Professional Documents
Culture Documents
FZ6-SA
4P5-28199-EA
U4P5E0E0.book Page 1 Wednesday, December 14, 2005 11:15 AM
EAU26942
DECLARATION of CONFORMITY
We
Company: MORIC CO., LTD.
Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan
Type-designation: 5SL-00
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Revolution record
No. Contents Date
1 To change contact person and integrate type-designation. 9 Jun. 2005
INTRODUCTION
EAU10100
Failure to follow WARNING instructions could result in severe injury or death to the
WARNING motorcycle operator, a bystander, or a person inspecting or repairing the motor-
cycle.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
U4P5E0E0.book Page 2 Wednesday, December 14, 2005 11:15 AM
EAU10200
FZ6-SA
OWNER’S MANUAL
©2005 by Yamaha Motor Co., Ltd.
1st edition, December 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
U4P5E0E0.book Page 1 Wednesday, December 14, 2005 11:15 AM
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1 PRE-OPERATION CHECKS ............. 4-1 Adjusting the rear brake light
Pre-operation check list .................. 4-2 switch ....................................... 6-21
DESCRIPTION ..................................2-1 Checking the front and rear
Left view ..........................................2-1 OPERATION AND IMPORTANT brake pads ................................ 6-21
Right view ........................................2-2 RIDING POINTS................................. 5-1 Checking the brake fluid level ...... 6-22
Controls and instruments.................2-3 Starting the engine ......................... 5-1 Changing the brake fluid .............. 6-23
Shifting ........................................... 5-2 Drive chain slack .......................... 6-23
INSTRUMENT AND CONTROL Tips for reducing fuel Cleaning and lubricating the
FUNCTIONS .......................................3-1 consumption ............................... 5-3 drive chain ................................ 6-25
Immobilizer system .........................3-1 Engine break-in .............................. 5-3 Checking and lubricating the
Main switch/steering lock ................3-2 Parking ........................................... 5-4 cables ....................................... 6-25
Indicator and warning lights ............3-3 Checking and lubricating the
LCD tachometer .............................3-5 PERIODIC MAINTENANCE AND throttle grip and cable ............... 6-26
Multi-function display ......................3-6 MINOR REPAIR ................................. 6-1 Checking and lubricating the
Anti-theft alarm (optional) .............3-10 Owner’s tool kit ............................... 6-1 brake and shift pedals .............. 6-26
Handlebar switches ......................3-10 Periodic maintenance and Checking and lubricating the
Clutch lever ...................................3-11 lubrication chart .......................... 6-2 brake and clutch levers ............ 6-27
Shift pedal .....................................3-12 Removing and installing panels ..... 6-6 Checking and lubricating the
Brake lever ...................................3-12 Checking the spark plugs ............... 6-7 centerstand and sidestand ....... 6-27
Brake pedal ..................................3-12 Engine oil and oil filter cartridge ..... 6-8 Lubricating the swingarm
ABS ..............................................3-13 Coolant ......................................... 6-11 pivots ........................................ 6-28
Fuel tank cap ................................3-13 Replacing the air filter element ..... 6-15 Checking the front fork ................. 6-28
Fuel ...............................................3-14 Adjusting the engine idling Checking the steering .................. 6-29
Fuel tank breather hose ................3-15 speed ........................................ 6-16 Checking the wheel bearings ....... 6-29
Catalytic converter ........................3-15 Checking the throttle cable Battery ......................................... 6-30
Seat ..............................................3-16 free play .................................... 6-17 Replacing the fuses ..................... 6-31
Storage compartment ...................3-16 Valve clearance ............................ 6-17 Replacing the headlight bulb ....... 6-33
Adjusting the shock absorber Tires ............................................. 6-17 Replacing the tail/brake light
assembly ...................................3-17 Cast wheels .................................. 6-20 bulb ........................................... 6-34
Sidestand ......................................3-18 Adjusting the clutch lever Replacing a turn signal light
Ignition circuit cut-off system ........3-19 free play .................................... 6-20 bulb ........................................... 6-35
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TABLE OF CONTENTS
Replacing the license plate light
bulb ...........................................6-35
Replacing an auxiliary light bulb ...6-36
Troubleshooting ............................6-36
Troubleshooting charts .................6-37
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
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SAFETY INFORMATION
EAU10281
AND/OR WHEN MADE NECES- • Ride where other motorists can
SARY BY MECHANICAL CONDI- see you. Avoid riding in another
MOTORCYCLES ARE SINGLE TIONS. motorist’s blind spot.
