Yamaha FZS6V Owner'S Manual Download Page 55 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

6

CAUTION:

ECA10480

●

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

●

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

7. Install the air filter case cover by in-

stalling the screws.

8. Place the fuel tank in the original

position and install the bolts.

WARNING

EWA12462

●

Before placing the fuel tank in
the original position, make sure
that all hoses (i.e., fuel hose,
fuel tank breather hose, fuel
tank overflow hose) are not
damaged, that they are properly
connected and routed, and that
they are not pinched.

●

If any hose is damaged, have a
Yamaha dealer replace the hose
before starting the engine, oth-
erwise fuel may leak.

WARNING

EWA12471

Be sure to place the hoses in their
original position as shown.

9. Install the panels.

10. Install the seat.

EAU21381

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 dealer adjust it.

1. Hose

1. Original position (paint mark)

1. Throttle cable free play

U5VX12E0.book Page 16 Monday, October 17, 2005 9:58 AM

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Summary of Contents for FZS6V

Page 1: ...5VX 28199 12 FZS6V C OWNER S MANUAL LIT 11626 19 76 ...

Page 2: ...EAU10041 U5VX12E0 book Page 1 Monday October 17 2005 9 58 AM ...

Page 3: ...ycle 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 sta...

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: ...ECHNIQUES 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 U5VX12E0 book Page 2 Monday October 17 2005 9 58 AM ...

Page 6: ...ion U S A 1st edition October 2005 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 19 76 AFFIX DEALER LABEL HERE U5VX12E0 book Page 3 Monday October 17 2005 9 58 AM ...

Page 7: ...6 8 Checking the spark plugs 6 9 Canister for California only 6 10 Engine oil and oil filter cartridge 6 11 Coolant 6 13 Replacing the air filter element 6 15 Checking the throttle cable free play 6 16 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 brake light switch 6 21 Checking the front and re...

Page 8: ...E AND STORAGE 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 U5VX12E0 book Page 2 Monday October 17 2005 9 58 AM ...

Page 9: ...ts 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 mot...

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: ...aution 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 sus...

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 f...

Page 13: ...NFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3 4 5 6 7 8 9 10 U5VX12E0 book Page 5 Monday October 17 2005 9 58 AM ...

Page 14: ...with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 U5VX12E0 book Page 6 Monday October 17 2005 9 58 AM ...

Page 15: ...SAFETY INFORMATION 1 7 1 California only 8 California only 9 10 California only 7 01 U5VX12E0 book Page 7 Monday October 17 2005 9 58 AM ...

Page 16: ... 30 3 Air filter element page 6 15 4 Shock absorber assembly spring preload adjusting ring page 3 11 5 Owner s tool kit page 6 1 6 Shift pedal page 3 7 7 Engine oil drain bolt page 6 11 8 Engine oil filter cartridge page 6 11 U5VX12E0 book Page 1 Monday October 17 2005 9 58 AM ...

Page 17: ...ge compartment page 3 11 3 Rear brake fluid reservoir page 6 22 4 Coolant reservoir cap page 6 13 5 Engine oil filler cap page 6 11 6 Front brake fluid reservoir page 6 22 7 Dipstick page 6 11 8 Brake pedal page 3 8 U5VX12E0 book Page 2 Monday October 17 2005 9 58 AM ...

Page 18: ... 3 7 2 Left handlebar switches page 3 6 3 LCD tachometer page 3 3 4 Multi function display page 3 3 5 Right handlebar switches page 3 6 6 Brake lever page 3 7 7 Throttle grip page 6 16 8 Main switch steering lock page 3 1 U5VX12E0 book Page 3 Monday October 17 2005 9 58 AM ...

Page 19: ...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 20: ...tion or deceleration 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 EAU...

Page 21: ...perature has reached 60 C 140 F so this is not a malfunction CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 14000 r min and above EAU33672 Multi function display WARNING EWA12311 Be sure to stop the vehicle before making any setting changes to the multi function display The multi function display is equipped with the following a speedometer which shows the riding s...

Page 22: ...lashing and the odometer display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT button switches the display between the vari ous tripmeter and odometer modes in the following order TRIP F E ODO TRIP 1 TRIP 2 TRIP F To reset a tripmeter select it by push ing the SELECT button and then push ...

Page 23: ...cates the temperature of the coolant When the key is turned to ON all of the dis play segments of the coolant tempera ture meter will appear one after the other and then disappear in order to test the electrical circuit The coolant temperature varies with changes in the weather and engine load If the top seg ment flashes stop the vehicle and let the engine cool See page 6 39 CAUTION ECA10020 Do no...

Page 24: ...gen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12764 Hazard switch With the key in the ON position turn this switch to to turn on the hazard lights simultaneous flashing of all turn signal lights The haza...

Page 25: ...er when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU26822 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever 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 whil...

Page 26: ... tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed 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 sur...

Page 27: ...ell as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasoho...

Page 28: ...ic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU32980 Seat To remove the seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the rear of the seat up and then pull the seat off To install the seat 1 Insert the projection ...

Page 29: ...e 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 EAU36461 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring p...

Page 30: ...to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU15301 Sidestand The 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 circ...

Page 31: ...t 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 32: ...r 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 sh...

Page 33: ...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 34: ...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 22 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 35: ...6 17 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 26 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 36: ... is in gear with the clutch 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 13 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11310 The oil level warning light and en gine trouble warning li...

Page 37: ...ON 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 Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train whi...

Page 38: ...come on EAU16740 Recommended shift points The recommended 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 o...

Page 39: ... the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 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 Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUT...

Page 40: ...IONS 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 EAU175...

Page 41: ...RNING 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 U5VX12E0 book Page 2 Monday October 17 2005 9 58 AM ...

