OWNER’S MANUAL FZ6-SA 4P5-28199-E1
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM EAU26943 DECLARATION of CONFORMITY We Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the FZ6-SA, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FZ6-SA.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM IMPORTANT MANUAL INFORMATION EAU10151 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM IMPORTANT MANUAL INFORMATION EAU10200 FZ6-SA OWNER’S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, August 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Ignition circuit cut-off system ........ 3-19 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 PRE-OPERATION CHECKS ............. 4-1 Pre-operation check list .................. 4-2 INSTRUMENT AND CONTROL FUNCTIONS ....................
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM TABLE OF CONTENTS Replacing a turn signal light bulb ...........................................6-34 Replacing the license plate light bulb ...........................................6-35 Replacing an auxiliary light bulb ...6-35 Troubleshooting ............................6-36 Troubleshooting charts .................6-37 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Matte color caution .........................7-1 Care ...
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM SAFETY INFORMATION EAU10281 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM SAFETY INFORMATION ● ● due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 185 kg (408 lb) When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
U4P5E1E0.book Page 4 Monday, September 11, 2006 1:33 PM SAFETY INFORMATION ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Shift pedal (page 3-12) 10.Engine oil drain bolt (page 6-8) 11.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Coolant drain bolt (page 6-12) 10.Dipstick (page 6-8) 11.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10972 Immobilizer system 1. Code re-registering key (red bow) 2. Standard keys (black bow) This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10471 Main switch/steering lock 3 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. NOTE: Be sure to use the standard key (black bow) for regular use of the vehicle. To minimize the risk of losing the code reregistering key (red bow), keep it in a safe place and only use it for code reregistering.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU10941 (Parking) The steering is locked, and the taillight, license plate light and auxiliary lights are on. The hazard lights and turn signal lights can be turned on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”. EAU11003 Indicator and warning lights 3 ECA11020 CAUTION: 1. Push. 2. Turn.
U4P5E1E0.book Page 4 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. 3 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. EAU11250 EAU11530 Oil level warning light “ ” This warning light comes on when the engine oil level is low.
U4P5E1E0.book Page 5 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS When the key is turned to “OFF” and 30 seconds have passed, the indicator light will start flashing indicating the immobilizer system is enabled. After 24 hours have passed, the indicator light will stop flashing, however the immobilizer system is still enabled. This model is also equipped with a selfdiagnosis device for the immobilizer system. (See page 3-6 for an explanation of the self-diagnosis device.
U4P5E1E0.book Page 6 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU32979 Multi-function display ● EWA12311 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 3 ● ● ● ● ● ● ● 1. 2. 3. 4. 5. 6. 7.
U4P5E1E0.book Page 7 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS distance traveled from that point. In that case, pushing the “SELECT” button switches the display between the various 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 pushing the “SELECT” button, and then push the “RESET” button for at least one second.
U4P5E1E0.book Page 8 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS Fuel meter repeated until the malfunction is corrected: the display segments, except the “F” (Full) and “E” (Empty) segments, will flash eight times and then go off for 3 seconds. If this occurs, have a Yamaha dealer check the electrical circuit. 3 Coolant temperature meter 1. Fuel meter With the key in the “ON” position, the fuel meter indicates the amount of fuel in the fuel tank.
U4P5E1E0.book Page 9 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS If any of those circuits are defective, the engine trouble warning light will come on, and then the multi-function display will indicate a two-digit error code. This model is also equipped with a selfdiagnosis device for the immobilizer system.
U4P5E1E0.book Page 10 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12331 Anti-theft alarm (optional) This model can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. EAU12347 Handlebar switches Right Left 3 1. Engine stop switch “ 2. Start switch “ ” 1. 2. 3. 4. 5.
U4P5E1E0.book Page 11 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU42340 The engine trouble warning light and ABS 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.
U4P5E1E0.book Page 12 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal EAU26822 Brake lever EAU12941 Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Shift pedal 1.
U4P5E1E0.book Page 13 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU39530 ABS The Yamaha ABS (Anti-lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. The ABS is monitored by an ECU (Electronic Control Unit), which will have recourse to manual braking if a malfunction occurs. ● This ABS has a test mode which allows the owner to experience the pulsating at the brake lever or brake pedal when the ABS is operating.
U4P5E1E0.book Page 14 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13220 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EWA11090 WARNING 3 EAU13320 Make sure that the fuel tank cap is properly closed before riding. 1.
U4P5E1E0.book Page 15 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. EAU13411 Fuel tank breather hose EAU13441 Catalytic converter This vehicle is equipped with catalytic converters in the exhaust system. EWA10860 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. ECA10700 1.
U4P5E1E0.book Page 16 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU32980 EAU14281 Seat Helmet holder To remove the seat 1. Insert the key into the seat lock, and then turn it counterclockwise. 3 1. Projection 2. Seat holder 2. Push the rear of the seat down to lock it in place. 3. Remove the key. 1. Seat lock 2. Unlock. 2. While holding the key in that position, lift the rear of the seat up, and then pull the seat off.