1 TRACK VEHICLES. THEIR SAFE USE ● Many accidents involve inexperi-
AND OPERATION ARE DEPENDENT Safe riding enced operators. In fact, many op-
UPON THE USE OF PROPER RIDING ● Always make pre-operation erators who have been involved in
TECHNIQUES AS WELL AS THE EX- checks. Careful checks may help accidents do not even have a cur-
PERTISE OF THE OPERATOR. EV- prevent an accident. rent motorcycle license.
ERY OPERATOR SHOULD KNOW ● This motorcycle is designed to car- • Make sure that you are qualified
THE FOLLOWING REQUIREMENTS ry the operator and a passenger. and that you only lend your
BEFORE RIDING THIS MOTOR- ● The failure of motorists to detect motorcycle to other qualified op-
CYCLE. and recognize motorcycles in traf- erators.
HE OR SHE SHOULD: fic is the predominating cause of • Know your skills and limits.
● OBTAIN THOROUGH INSTRUC- automobile/motorcycle accidents. Staying within your limits may
TIONS FROM A COMPETENT Many accidents have been caused help you to avoid an accident.
SOURCE ON ALL ASPECTS OF by an automobile driver who did • We recommend that you prac-
MOTORCYCLE OPERATION. not see the motorcycle. Making tice riding your motorcycle
● OBSERVE THE WARNINGS AND yourself conspicuous appears to where there is no traffic until you
MAINTENANCE REQUIRE- be very effective in reducing the have become thoroughly famil-
MENTS IN THE OWNER’S MAN- chance of this type of accident. iar with the motorcycle and all of
UAL. Therefore: its controls.
● OBTAIN QUALIFIED TRAINING • Wear a brightly colored jacket. ● Many accidents have been caused
IN SAFE AND PROPER RIDING • Use extra caution when you are by error of the motorcycle opera-
TECHNIQUES. approaching and passing tor. A typical error made by the op-
● OBTAIN PROFESSIONAL TECH- through intersections, since in- erator is veering wide on a turn
NICAL SERVICE AS INDICATED tersections are the most likely
BY THE OWNER’S MANUAL places for motorcycle accidents
to occur.
1-1
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SAFETY INFORMATION
due to EXCESSIVE SPEED or un- ● This motorcycle is designed for on- cause burns. Always wear protec-
dercornering (insufficient lean an- road use only. It is not suitable for tive clothing that covers your legs,
gle for the speed). off-road use. ankles, and feet.
• Always obey the speed limit and ● A passenger should also observe 1
never travel faster than warrant- Protective apparel the above precautions.
ed by road and traffic conditions. The majority of fatalities from motor-
• Always signal before turning or cycle accidents are the result of head Modifications
changing lanes. Make sure that injuries. The use of a safety helmet is Modifications made to this motorcycle
other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re-
● The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren-
passenger is important for proper ● Always wear an approved helmet. der the motorcycle unsafe for use and
control. ● Wear a face shield or goggles. may cause severe personal injury.
• The operator should keep both Wind in your unprotected eyes Modifications may also make your
hands on the handlebar and could contribute to an impairment motorcycle illegal to use.
both feet on the operator foot- of vision that could delay seeing a
rests during operation to main- hazard. Loading and accessories
tain control of the motorcycle. ● The use of a jacket, heavy boots, Adding accessories or cargo to your
• The passenger should always trousers, gloves, etc., is effective in motorcycle can adversely affect stabili-
hold onto the operator, the seat preventing or reducing abrasions ty and handling if the weight distribution
strap or grab bar, if equipped, or lacerations. of the motorcycle is changed. To avoid
with both hands and keep both ● Never wear loose-fitting clothes, the possibility of an accident, use ex-
feet on the passenger footrests. otherwise they could catch on the treme caution when adding cargo or
• Never carry a passenger unless control levers, footrests, or wheels accessories to your motorcycle. Use
he or she can firmly place both and cause injury or an accident. extra care when riding a motorcycle
feet on the passenger footrests. ● Never touch the engine or exhaust that has added cargo or accessories.
● Never ride under the influence of system during or after operation. Here are some general guidelines to
alcohol or other drugs. They become very hot and can follow if loading cargo or adding acces-
sories to your motorcycle:
1-2
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SAFETY INFORMATION
Loading bags, duffel bags, or tents, can limit suspension travel, steering
The total weight of the operator, pas- create unstable handling or a slow travel or control operation, or ob-
senger, accessories and cargo must steering response. scure lights or reflectors.
