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Yamaha FZS10W, Owner'S Manual, Page: 69 / 106

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Yamaha FZS10W Owner'S Manual Download Page 69

PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

6

CAUTION:

ECA10570

Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.

3. Tighten the locknuts, then the axle

nut to their specified torques.

EAU23022

Cleaning and lubricating the 
drive chain 

The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.

CAUTION:

ECA10581

The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.

1. Clean the drive chain with kero-

sene and a small soft brush.

CAUTION:

ECA11120

To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers or
inappropriate solvents.

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive

chain with a special O-ring chain
lubricant.

1. Axle nut
2. Locknut

3. Drive chain slack adjusting bolt

4. Alignment marks

Tightening torques:

Locknut:

16 Nm (1.6 m·kgf, 11 ft·lbf)

Axle nut:

150 Nm (15.0 m·kgf, 110 ft·lbf)

U3C311E0.book  Page 25  Monday, September 11, 2006  1:18 PM

Summary of Contents for FZS10W

Page 1: ...3C3 28199 11 FZS10W FZS10WC OWNER S MANUAL LIT 11626 20 54 ...

Page 2: ...EAU10041 U3C311E0 book Page 1 Monday September 11 2006 1 18 PM ...

Page 3: ...orcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high ...

Page 4: ...onsult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WAR...

Page 5: ...CHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications are subject to change without notice U3C311E0 book Page 2 Monday September 11 2006 1 18 PM ...

Page 6: ...ation U S A 1st edition September 2006 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 20 54 AFFIX DEALER LABEL HERE U3C311E0 book Page 3 Monday September 11 2006 1 18 PM ...

Page 7: ...rication chart 6 4 Removing and installing panels 6 8 Checking the spark plugs 6 9 Canister for California only 6 10 Engine oil and oil filter cartridge 6 10 Coolant 6 13 Replacing the air filter element 6 15 Checking the throttle cable free play 6 17 Valve clearance 6 17 Tires 6 17 Cast wheels 6 20 Accessories and replacement parts 6 20 Adjusting the clutch lever free play 6 21 Adjusting the rear...

Page 8: ... 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U3C311E0 book Page 2 Monday September 11 2006 1 18 PM ...

Page 9: ...s have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other moto...

Page 10: ...eld or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or ex...

Page 11: ...caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit su...

Page 12: ...quate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fa...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3C311E0 book Page 5 Monday September 11 2006 1 18 PM ...

Page 14: ...ATION 1 6 1 1 3 2 5 4 6 7 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 California only U3C311E0 book Page 6 Monday September 11 2006 1 18 PM ...

Page 15: ...e 6 31 5 Fuel injection system fuse page 6 31 6 Storage compartment page 3 14 7 Passenger seat lock page 3 12 8 Shock absorber assembly spring preload adjusting ring page 3 16 9 Shock absorber assembly rebound damping force adjusting screw page 3 16 10 Shift pedal page 3 9 11 Engine oil drain bolt page 6 10 12 Engine oil filter cartridge page 6 10 U3C311E0 book Page 1 Monday September 11 2006 1 18...

Page 16: ...rake fluid reservoir page 6 23 6 Engine oil filler cap page 6 10 7 Front brake fluid reservoir page 6 23 8 Front fork rebound damping force adjusting screw page 3 14 9 Engine oil level check window page 6 10 10 Brake pedal page 3 10 11 Coolant reservoir page 6 13 12 Luggage strap holder page 3 18 U3C311E0 book Page 2 Monday September 11 2006 1 18 PM ...

Page 17: ...lever page 3 9 2 Left handlebar switches page 3 8 3 Main switch steering lock page 3 1 4 Multi function meter unit page 3 4 5 Right handlebar switches page 3 8 6 Throttle grip page 6 17 7 Brake lever page 3 10 U3C311E0 book Page 3 Monday September 11 2006 1 18 PM ...

Page 18: ...U10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF whi...

Page 19: ...n but this is not a malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11423 Coolant tempe...

Page 20: ... 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 6 40 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 40 U3C311E0 book Page 3 Monday September 11 2006 ...

Page 21: ...ter which shows the riding speed a tachometer which shows engine speed an odometer which shows the to tal distance traveled 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 the fuel meter started flashing a clock a fuel meter a coolant temperature display an air intake temperature d...