U4P5E1E0.book Page 17 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14422 Storage compartment ● Do not exceed the maximum load of 185 kg (408 lb) for the vehicle. EAU36462 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring. ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 1. CYCLELOK bar (optional) 2. Yamaha CYCLELOK (optional) 3.
U4P5E1E0.book Page 18 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS 3. Install the seat. EAU15301 EWA10220 WARNING 3 1. Spring preload adjusting ring 2. Special wrench 3. Position indicator NOTE: ● Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. ● Use the special wrench included in the owner’s tool kit to make the adjustment.
U4P5E1E0.book Page 19 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. EAU15321 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U4P5E1E0.book Page 20 Monday, September 11, 2006 1:33 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM 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.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM PRE-OPERATION CHECKS EAU15605 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-14 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-8 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Wheels and tires • • • • Check for damage.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU39890 Starting the engine EWA10270 WARNING ● ● 5 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM OPERATION AND IMPORTANT RIDING POINTS ECA11040 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM OPERATION AND IMPORTANT RIDING POINTS EAU16810 Tips for reducing fuel consumption 5 Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Shift up swiftly, and avoid high engine speeds during acceleration. ● Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine. ● Turn the engine off instead of letting it idle for an extended length of time (e.g.
U4P5E1E0.book Page 4 Monday, September 11, 2006 1:33 PM OPERATION AND IMPORTANT RIDING POINTS EAU17212 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 pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17520 Owner’s tool kit 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17705 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km) NO.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM 1 20 30 40 ANNUAL CHECK √ √ √ √ √ 10 * Tires • • • • 11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ • Check operation and for excessive play. √ √ √ √ 12 * Swingarm 13 Drive chain 14 * Steering bearings 6 10 CHECK OR MAINTENANCE JOB Check tread depth and for damage. Replace if necessary. Check air pressure.
U4P5E1E0.book Page 4 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM 1 23 * Cooling system 10 √ • Check coolant level and vehicle for coolant leakage. • Change. 24 * Front and rear brake switches • Check operation. 25 Moving parts and cables 26 * Throttle grip housing and cable 27 * Air induction system 20 30 40 ANNUAL CHECK √ √ √ √ CHECK OR MAINTENANCE JOB Every 3 years √ √ √ √ √ √ • Lubricate.
U4P5E1E0.book Page 5 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR • 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.
U4P5E1E0.book Page 6 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel C EAU32863 Panels A and B 1. Panel A 2. Panel B 1. Panel A 2. Bolt 3.
U4P5E1E0.book Page 7 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33020 EAU19642 Checking the spark plugs Panel C To remove the panel 1. Remove the seat. (See page 3-16.) 2. Remove the bolt, and then pull the panel off as shown. 2. Install the seat. 6 1. Panel C 2. Bolt To install the panel 1. Place the panel in the original position, and then install the bolt.
U4P5E1E0.book Page 8 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. EAU42620 NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
U4P5E1E0.book Page 9 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Dipstick 2. Maximum level mark 3. Minimum level mark 6 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. 1. Engine oil filler cap 1. Engine oil drain bolt 6.
U4P5E1E0.book Page 10 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.50 L (2.64 US qt) (2.20 Imp.qt) With oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt) 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 cartridge. ECA11620 CAUTION: 1.
U4P5E1E0.book Page 11 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. ECA10400 CAUTION: If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. 10. Turn the engine off, and then check the oil level and correct it if necessary.
U4P5E1E0.book Page 12 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● wise the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. 1. Coolant reservoir cap Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.
U4P5E1E0.book Page 13 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the coolant reservoir and its reservoir cover by placing them in the original position, and then installing the bolts. 9. Remove the coolant drain bolt to drain the cooling system. 1. Coolant reservoir cap 2. Coolant reservoir 6. Remove the coolant reservoir cover and coolant reservoir by removing the bolts. 6 1. Coolant drain bolt 10.
U4P5E1E0.book Page 14 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. 13. Install the coolant reservoir cap. 14.
U4P5E1E0.book Page 15 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10480 CAUTION: ● ● 1. Screw 2. Air filter case cover 5. Pull the air filter element out. Make sure that the air filter element is properly seated in the air filter case. The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 7. Install the air filter case cover by installing the screws. 8.
U4P5E1E0.book Page 16 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU34300 EAU21381 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The engine should be warm before making this adjustment. NOTE: The engine is warm when it quickly responds to the throttle.
U4P5E1E0.book Page 17 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21401 EAU21771 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
U4P5E1E0.book Page 18 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● ● ● ● NEVER OVERLOAD THE MOTORCYCLE! Operation of an overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure that the total weight of rider, passenger, cargo, and accessories does not exceed the specified maximum load for the vehicle. Do not carry along loosely packed items, which can shift during a ride.
U4P5E1E0.book Page 19 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR This motorcycle is equipped with cast wheels and tubeless tires with valves. EWA10480 WARNING ● ● ● 6 ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
U4P5E1E0.book Page 20 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21960 Cast wheels To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.
U4P5E1E0.book Page 21 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front and rear brake pads indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
U4P5E1E0.book Page 22 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU40260 Checking the brake fluid level Front brake 1. Minimum level mark Rear brake Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
U4P5E1E0.book Page 23 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22730 6 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.