1 not exceed the maximum load limit. Accessories • Accessories fitted to the handle-
Genuine Yamaha accessories have bar or the front fork area can
Maximum load: been specifically designed for use on create instability due to improper
185 kg (408 lb) this motorcycle. Since Yamaha cannot weight distribution or aerody-
test all other accessories that may be namic changes. If accessories
When loading within this weight limit,
available, you must personally be re- are added to the handlebar or
keep the following in mind:
sponsible for the proper selection, in- front fork area, they must be as
● Cargo and accessory weight
stallation and use of non-Yamaha lightweight as possible and
should be kept as low and close to
accessories. Use extreme caution should be kept to a minimum.
the motorcycle as possible. Make
when selecting and installing any ac- • Bulky or large accessories may
sure to distribute the weight as
cessories. seriously affect the stability of
evenly as possible on both sides of
Keep the following guidelines in mind, the motorcycle due to aerody-
the motorcycle to minimize imbal-
as well as those provided under “Load- namic effects. Wind may at-
ance or instability.
ing” when mounting accessories. tempt to lift the motorcycle, or
● Shifting weights can create a sud-
● Never install accessories or carry the motorcycle may become un-
den imbalance. Make sure that ac-
cargo that would impair the perfor- stable in cross winds. These ac-
cessories and cargo are securely
mance of your motorcycle. Care- cessories may also cause
attached to the motorcycle before
fully inspect the accessory before instability when passing or being
riding. Check accessory mounts
using it to make sure that it does passed by large vehicles.
and cargo restraints frequently.
not in any way reduce ground • Certain accessories can dis-
● Never attach any large or heavy
clearance or cornering clearance, place the operator from his or
items to the handlebar, front fork,
her normal riding position. This
or front fender. These items, in-
improper position limits the free-
cluding such cargo as sleeping
dom of movement of the opera-
1-3
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SAFETY INFORMATION
tor and may limit control ability, ● Always turn the engine off before or clothing, immediately wash the
therefore, such accessories are leaving the motorcycle unattended affected area with soap and water
not recommended. and remove the key from the main and change your clothes.
● Use caution when adding electri- switch. When parking the motor- 1
cal accessories. If electrical acces- cycle, note the following:
sories exceed the capacity of the • The engine and exhaust system
motorcycle’s electrical system, an may be hot, therefore, park the
electric failure could result, which motorcycle in a place where pe-
could cause a dangerous loss of destrians or children are not like-
lights or engine power. ly to touch these hot areas.
• Do not park the motorcycle on a
Gasoline and exhaust gas slope or soft ground, otherwise it
● GASOLINE IS HIGHLY FLAMMA- may fall over.
BLE: • Do not park the motorcycle near
• Always turn the engine off when a flammable source, (e.g., a ker-
refueling. osene heater, or near an open
• Take care not to spill any gaso- flame), otherwise it could catch
line on the engine or exhaust fire.
system when refueling. ● When transporting the motorcycle
• Never refuel while smoking or in in another vehicle, make sure that
the vicinity of an open flame. it is kept upright. If the motorcycle
● Never start the engine or let it run should lean over, gasoline may
for any length of time in a closed leak out of the fuel tank.
area. The exhaust fumes are poi- ● If you should swallow any gaso-
sonous and may cause loss of line, inhale a lot of gasoline vapor,
consciousness and death within a or allow gasoline to get into your
short time. Always operate your eyes, see your doctor immediately.
motorcycle in an area that has ad- If any gasoline spills on your skin
equate ventilation.
1-4
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DESCRIPTION
EAU10410
Left view
1. Main fuse (page 6-31) 9. Engine oil drain bolt (page 6-8)
2. Fuse box 1 (page 6-31) 10.Engine oil filter cartridge (page 6-8)
3. Battery (page 6-30)
4. Air filter element (page 6-15)
5. Idle adjusting screw (page 6-16)
6. Shock absorber assembly spring preload adjusting ring (page 3-17)
7. Owner’s tool kit (page 6-1)
8. Shift pedal (page 3-12)
2-1
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DESCRIPTION
EAU10420
Right view
2-2
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DESCRIPTION
EAU10430
2-3
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3-1
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3-2
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1. Push. CAUTION:
2. Turn. 1. Oil level warning light “ ”
Do not use the parking position for 2. Engine trouble warning light “ ”
Push the key in, and then turn it to an extended length of time, other- 3. Neutral indicator light “ ”
“OFF” while still pushing it. wise the battery may discharge. 4. High beam indicator light “ ”
EWA10060 5. Immobilizer system indicator light “ ”
WARNING 6. Anti-lock Brake System (ABS) warning light
“ ABS ”
Never turn the key to “OFF” or
7. Turn signal indicator light “ ”
“LOCK” while the vehicle is moving,
otherwise the electrical systems will EAU11020
be switched off, which may result in Turn signal indicator light “ ”
loss of control or an accident. Make This indicator light flashes when the
sure that the vehicle is stopped be- turn signal switch is pushed to the left or
fore turning the key to “OFF” or right.