Page 22: ...the key to ON 2 Push the SELECT 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 swit...

Page 23: ...er disappear to wards E Empty as the fuel level decreases When only one segment is left near E refuel as soon as possible NOTE This fuel meter is equipped with a self diagnosis system If the electrical circuit is defective the following cycle will be repeated until the malfunction is cor rected E Empty F Full and sym bol will flash eight times then go off for approximately 3 seconds If this oc cur...

Page 24: ...e temperature is displayed Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on and then the display will indicate a two digit error code If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle CAUTION ECA1...

Page 25: ...nal 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 the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to sto...

Page 26: ...he hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever The clutch lever is located at the left handlebar grip 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 e...

Page 27: ... brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13072 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 ins...

Page 28: ...d expands Avoid spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13300 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha...

Page 29: ... after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials...

Page 30: ...t as shown and then pull the seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock it in place 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Rider seat lock lever 1 Projection 2 Seat holder U3C311E0 book Page 13 Monday September 11 2006...

Page 31: ... left front fork leg with a com pression damping force adjusting screw WARNING EWA14670 Always adjust the spring preload on both fork legs equally otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the susp...

Page 32: ...ease the com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b NOTE Be sure to perform this adjustment on the left front fork leg CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload setting Minimum soft 8 Standard 5 5 Maximum hard 0 1 Rebound damping force adjusting screw Rebound...

Page 33: ...d adjust ing ring and a rebound damping force adjusting screw CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE Align t...

Page 34: ...WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an o...

Page 35: ...he sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sides...

Page 36: ... 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 sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10260 The vehicle must be placed on ...

Page 37: ... the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle sho...

Page 38: ...uences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not wo...

Page 39: ...ft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservo...

Page 40: ... 17 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened ...

Page 41: ...estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15480 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warnin...

Page 42: ...le warning light flashes or remains on after starting immediately stop the engine and have a Yamaha dealer check the cause CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold NOTE The engine is warm when it quickly re sponds to the throttle EAU16671 Shifting Shifting gears lets you control the amount of engine power a...

Page 43: ... shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 2...

Page 44: ...bove 7200 r min CAUTION ECA10301 After 1000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge or element re placed 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA10310 Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the ...

Page 45: ... TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VIC...

Page 46: ...NING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U3C311E0 book Page 2 Monday September 11 2006 1 18 PM ...

Page 47: ...lugs 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 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 Tighte...

Page 48: ...able 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 necessary Check air pressure C...

Page 49: ...d clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Centerstand and sidestand pivots Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil ...

Page 50: ...coolant every 24 months Change 23 Front and rear brake switches Check operation 24 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 25 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 No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 400...

Page 51: ...wet or dusty areas Hydraulic brake service After disassembling 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 Replace the brake hoses every four years and if cracked or damaged 26 Lights sig...

Page 52: ...ed and installed EAU40030 Panels A and B To remove one of the panels Remove the bolts and the screws and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screws and the bolts EAU19272 Panel C To remove the panel Remove the screw and then pull out ward on the areas shown 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Screw 3 Bolt U3C311E...

Page 53: ...is ridden normally 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 ...

Page 54: ...here Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged Make sure that the canister breath er is not blocked and if necessary clean it EAU19871 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 filte...

Page 55: ...under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 1 En...

Page 56: ... a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 1 O ring 1 Torque wrench Tighten...

Page 57: ...ation chart EAU40041 To check the coolant level 1 Place the vehicle on the center stand NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in an incorrect reading 2 Check the coolant level in the cool ant reservoir NOTE The c...

Page 58: ... the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 40 for further instructions EAU33030 Changing the coolant WARNING EWA10380 Never attempt to remove the radiator cap when ...

Page 59: ...uel tank bolts 5 Lift the front of the fuel tank and then tilt it back and away from the air filter case Do not disconnect the fuel hoses WARNING EWA10410 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 which could cause fuel leakage 6 Remove the air filter case cover by removing the screws CAUTION ECA12880 When remo...

Page 60: ...EWA11360 Before placing the fuel tank in the original position make sure that the fuel hoses are not dam aged If any fuel hose is dam aged do not start the engine but have a Yamaha dealer replace the hose otherwise fuel may leak 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 origina...

