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PERIODIC MAINTENANCE AND MINOR REPAIR

6-41

6

EAU25870

Troubleshooting

Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.

U3C312E0.book Page 41 Monday, August 6, 2007 10:41 AM

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Summary of Contents for FZS10X

Page 1: ...3C3 28199 12 FZS10X FZS10XC OWNER S MANUAL LIT 11626 21 51 ...

Page 2: ...EAU10041 U3C312E0 book Page 1 Monday August 6 2007 10 41 AM ...

Page 3: ...torcycle 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: ...consult 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 WA...

Page 5: ...TECHNIQUES 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 U3C312E0 book Page 2 Monday August 6 2007 10 41 AM ...

Page 6: ...rporation U S A 1st edition July 2007 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 21 51 AFFIX DEALER LABEL HERE U3C312E0 book Page 3 Monday August 6 2007 10 41 AM ...

Page 7: ...lubrication chart 6 4 Removing and installing panels 6 9 Checking the spark plugs 6 10 Canister for California only 6 11 Engine oil and oil filter cartridge 6 11 Coolant 6 14 Replacing the air filter element 6 16 Checking the engine idling speed 6 18 Checking the throttle cable free play 6 18 Valve clearance 6 19 Tires 6 19 Cast wheels 6 22 Accessories and replacement parts 6 22 Adjusting the clut...

Page 8: ...YCLE CARE AND STORAGE 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 U3C312E0 book Page 2 Monday August 6 2007 10 41 AM ...

Page 9: ...nts 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 mo...

Page 10: ...ield 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 e...

Page 11: ...ution 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 susp...

Page 12: ... equate 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 ...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3C312E0 book Page 5 Monday August 6 2007 10 41 AM ...

Page 14: ...N 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 as follows U3C312E0 book Page 6 Monday August 6 2007 10 41 AM ...

Page 15: ...ge 6 33 5 Fuel injection system fuse page 6 33 6 Storage compartment page 3 14 7 Passenger seat lock page 3 13 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 10 11 Engine oil drain bolt page 6 11 12 Engine oil filter cartridge page 6 11 U3C312E0 book Page 1 Monday August 6 2007 10 41 ...

Page 16: ...oir page 6 24 6 Engine oil filler cap page 6 11 7 Front brake fluid reservoir page 6 24 8 Front fork rebound damping force adjusting screw page 3 14 9 Engine oil level check window page 6 11 10 Brake pedal page 3 10 11 Coolant reservoir page 6 14 12 Rear brake light switch page 6 23 13 Luggage strap holder page 3 18 U3C312E0 book Page 2 Monday August 6 2007 10 41 AM ...

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 18 7 Brake lever page 3 10 U3C312E0 book Page 3 Monday August 6 2007 10 41 AM ...

Page 18: ...AU10660 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 wh...

Page 19: ...on 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 temp...

Page 20: ...OK 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 42 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 42 U3C312E0 book Page 3 Monday August 6 2007 10...

Page 21: ...meter 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...

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 swi...

Page 23: ...y 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 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 symbol will flash eight times then go off for...

Page 24: ...ture was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed for one second and then the air in take 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 wil...

Page 25: ... key to ON and then re lease the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to con firm the selected brightness level The display will return to the odom eter or tripmeter mode EAU12347 Handlebar switches Left Right 1 Tachometer panel 2 Tachometer needle 3 LCD 4 Brightness level 1 Dimmer switch 2 Turn signal switch 3 Hor...

Page 26: ...41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12765 Hazard switch With the key in the ON position use this switch to turn on the hazard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is st...

Page 27: ... is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear b...

Page 28: ...osed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13220 Fuel Make sure that there is sufficient fuel in the tank When refueling be sure to in sert the pump nozzle into the fuel tank filler hole and to fill the tank to the bot tom of the filler t...

Page 29: ...sohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13442 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10860 The exhaust system is hot after op eration Make sure that the ...

Page 30: ...k it in place 2 Remove the key Rider seat To remove the rider seat 1 Remove the passenger seat 2 Push the rider seat lock lever lo cated under the back of the rider seat to the right 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 ...

Page 31: ...ZS10XC 189 kg 417 lb for the vehicle EAU39332 Adjusting the front fork Each front fork leg is equipped with a spring preload adjusting bolt the right front fork leg is equipped with a re bound damping force adjusting screw and the 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...

Page 32: ...g screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b NOTE Be sure to perform this adjustment on the right front fork leg Compression damping force The compression damping force is ad justed on the left front fork leg only To increase the compression damping 1 Current setting 2 Front fork cap bolt Spring preload...

Page 33: ...s always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary EAU39341 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and a rebound damping force adjusting screw CAUTION EC...

Page 34: ...ove specifications due to small differ ences in production the actual number of clicks always represents the entire adjusting range To obtain a precise ad justment it would be advisable to check the number of clicks of the rebound damping force adjusting mechanism and to modify the specifications as nec essary WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop e...

Page 35: ...ootrest EAU41940 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer controlled servo motor CAUTION ECA15610 The EXUP system has been set and extensively tested at th...

Page 36: ...e 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 EAU44900 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 functions It prevents starting when the trans mission is in gear and the side ...

Page 37: ...tand down Does the engine stall After 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 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 should not be ridden until chec...

Page 38: ...quences 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 w...

Page 39: ...oft 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 24 6 24 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 reserv...

Page 40: ...6 19 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 30 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened...

Page 41: ... lever pulled and the sid 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 ECA15481 The following warning lights should come on for a few seconds then go off Oil level w...

Page 42: ...ing light again If the engine trouble 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 EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accel...

Page 43: ...to 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...

Page 44: ...above 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: ...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 VICES EAU17480 Ow...