“LOCK”.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
3-3
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3-4
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3-5
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1. Clock
3-7
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3-8
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3-9
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EAU12460
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re-
leased, the switch returns to the center
3-10
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3-11
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The shift pedal is located on the left The brake pedal is on the right side of
side of the engine and is used in com- the motorcycle. To apply the rear
bination with the clutch lever when brake, press down on the brake pedal.
1. Brake lever
shifting the gears of the 6-speed con- 2. Brake lever position adjusting dial
stant-mesh transmission equipped on 3. “ ” mark
this motorcycle. 4. Distance between brake lever and handlebar
grip
WARNING
● The ABS performs best on long 1. Fuel tank cap lock cover
braking distances. 2. Unlock.
● On certain (rough or gravel)
roads, the braking distance may To open the fuel tank cap
be longer with than without the Open the fuel tank cap lock cover, in-
ABS. Therefore, always keep a sert the key into the lock, and then turn
sufficient distance to the vehicle it 1/4 turn clockwise. The lock will be re-
ahead to match the riding leased and the fuel tank cap can be
speed. opened.
3-13
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WARNING EAU13320
3 Make sure that the fuel tank cap is
properly closed before riding.
Recommended fuel:
1. Fuel tank filler tube REGULAR UNLEADED GASOLINE
ONLY
2. Fuel level
Fuel tank capacity:
Make sure that there is sufficient fuel in 19.4 L (5.13 US gal) (4.27 Imp.gal)
Fuel reserve amount:
the tank. When refueling, be sure to in- 3.6 L (0.95 US gal) (0.79 Imp.gal)
sert the pump nozzle into the fuel tank
filler hole and to fill the tank to the bot- ECA11400
leaded fuel will extend spark plug life Fuel tank breather hose Catalytic converter
and reduce maintenance costs. This model is equipped with a catalytic
converter in the exhaust system.
EWA10860
WARNING
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do- 3
ing any maintenance work.
ECA10700
3-15
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3
1. Projection
2. Seat holder
1. U-LOCK bar (optional)
2. Push the rear of the seat down to 2. Yamaha U-LOCK (optional)
lock it in place. 3. Strap
3. Remove the key.
This storage compartment is designed
1. Seat lock NOTE: to hold a genuine Yamaha U-LOCK.
2. Unlock.
Make sure that the seat is properly se- (Other locks may not fit.) When placing
2. While holding the key in that posi- cured before riding. a U-LOCK in the storage compartment,
tion, lift the rear of the seat up, and securely fasten it with the straps. When
then pull the seat off. the U-LOCK is not in the storage com-
partment, be sure to secure the straps
To install the seat to prevent losing them.
EWA10961
1. Insert the projection on the front of
the seat into the seat holder as WARNING
shown. ● Do not exceed the load limit of 3
kg (7 lb) for the storage com-
partment.
3-16
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load of 185 kg (408 lb) for the ve- Adjusting the shock absorber
hicle. assembly
This shock absorber assembly is
equipped with a spring preload adjust-
ing ring.
ECA10100
CAUTION:
Never attempt to turn an adjusting 3
mechanism beyond the maximum or
1. Spring preload adjusting ring
minimum settings. 2. Special wrench
Adjust the spring preload as follows. 3. Position indicator
1. Remove the seat. (See page
3-16.) NOTE:
2. To increase the spring preload and ● Align the appropriate notch in the
thereby harden the suspension, adjusting ring with the position in-
turn the adjusting ring in direction dicator on the shock absorber.
(a). To decrease the spring pre- ● Use the special wrench included in
load and thereby soften the sus- the owner’s tool kit to make the ad-
pension, turn the adjusting ring in justment.
direction (b).
Spring preload setting:
Minimum (soft):
1
Standard:
3
Maximum (hard):
7
3-17
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3-18
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WARNING
● The vehicle must be placed on
the centerstand during this in-
spection.
● If a malfunction is noted, have a
Yamaha dealer check the sys-
tem before riding.