Page 61: ...cified in the periodic maintenance and lubrication chart EAU21750 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when t...

Page 62: ...uld cause tire damage an accident or even injury 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 0 198 lb Front 250 kPa 36 psi 2...

Page 63: ...Motor Co Ltd Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tir...

Page 64: ... 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 EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts yo...

Page 65: ...ee play and if necessary adjust it as follows To increase the clutch lever free play turn the adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE 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 1 Clutch lever free play a...

Page 66: ...fied 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 the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicators while applying the brake If a brake pad has worn to the point that a wear indicator almost touches the brake ...

Page 67: ... fluid 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 lo...

Page 68: ...stand 2 Shift the transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measure the drive chain slack as shown 5 If the drive chain slack is incorrect adjust it as follows EAU34311 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusti...

Page 69: ...se it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or ina...

Page 70: ...oes not move smoothly have a Yamaha dealer check or replace it WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In...

Page 71: ... pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U3C311E0 book Page 27 Monday September 11 2006 1 18 PM ...

Page 72: ... follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front bra...

Page 73: ...must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamah...

Page 74: ...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 Therefore keep spark...

Page 75: ... con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer charge your ba...

Page 76: ...possibly a fire 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 Headlight fuse 3 Ignition fuse 4 Signaling system fuse 5 Backup fuse for odometer and clock 6 Right radiator fan fuse 7 Left radiator fan fuse 8 Spare fuse 1 Battery band 2 Battery cov...

Page 77: ...e bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb WARNING EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 3 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts 1 Headli...

Page 78: ...her than specified 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU24112 Replacing the tail brake light bulb 1 Remove the passenger seat See page 3 12 2 Remove the socket together with the bulb by turning it counter clockwise 3 Remove the defective bulb by pushing it in and turning it counter clockwise 4 Insert a new ...

Page 79: ...move the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 6 Install the turn signal light unit by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break 1 Turn signal light unit 2 Screw 1 Turn signal light bulb socket 1 Turn signal light bulb U3C311E0 book Page 35 Mond...

Page 80: ... Install the license plate light unit by installing the screws EAU24360 Front wheel EAU40200 To remove the front wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Place the vehicle on the center stand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolt...

Page 81: ...he bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 4 Install the brake hose holder on each side by installing the bolt and nut 5 Take the vehicle off the center stand so that the front wheel is on the ground 6 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques ...

Page 82: ... wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU39411 To i...

Page 83: ...oblem 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 experience and know how to service the motorcycle pr...

Page 84: ...There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric start...

Page 85: ...d press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for lea...

Page 86: ...ffler outlet 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...

Page 87: ...y 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 corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into...

Page 88: ...reat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26180 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it w...

Page 89: ... ground the spark plug electrodes while turning the engine over 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 fro...

Page 90: ...rtridge 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 Unleaded gasoline only Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve amount 3 4 L 0 9...

Page 91: ...50 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 189 kg 198 417 lb CAL 90 190 kg 198 419 lb U49 Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT6 00 Front brake...

Page 92: ...gnal position 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 50 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition f...

Page 93: ...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 NOTE The vehicle identification number is used to identify your motorcycle and ma...

Page 94: ... is affixed to the frame under the rider seat See page 3 12 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U3C311E0 book Page 2 Monday September 11 2006 1 18 PM ...

Page 95: ...d 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 Seventh...

Page 96: ...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 97: ...er 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 98: ...MATION 9 6 9 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 U3C311E0 book Page 6 Monday September 11 2006 1 18 PM ...

Page 99: ...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 100: ...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 101: ...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 ph...

Page 102: ...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 U3C311E0 book Page 10 Monday September 11 2006 1 18 PM ...

Page 103: ... indicator light 3 2 Horn switch 3 8 I Identification numbers 9 1 Ignition circuit cut off system 3 19 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 36 Luggage strap holders 3 18 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Ma...

Page 104: ...Turn signal light bulb replacing 6 35 Turn signal switch 3 8 V Valve clearance 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 30 Wheel front 6 36 Wheel rear 6 38 Wheels 6 20 U3C311E0 book Page 2 Monday September 11 2006 1 18 PM ...

Page 105: ...U3C311E0 book Page 3 Monday September 11 2006 1 18 PM ...

Page 106: ...PRINTED IN JAPAN 2006 09 0 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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