r 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 engine turns ov...

Page 86: ...hissing sound has stopped 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...

Page 87: ...utlet 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 88: ...ld 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 corrosi...

Page 89: ... to any rubber and plastic 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 EAU26182 Stor...

Page 90: ...he engine over EWA10951 e Remove the spark plug caps from the spark 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 tur...

Page 91: ...mp qt With oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 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 25 L 2 38 US qt 1 98 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline or gasohol E10 Fuel tank capacity 17 0 L 4 49 US gal ...

Page 92: ...ndition FZ8NA 90 198 kg 198 437 lb FZ8NAC 90 197 kg 198 434 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 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 MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommende...

Page 93: ...nal 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 50 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Radiator fan fuse 10 0 A 2 Fuel injectio...

Page 94: ...tification 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 ma...

Page 95: ...dering 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 U39P10E0 book Page 2 Thursd...

Page 96: ...and 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 Seven...

Page 97: ...cle 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 Ex...

Page 98: ...nder 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 o...

Page 99: ...MATION 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 U39P10E0 book Page 6 Thursday October 7 2010 5 12 PM ...

Page 100: ... 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 m...

Page 101: ... 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 warr...

Page 102: ...d 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 ...

Page 103: ...ed 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 U39P10E0 book Page 10 Thursday October 7 2010 5 12 PM ...

Page 104: ...10 1 Ignition circuit cut off system 4 18 Indicator lights and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light bulb replacing 7 36 Luggage strap holders 4 17 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color caution 8 1 Model label 10 2 Multi function met...

Page 105: ...ehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 30 Wheel front 7 38 Wheel rear 7 39 Wheels 7 20 U39P10E0 book Page 2 Thursday October 7 2010 5 12 PM ...

Page 106: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 107: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 108: ...PRINTED IN JAPAN 2010 10 0 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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