3-19
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3-20
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PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. 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.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4-1
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PRE-OPERATION CHECKS
EAU15603
4-2
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PRE-OPERATION CHECKS
ITEM CHECKS PAGE
4-3
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5-2
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5-3
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Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
WARNING
● 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 5
may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5-4
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6-1
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6-2
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6-3
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EAU18680
NOTE:
● Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
6-4
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6-5
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1. Panel C 1. Panel A
2. Bolt
EAU32863 3. Quick fastener screw
Panels A and B
6-6
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6-7
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6-8
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6-9
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ECA11620
CAUTION:
1. Torque wrench
● In order to prevent clutch slip-
Tightening torque: page (since the engine oil also
Oil filter cartridge: lubricates the clutch), do not
17 Nm (1.7 m·kgf, 12 ft·lbf) mix any chemical additives. Do
not use oils with a diesel speci-
7. Install the engine oil drain bolt, and fication of “CD” or oils of a high- 6
then tighten it to the specified er quality than specified. In
1. O-ring torque. addition, do not use oils labeled
NOTE: NOTE: “ENERGY CONSERVING II” or
Make sure that the O-ring is properly Check the washer for damage and re- higher.
place it if necessary. ● Make sure that no foreign mate-
seated.
rial enters the crankcase.
6. Install the new oil filter cartridge
Tightening torque: 9. Start the engine, and then let it idle
with an oil filter wrench, and then
Engine oil drain bolt: for several minutes while checking
tighten it to the specified torque 43 Nm (4.3 m·kgf, 31 ft·lbf) it for oil leakage. If oil is leaking, im-
with a torque wrench.
mediately turn the engine off and
8. Add the specified amount of the
check for the cause.
recommended engine oil, and then
install and tighten the oil filler cap.
6-10
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6-11
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6-13
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6-14
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6-15
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6-16
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WARNING
1. Throttle cable free play
● The tire air pressure must be
The throttle cable free play should mea- checked and adjusted on cold
6 sure 3.0–5.0 mm (0.12–0.20 in) at the tires (i.e., when the temperature
throttle grip. Periodically check the of the tires equals the ambient
throttle cable free play and, if neces- temperature).
sary, have a Yamaha dealer adjust it. ● 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.
6-17
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6-18
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6-19
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visable before doing any high- Cast wheels Adjusting the clutch lever free
speed riding to ride conserva- To maximize the performance, durabil- play
tively for approximately 100 km ity, and safe operation of your vehicle,
(60 mi) after installing a new tire. note the following points regarding the
● The tires must be warmed up specified wheels.
before a high-speed run. ● The wheel rims should be checked
● Always adjust the tire air pres- for cracks, bends or warpage be-
sure according to the operating fore each ride. If any damage is
conditions. found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
1. Clutch lever free play adjusting bolt
wheel must be replaced. 2. Clutch lever free play
● The wheel should be balanced
whenever either the tire or wheel The clutch lever free play should mea- 6
has been changed or replaced. An sure 10.0–15.0 mm (0.39–0.59 in) as
unbalanced wheel can result in shown. Periodically check the clutch le-
poor performance, adverse han- ver free play and, if necessary, adjust it
dling characteristics, and a short- as follows.
ened tire life. To increase the clutch lever free play,
● Ride at moderate speeds after turn the adjusting bolt in direction (a).
changing a tire since the tire sur- To decrease the clutch lever free play,
face must first be “broken in” for it turn the adjusting bolt in direction (b).
to develop its optimal characteris-
tics.
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6-21
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6-22
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and dirt may clog the ABS hydrau- Changing the brake fluid Drive chain slack
lic unit valves. Have a Yamaha dealer change the The drive chain slack should be
● Brake fluid may deteriorate paint- brake fluid at the intervals specified in checked before each ride and adjusted
ed surfaces or plastic parts. Al- the NOTE after the periodic mainte- if necessary.
ways clean up spilled fluid nance and lubrication chart. In addition,
immediately. have the oil seals of the master cylin- EAU22791
To check the drive chain slack
● As the brake pads wear, it is nor- ders and calipers as well as the brake
1. Place the motorcycle on the cen-
mal for the brake fluid level to grad- hoses replaced at the intervals listed
terstand.
ually go down. However, if the below or whenever they are damaged
2. Shift the transmission into the neu-
brake fluid level goes down sud- or leaking.
tral position.
denly, have a Yamaha dealer ● Oil seals: Replace every two
3. Spin the rear wheel several times
check the cause. years.
to locate the tightest portion of the
● Brake hoses: Replace every four
drive chain.
years.