U4P5E1E0.book Page 24 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23022 Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle nut: 120 Nm (12.0 m·kgf, 85 ft·lbf) 1. 2. 3. 4.
U4P5E1E0.book Page 25 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11110 CAUTION: Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. EAU23100 Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary.
U4P5E1E0.book Page 26 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 Checking and lubricating the brake and shift pedals EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the brake and clutch levers Brake lever Clutch lever 6 The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U4P5E1E0.book Page 27 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23211 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the centerstand and sidestand EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
U4P5E1E0.book Page 28 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
U4P5E1E0.book Page 29 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU34371 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Battery 2. Negative battery terminal 3.
U4P5E1E0.book Page 30 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. EWA10760 WARNING ● ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries.
U4P5E1E0.book Page 31 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU40140 Replacing the fuses The main fuse and fuse box 1 are located under the fuel tank. (See page 6-14.) 1. ABS control unit fuse 2. ABS motor fuse 3. ABS motor spare fuse 6 1. Fuse box 1 2. Main fuse 3. Spare main fuse Fuse box 2 is located behind panel C. (See page 6-6.) 1. 2. 3. 4. 5.
U4P5E1E0.book Page 32 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. Specified fuses: Main fuse: 30.0 A Headlight fuse: 20.0 A Taillight fuse: 10.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Radiator fan fuse: 20.0 A Fuel injection system fuse: 10.0 A Backup fuse: 10.
U4P5E1E0.book Page 33 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Headlight bulb holder EWA10790 WARNING 6 Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. ● Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected.
U4P5E1E0.book Page 34 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32822 Replacing the tail/brake light bulb 1. Remove the seat. (See page 3-16.) 2. Remove the socket (together with the bulb) by turning it counterclockwise. 4. Insert a new bulb into the socket, push it in, and then turn it clockwise 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.
U4P5E1E0.book Page 35 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24310 EAU32831 Replacing the license plate light bulb Replacing an auxiliary light bulb 1. Remove the license plate light unit by removing the screws. 1. License plate light bulb 2. License plate light bulb socket 6 1. Screw 2. License plate light unit 2. Remove the socket (together with the bulb) by pulling it out. 3. Remove the defective bulb by pulling it out. 4. Insert a new bulb into the socket.
U4P5E1E0.book Page 36 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the auxiliary light socket (together with the bulb) by pushing it in. 6. Install the panel. EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U4P5E1E0.book Page 37 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU42360 Troubleshooting charts Starting problems or poor engine performance EWA10840 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. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
U4P5E1E0.book Page 38 Monday, September 11, 2006 1:33 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 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.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 CAUTION: Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM MOTORCYCLE CARE AND STORAGE ● ● cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM MOTORCYCLE CARE AND STORAGE 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it.
U4P5E1E0.book Page 4 Monday, September 11, 2006 1:33 PM MOTORCYCLE CARE AND STORAGE 3. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM SPECIFICATIONS Dimensions: Overall length: 2095 mm (82.5 in) Overall width: 750 mm (29.5 in) Overall height: 1215 mm (47.8 in) Seat height: 795 mm (31.3 in) Wheelbase: 1440 mm (56.7 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 2800 mm (110.2 in) Weight: With oil and fuel: 212.0 kg (467 lb) Engine: 8 Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined parallel 4-cylinder Displacement: 600.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM SPECIFICATIONS Gear ratio: 1st: 37/13 (2.846) 2nd: 37/19 (1.947) 3rd: 28/18 (1.556) 4th: 32/24 (1.333) 5th: 25/21 (1.190) 6th: 26/24 (1.083) Chassis: Frame type: Diamond Caster angle: 25.00 ° Trail: 97.5 mm (3.
U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM SPECIFICATIONS Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: AC magneto Battery: Model: GT12B-4 Voltage, capacity: 12 V, 10.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: 8 Headlight: 12 V, 60 W/55.0 W × 1 Headlight: 12 V, 55.0 W × 1 Tail/brake light: 12 V, 5.0 W/21.0 W × 1 Front turn signal light: 12 V, 10.0 W × 2 Rear turn signal light: 12 V, 10.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 2. Code re-registering key (red bow) 3. Standard keys (black bow) 1.
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM CONSUMER INFORMATION EAU26540 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-16.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM INDEX A ABS ...................................................... 3-13 ABS warning light ................................... 3-4 Air filter element, replacing ................... 6-14 Anti-theft alarm (optional) ..................... 3-10 Auxiliary light bulb, replacing ................ 6-35 B Battery .................................................. 6-29 Brake and clutch levers, checking and lubricating ...........................................
U4P5E1E0.book Page 2 Monday, September 11, 2006 1:33 PM INDEX Troubleshooting .................................... 6-36 Troubleshooting charts ......................... 6-37 Turn signal indicator light ........................ 3-3 Turn signal light bulb, replacing ............ 6-34 Turn signal switch ................................. 3-10 V Valve clearance .................................... 6-17 Vehicle identification number .................. 9-1 W Wheel bearings, checking.....................
U4P5E1E0.
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.10-0.