Page 46: ...ARNING 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 U3C312E0 book Page 2 Monday August 6 2007 10 41 AM ...

Page 47: ...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 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 Tight...

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

Page 49: ...sary 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 Centerstand and sidestand pivots Check operation Apply lithium soap based grease lightly 18 Sidestand switch Check operation and repl...

Page 50: ...lace 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 SAE 10W 30 thoroughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km o...

Page 51: ...er 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 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate t...

Page 52: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U3C312E0 book Page 8 Monday August 6 2007 10 41 AM ...

Page 53: ...emoved 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 EAU19281 Panel C To remove the panel Remove the screw and then pull the panel off as shown 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Screw 3 Bolt U3C312E0...

Page 54: ... 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 55: ...phere 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 EAU19873 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 filt...

Page 56: ... 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 E...

Page 57: ...n 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 enters the crankcase 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge...

Page 58: ...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 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 vehi...

Page 59: ...added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 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 overhe...

Page 60: ...ubrication 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 3 13 2 Remove panels A and B See page 6 9 3 Remove the cowling bolts and then pull the cowling off 4 Remove the fuel 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 W...

Page 61: ...d otherwise the piston s and or cylinder s may become excessively worn 9 Install the air filter case cover by in stalling the screws 10 Place the fuel tank in the original position and then install the bolts WARNING 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 dea...

Page 62: ...cified in the periodic mainte nance and lubrication chart Start the engine and warm it up for sev eral minutes at 1000 2000 r min while occasionally revving it to 4000 5000 r min EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha deal...

Page 63: ...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 EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Secur...

Page 64: ... 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 WARNING EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all whee...

Page 65: ... 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 approximately 10...

Page 66: ...t 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 you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the original design Genuine Yamaha...

Page 67: ...tly have a Yamaha dealer check the internal clutch mechanism EAU22270 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the b...

Page 68: ...ake If a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EAU22571 Checking the bra...

Page 69: ...r braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the br...

Page 70: ...g bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine...

Page 71: ...d 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 CAUTION ECA11110 Do not use engine oil or any other lu bricants for...

Page 72: ...nce 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 addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals The o...

Page 73: ...ver 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 U3C312E0 book Page 29 Monday August 6 2007 10 41 AM ...

Page 74: ...ntervals 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 brake push down hard...

Page 75: ...y 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 Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart ...

Page 76: ...BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and th...

Page 77: ... a fuse is blown replace it as follows NOTE Include steps 2 and 6 only for the fuel injection system fuse 1 Turn the key to OFF and turn off the electrical circuit in question 2 Unhook the battery band and then remove the battery cover 1 Main fuse 2 Fuse box 3 Fuel injection system fuse 4 Fuel injection system spare fuse 1 Fuse box 2 Headlight fuse 3 Ignition fuse 4 Signaling system fuse 5 Backup ...

Page 78: ...t in question to check if the device operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 Install the battery cover and then hook the battery band onto the holder 1 Battery band 2 Battery cover 1 Fuel injection system fuse 2 Fuel injection system spare fuse Specified fuses Main fuse 50 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition fuse...

Page 79: ... then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened wit...

Page 80: ...e defective bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the passenger seat EAU43000 Replacing a turn signal light bulb 1 Remove the turn signal light unit by removing the screw 2 Remove the socket together with the bulb b...

Page 81: ...installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bulb by pulling it out 1 Turn signal light bulb socket 1 Turn signal light bulb 1 License plate light unit 2 Screw 1 License plate light bulb U3C312E0 book ...

Page 82: ...g 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 bolts 3 Remove the brake hose holder on each side by removing the bolt and nut 4 Remove the brake caliper togeth er with the reflector on each side by removing the bolts CAUTION ECA11050 Do not apply the brake after the brake calipers have been removed otherwise the bra...

Page 83: ...xle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAU40020 To remove the rear 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 Loosen the axle nu...

Page 84: ...e after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU39411 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the left hand side NOTE Make sure that the slot in the brake caliper bracket is fit over the retain er on the swingarm Make sure that there is enough space between the brak...

Page 85: ...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 properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi...

Page 86: ... 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 star...

Page 87: ...ped 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 l...

Page 88: ...muffler 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 axl...

Page 89: ... 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 corrosive in combination with water carry out the following steps after each ride in the rain near the sea...

Page 90: ...any excess Never apply oil or wax 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 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 ECA108...

Page 91: ...to 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 f...

Page 92: ...dge 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 90 US...

Page 93: ... Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition FZS10X 90 190 kg 198 419 lb FZS10XC 90 189 kg 198 417 lb 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 t...

Page 94: ...5 0 W 21 0 W 1 Front turn signal 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 s...

Page 95: ...ntification 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 ...

Page 96: ...l is affixed to the frame under the rider seat See page 3 13 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 U3C312E0 book Page 2 Monday August 6 2007 10 41 AM ...

Page 97: ...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 98: ...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 99: ...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 100: ...ORMATION 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 U3C312E0 book Page 6 Monday August 6 2007 10 41 AM ...

Page 101: ... 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 102: ... 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 103: ...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 104: ...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 U3C312E0 book Page 10 Monday August 6 2007 10 41 AM ...

Page 105: ...ing 6 35 High beam indicator light 3 2 Horn switch 3 9 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 37 Luggage strap holders 3 18 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenan...

Page 106: ... Turn signal light bulb replacing 6 36 Turn signal switch 3 9 V Valve clearance 6 19 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheel front 6 38 Wheel rear 6 39 Wheels 6 22 U3C312E0 book Page 2 Monday August 6 2007 10 41 AM ...

Page 107: ...U3C312E0 book Page 3 Monday August 6 2007 10 41 AM ...

Page 108: ...PRINTED IN JAPAN 2007 08 1 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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