4. Measure the drive chain slack as
6
shown.
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EAU34361
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm. 1. Axle nut
2. To tighten the drive chain, turn the 2. Drive chain slack adjusting nut
3. Locknut
adjusting nut at each end of the
4. Alignment marks
swingarm in direction (a). To loos-
en the drive chain, turn the adjust- ECA10570
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6-25
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Checking and lubricating the Checking and lubricating the Recommended lubricant:
Lithium-soap-based grease (all-pur-
throttle grip and cable brake and shift pedals pose grease)
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.
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Checking and lubricating the Recommended lubricant: Checking and lubricating the
Lithium-soap-based grease (all-pur-
brake and clutch levers pose grease) centerstand and sidestand
Brake lever
WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
The operation of the brake and clutch
levers should be checked before each Recommended lubricant:
Lithium-soap-based grease (all-pur-
ride, and the lever pivots should be lu- pose grease)
bricated if necessary.
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WARNING
Securely support the vehicle so that ECA10590
6-28
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WARNING
Securely support the vehicle so that
there is no danger of it falling over.
6 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.
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WARNING
To store the battery
● Electrolyte is poisonous and
1. If the vehicle will not be used for
dangerous since it contains sul-
more than one month, remove the
furic acid, which causes severe
battery, fully charge it, and then
burns. Avoid any contact with
place it in a cool, dry place.
skin, eyes or clothing and al-
2. If the battery will be stored for more
ways shield your eyes when
than two months, check it at least
1. Battery working near batteries. In case
once a month and fully charge it if
2. Negative battery terminal of contact, administer the fol-
3. Positive battery terminal
necessary.
lowing FIRST AID.
3. Fully charge the battery before in-
The battery is located under the fuel • EXTERNAL: Flush with plenty
stallation. 6
tank. (See page 6-15.) of water.
4. After installation, make sure that
This model is equipped with a sealed- • INTERNAL: Drink large quan-
the battery leads are properly con-
type (MF) battery, which does not re- tities of water or milk and im-
nected to the battery terminals.
quire any maintenance. There is no mediately call a physician. ECA10630
need to check the electrolyte or to add • EYES: Flush with water for 15 CAUTION:
distilled water. minutes and seek prompt
● Always keep the battery
medical attention.
charged. Storing a discharged
To charge the battery ● Batteries produce explosive hy-
battery can cause permanent
Have a Yamaha dealer charge the bat- drogen gas. Therefore, keep
battery damage.
tery as soon as possible if it seems to sparks, flames, cigarettes, etc.,
● To charge a sealed-type (MF)
have discharged. Keep in mind that the away from the battery and pro-
battery, a special (constant-volt-
vide sufficient ventilation when
age) battery charger is required.
charging it in an enclosed
Using a conventional battery
space.
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1. Fuse box 2
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6-32
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CAUTION:
Take care not to damage the follow-
ing parts:
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WARNING
Do not touch the muffler bracket un-
til the exhaust system has cooled.
3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
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CAUTION:
Do not overtighten the screw, other-
wise the lens may break.
6-35
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6-36
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Troubleshooting charts
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
6 Operate the electric starter.
Have a Yamaha dealer
There is no compression.
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
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WARNING
● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the 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.