Page 42: ...heck condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and synchronization 6 Exhaust system Check for leakage Tighten if n...

Page 43: ...lutch Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam age ...

Page 44: ...sis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake and 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 swi...

Page 45: ...r cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 22 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 23 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 READIN...

Page 46: ...sually 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 U5VX12...

Page 47: ... a panel needs to be removed and installed EAU32863 Panels A and B To remove one of the panels Remove the bolts and the quick fasten er screw and then pull the panel off as shown To install the panel Place the panel in the original position and then install the quick fastener screw and the bolts 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Bolt 3 Quick fastener screw U5VX12E0 book Page 8 Monday Octob...

Page 48: ...he 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 should have the same color If any spark plug shows a distinctly dif...

Page 49: ... ignition coil coupler may get 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...

Page 50: ... dipstick and wipe it clean insert it back into the hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark remove the oil filler cap and then add sufficient oil of the recommended type to raise it to the correct level 6 Insert and tighten the engi...

Page 51: ...oil filter wrench and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Engine oil drain bolt 1 Engine oil filter cartridge 2 Oil filter wre...

Page 52: ...r check the vehicle 10 Turn the engine off 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 EAU34352 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion ...

Page 53: ...ed instead of coolant replace it with cool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never ...

Page 54: ...rvals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the seat See page 3 10 2 Remove panels A and B See page 6 8 3 Remove the fuel tank bolts and then lift the fuel tank away from the air filter case 4 Remove the air filter case cover by removing the screws 5 Pull the air filter ...

Page 55: ...hose fuel tank breather hose fuel tank overflow hose are not damaged that they are properly connected and routed and that they are not pinched If any hose is damaged have a Yamaha dealer replace the hose before starting the engine oth erwise fuel may leak WARNING EWA12471 Be sure to place the hoses in their original position as shown 9 Install the panels 10 Install the seat EAU21381 Checking the t...

Page 56: ... 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 Secu...

Page 57: ...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 wheel...

Page 58: ... 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 59: ...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 60: ...E 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 EAU36500 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 have a Yamaha dealer...

Page 61: ...has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EAU36470 Checking the brake fluid level F...

Page 62: ...poor 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...

Page 63: ...g nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at each end 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 adjusting nuts are in the same po sition for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as...

Page 64: ...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 65: ...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 EAU23131 Checking and lubricating the brake and shift pedals The opera...

Page 66: ...ever 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 Recommended lubricant Lithium soap based grease all pur pose grease U5VX12E0 book Page 27 Monday October 17 2005 9 58 AM ...

Page 67: ...71 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition 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 veh...

Page 68: ... 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 Yama...

Page 69: ...Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EX...

Page 70: ...he battery leads are properly 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...

Page 71: ...ctrical system EAU23740 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan fuse 5 Backup fuse for odometer a...

Page 72: ... from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do 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 4 Instal...

Page 73: ...n it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the seat EAU24202 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install th...

Page 74: ...nse plate light unit by installing the screws EAU24360 Front wheel EAU33681 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 motorcycle on the cen terstand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 1 Screw 2 Li...

Page 75: ...t there is enough space between the brake pads before install ing the brake calipers onto the brake discs 4 Install the brake hose holder and reflector on each side by installing the bolts 5 Take the motorcycle 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 7 Push down hard ...

Page 76: ...nut on each side of the swingarm 5 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the rear wheel 6 While supporting the brake caliper and slightly lifting the wheel pull the wheel axle out NOTE A rubber mallet may be useful to tap the wheel axle out 7 Remove the wheel 1 Axle nut 2 Dr...

Page 77: ...ten the axle nut to the speci fied torque 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 vita...

Page 78: ...mpression 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 starter 4 Battery T...

Page 79: ...hissing sound has stopped 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 th...

Page 80: ...dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on p...

Page 81: ...chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved...

Page 82: ...ore storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful o...

Page 83: ... month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the batt...

Page 84: ...eplacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 27 L 0 29 US qt 0 24 Imp qt Radiator capacity including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 19 4 L 5 13 US gal 4 27 Imp gal Fuel reserve amount 3 6 L 0 95 US gal ...

Page 85: ...Rear 250 kPa 36 psi 2 50 kgf cm Loading condition FZS6V 90 190 kg 198 419 lb FZS6VC 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 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 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 MT5 50 Front brake Type Dual disc brake...

Page 86: ...ignal 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 EL backlight LCD Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fus...

Page 87: ...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 NOTE The vehicle identification number is used to identify your motorcycle and m...

Page 88: ...abel is affixed to the frame under the seat See page 3 10 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 U5VX12E0 book Page 2 Monday October 17 2005 9 58 AM ...

Page 89: ...tigation 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 either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tran...

Page 90: ...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 91: ...der that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or...

Page 92: ...RMATION 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 U5VX12E0 book Page 6 Monday October 17 2005 9 58 AM ...

Page 93: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5VX12E0 book Page 7 Monday October 17 2005 9 58 AM ...

Page 94: ...CONSUMER INFORMATION 9 8 9 U5VX12E0 book Page 8 Monday October 17 2005 9 58 AM ...

Page 95: ... repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing p...

Page 96: ...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 U5VX12E0 book Page 10 Monday October 17 2005 9 58 AM ...

Page 97: ...13 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 LCD tachometer 3 3 License plate light bulb replacing 6 35 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model label 9 2 Multi function display 3 3 N Neutral indicator light 3 2 Noise regulati...

Page 98: ...6 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 35 Wheel rear 6 37 Wheels 6 20 U5VX12E0 book Page 2 Monday October 17 2005 9 58 AM ...

Page 99: ...U5VX12E0 book Page 3 Monday October 17 2005 9 58 AM ...

Page 100: ...PRINTED IN JAPAN 2005 11 3 4 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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