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7-2
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7-4
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SPECIFICATIONS
Dimensions: Engine oil: Fuel:
Overall length: Type: Recommended fuel:
2095 mm (82.5 in) SAE10W30 or SAE10W40 or SAE15W40 Regular unleaded gasoline only
Overall width: or SAE20W40 or SAE20W50 Fuel tank capacity:
750 mm (29.5 in) 19.4 L (5.13 US gal) (4.27 Imp.gal)
Overall height: -20 -10 0 10 20 30 40 50 ˚C Fuel reserve amount:
1215 mm (47.8 in) 3.6 L (0.95 US gal) (0.79 Imp.gal)
SAE 10W-30
Seat height: Fuel injection:
795 mm (31.3 in) SAE 10W-40 Manufacturer:
Wheelbase: MIKUNI
1440 mm (56.7 in) SAE 15W-40 Model/quantity:
Ground clearance: 36EIDW x 2
SAE 20W-40
145 mm (5.71 in) Spark plug (s):
Minimum turning radius: SAE 20W-50 Manufacturer/model:
2800 mm (110.2 in) NGK/CR9EK
Weight: Spark plug gap:
With oil and fuel: Recommended engine oil grade:
0.6–0.7 mm (0.024–0.028 in)
212.0 kg (467 lb) API service SE, SF, SG type or higher
Engine oil quantity:
Clutch:
Engine: Clutch type:
Without oil filter cartridge replacement:
Engine type: Wet, multiple-disc
2.50 L (2.64 US qt) (2.20 Imp.qt)
Liquid cooled 4-stroke, DOHC Transmission:
With oil filter cartridge replacement:
Cylinder arrangement: Primary reduction system:
2.80 L (2.96 US qt) (2.46 Imp.qt)
Forward-inclined parallel 4-cylinder Spur gear
Displacement:
Cooling system:
8 Coolant reservoir capacity (up to the
Primary reduction ratio:
600.0 cm³ (36.61 cu.in) 86/44 (1.955)
maximum level mark):
Bore × stroke: Secondary reduction system:
0.27 L (0.29 US qt) (0.24 Imp.qt)
65.5 × 44.5 mm (2.58 × 1.75 in) Chain drive
Radiator capacity (including all routes):
Compression ratio: Secondary reduction ratio:
2.00 L (2.11 US qt) (1.76 Imp.qt)
12.20 :1 46/16 (2.875)
Starting system: Air filter:
Transmission type:
Electric starter Air filter element:
Constant mesh 6-speed
Lubrication system: Oil-coated paper element
Operation:
Wet sump Left foot operation
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SPECIFICATIONS
Gear ratio: Manufacturer/model: Rear wheel:
1st: BRIDGESTONE/BT020R GG Wheel type:
37/13 (2.846) Manufacturer/model: Cast wheel
2nd: DUNLOP/D252 Rim size:
37/19 (1.947) Loading: 17M/C x MT5.50
3rd: Maximum load: Front brake:
28/18 (1.556) 185 kg (408 lb) Type:
4th: (Total weight of rider, passenger, cargo and Dual disc brake
32/24 (1.333) accessories) Operation:
5th: Tire air pressure (measured on cold Right hand operation
25/21 (1.190) tires): Recommended fluid:
6th: Loading condition: DOT 4
26/24 (1.083) 0–90 kg (0–198 lb) Rear brake:
Chassis: Front: Type:
Frame type: 225 kPa (33 psi) (2.25 kgf/cm²) Single disc brake
Diamond Rear: Operation:
Caster angle: 250 kPa (36 psi) (2.50 kgf/cm²) Right foot operation
25.00 ° Loading condition: Recommended fluid:
Trail: 90–185 kg (198–408 lb) DOT 4
97.5 mm (3.84 in) Front: Front suspension:
Front tire: 250 kPa (36 psi) (2.50 kgf/cm²) Type:
Type: Rear: Telescopic fork
Tubeless 290 kPa (42 psi) (2.90 kgf/cm²) Spring/shock absorber type:
Size: High-speed riding: Coil spring/oil damper 8
120/70 ZR17M/C (58W) Front: Wheel travel:
Manufacturer/model: 225 kPa (33 psi) (2.25 kgf/cm²) 130.0 mm (5.12 in)
BRIDGESTONE/BT020F GG Rear: Rear suspension:
Manufacturer/model: 250 kPa (36 psi) (2.50 kgf/cm²) Type:
DUNLOP/D252F Front wheel: Swingarm (monocross)
Rear tire: Wheel type: Spring/shock absorber type:
Type: Cast wheel Coil spring/gas-oil damper
Tubeless Rim size: Wheel travel:
Size: 17M/C x MT3.50 130.0 mm (5.12 in)
180/55 ZR17M/C (73W)
8-2
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SPECIFICATIONS
Electrical system: Oil level warning light:
Ignition system: LED
Transistorized coil ignition (digital) Turn signal indicator light:
Charging system: LED
AC magneto Engine trouble warning light:
Battery: LED
Model: ABS warning light:
GT12B-4 LED
Voltage, capacity: Immobilizer system indicator light:
12 V, 10.0 Ah LED
Headlight: Fuses:
Bulb type: Main fuse:
Halogen bulb 30.0 A
Bulb voltage, wattage × quantity: Headlight fuse:
Headlight: 20.0 A
12 V, 60 W/55.0 W × 1 Signaling system fuse:
Headlight: 10.0 A
12 V, 55.0 W × 1 Ignition fuse:
Tail/brake light: 10.0 A
12 V, 5.0 W/21.0 W × 1 Parking lighting fuse:
Front turn signal light: 10.0 A
12 V, 10.0 W × 2 Radiator fan fuse:
Rear turn signal light: 20.0 A
8 12 V, 10.0 W × 2 Fuel injection system fuse:
Auxiliary light: 10.0 A
12 V, 5.0 W × 2 ABS control unit fuse:
License plate light: 10.0 A
12 V, 5.0 W × 1 ABS motor fuse:
Meter lighting: 30.0 A
EL backlight LCD Backup fuse:
Neutral indicator light: 10.0 A
LED
High beam indicator light:
LED
8-3
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CONSUMER INFORMATION
EAU26351 EAU26381 EAU26400
9-1
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CONSUMER INFORMATION
EAU26540
Model label
1. Model label
9-2
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INDEX
A Engine trouble warning light ....................3-4 P
ABS ...................................................... 3-13 F Panels, removing and installing .............. 6-6
ABS warning light ................................... 3-4 Front and rear brake pads, checking ....6-21 Parking.................................................... 5-4
Air filter element, replacing ................... 6-15 Front fork, checking...............................6-28 Part locations .......................................... 2-1
Anti-theft alarm (optional) ..................... 3-10 Fuel .......................................................3-14 Pass switch........................................... 3-10
Auxiliary light bulb, replacing ................ 6-36 Fuel consumption, tips for reducing ........5-3 Periodic maintenance and lubrication
B Fuel tank breather hose ........................3-15 chart...................................................... 6-2
Battery .................................................. 6-30 Fuel tank cap.........................................3-13 Pre-operation check list .......................... 4-2
Brake and clutch levers, Fuses, replacing....................................6-31 R
checking and lubricating..................... 6-27 H Rear brake light switch, adjusting ......... 6-21
Brake and shift pedals, Handlebar switches ...............................3-10 S
checking and lubricating..................... 6-26 Hazard switch........................................3-11 Safety information................................... 1-1
Brake fluid, changing ............................ 6-23 Headlight bulb, replacing.......................6-33 Seat ...................................................... 3-16
Brake fluid level, checking .................... 6-22 High beam indicator light.........................3-4 Shifting.................................................... 5-2
Brake lever ........................................... 3-12 Horn switch ...........................................3-11 Shift pedal............................................. 3-12
Brake pedal .......................................... 3-12 I Shock absorber assembly, adjusting .... 3-17
C Identification numbers .............................9-1 Sidestand.............................................. 3-18
Cables, checking and lubricating.......... 6-25 Ignition circuit cut-off system .................3-19 Spark plugs, checking............................. 6-7
Care........................................................ 7-1 Immobilizer system .................................3-1 Specifications.......................................... 8-1
Catalytic converter................................ 3-15 Immobilizer system indicator light ...........3-4 Starting the engine.................................. 5-1
Centerstand and sidestand, Indicator and warning lights ....................3-3 Start switch ........................................... 3-11
checking and lubricating..................... 6-27 K Steering, checking ................................ 6-29
Clutch lever........................................... 3-11 Key identification number........................9-1 Storage ................................................... 7-3
Clutch lever free play, adjusting ........... 6-20 L Storage compartment ........................... 3-16
Coolant ................................................. 6-11 LCD tachometer ......................................3-5 Swingarm pivots, lubricating ................. 6-28
D License plate light bulb, replacing .........6-35 T
Dimmer switch ...................................... 3-10 M Tail/brake light bulb, replacing .............. 6-34
Drive chain, cleaning and lubricating.... 6-25 Main switch/steering lock ........................3-2 Throttle cable free play, checking ......... 6-17
Drive chain slack .................................. 6-23 Model label..............................................9-2 Throttle grip and cable,
E Multi-function display...............................3-6 checking and lubricating ..................... 6-26
Engine break-in ...................................... 5-3 N Tires...................................................... 6-17
Engine idling speed .............................. 6-16 Neutral indicator light ..............................3-3 Tool kit .................................................... 6-1
Engine oil and oil filter cartridge ............. 6-8 O Troubleshooting .................................... 6-36
Engine stop switch................................ 3-11 Troubleshooting charts ......................... 6-37
Oil level warning light ..............................3-4
U4P5E0E0.book Page 2 Wednesday, December 14, 2005 11:15 AM
INDEX
Turn signal indicator light ........................ 3-3
Turn signal light bulb, replacing ............ 6-35
Turn signal switch ................................. 3-10
V
Valve clearance .................................... 6-17
Vehicle identification number .................. 9-1
W
Wheel bearings, checking..................... 6-29
Wheels .................................................. 6-20
U4P5E0E0.book Page 3 Wednesday, December 14, 2005 11:15 AM
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2006.01-0.4×1 CR
(E)