OWNER’S MANUAL FZS600 FZS600SP 5DM-28199-E3
E_5dm_Intro0.fm Page 1 Saturday, October 16, 1999 1:43 PM INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! As the owner of a FZS600/FZS600SP, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the 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 your FZS600/ FZS600SP’s advantages.
E_5dm_Info0.fm Page 1 Saturday, October 16, 1999 1:43 PM IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! 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.
E_5dm_Info0.fm Page 2 Saturday, October 16, 1999 1:43 PM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_5dm_Info0.fm Page 3 Saturday, October 16, 1999 1:43 PM IMPORTANT MANUAL INFORMATION EAU00008 FZS600/FZS600SP OWNER’S MANUAL © 1999 by Yamaha Motor Co., Ltd. 1st Edition, September 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
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E_5dm_LabelTOC.fm Page 1 Saturday, October 16, 1999 1:44 PM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY.................................................
E_5dm_Label.fm Page 1 Saturday, October 16, 1999 1:44 PM GIVE SAFETY THE RIGHT OF WAY EAU00021 1- Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition.
E_5dm_DescriptionTOC.fm Page 1 Saturday, October 16, 1999 1:44 PM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls/Instruments ..........................................................................
E_5dm_Description.fm Page 1 Saturday, October 16, 1999 1:45 PM DESCRIPTION EAU00026 2- Left view 2 1. Front fork spring preload adjusting bolt 2. Starter (choke) “ ” 3. Air filter 4. Fuses 5. Storage compartment 6. Grab bar 7. Luggage strap holder 8. Seat lock 9. Rear shock absorber spring preload adjusting ring 10.
E_5dm_Description.fm Page 2 Saturday, October 16, 1999 1:45 PM DESCRIPTION Right view 2 11. Luggage strap holder 12. Tool kit 13. Grab bar 14. Rear brake fluid master cylinder 15. Radiator cap 16. Front brake fluid master cylinder 17. Oil level check window 18. Rear brake pedal 19.
E_5dm_Description.fm Page 3 Saturday, October 16, 1999 1:45 PM DESCRIPTION Controls/Instruments 2 1. Clutch lever 2. Left handlebar switches 3. Speedometer 4. Main switch 5. Tachometer 6. Fuel gauge 7. Right handlebar switches 8. Front brake lever 9.
E_5dm_FunctionsTOC.fm Page 1 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS Main switch/Steering lock .....................................3-1 Indicator lights ......................................................3-3 Oil level indicator circuit check..............................3-4 Fuel indicator circuit check ...................................3-5 Speedometer ........................................................3-6 Tachometer ......................................................
E_5dm_Functions.fm Page 1 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029 Main switch/Steering lock The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00038 OFF All electrical circuits are switched off. The key can be removed in this position.
E_5dm_Functions.fm Page 2 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU03013 (Parking) The steering is locked in this position, and the taillights and auxiliary light come on but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to “ ”. Do not use this position for an extended length of time as the battery may discharge.
E_5dm_Functions.fm Page 3 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00063 EAU01716 High beam indicator light “ ” This indicator comes on when the headlight high beam is used. Coolant temperature indicator light “ ” This indicator light comes on when the engine overheats. If the light comes on, stop the engine immediately and allow the engine to cool. EAU01313 Oil level indicator light “ ” This indicator comes on when the oil level is low.
E_5dm_Functions.fm Page 4 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00071 Oil level indicator circuit check CB-48E Turn the main switch to “ON” and the engine stop switch to “ ”. Oil level indicator light does not come on. Oil level indicator light comes on. Put the transmission in neutral or apply the clutch lever, then push the start switch. Check engine oil level. Oil level indicator light comes on. Engine oil level and electrical circuit are OK.
E_5dm_Functions.fm Page 5 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00085 Fuel indicator circuit check CB-46E Turn the main switch to “ON” and the engine stop switch to “ ”. 3 Fuel indicator light does not come on. Fuel indicator light comes on. Put the transmission in neutral or apply the clutch lever, then push the start switch. Fuel indicator light comes on. Fuel level and electrical circuit are OK. Go ahead with riding. Check the fuel level.
E_5dm_Functions.fm Page 6 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS ride on a tank of fuel. This information will enable you to plan fuel stops in the future. 1. 2. 3. 4.
E_5dm_Functions.fm Page 7 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU01322* Diagnosis device @ This model is equipped with a diagnosis device for the Throttle Position Sensor (T.P.S.) circuit. If some trouble should occur in the circuit, the tachometer will repeatedly display as follows: 3 CB-70E 0 r/min for 3 seconds. 1. Tachometer 2. Red zone EAU00101 3,000 r/min for 2.5 seconds. Current engine r/min for 3 seconds.
E_5dm_Functions.fm Page 8 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Antitheft alarm (optional) An antitheft alarm can be equipped to this motorcycle. Consult your Yamaha dealer to obtain and install the alarm. 3 1. Fuel gauge EAU00110 Fuel gauge This model is equipped with an electric fuel gauge so the rider can monitor the fuel level in the fuel tank. When the needle indicates “E” (Empty), about 3.5 L remain in the fuel tank.
E_5dm_Functions.fm Page 9 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00127 Turn signal switch To signal a right-hand turn, push the switch to “ ”. To signal a left-hand turn, push the switch to “ ”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position. 3 1. 2. 3. 4. 5.
E_5dm_Functions.fm Page 10 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00134 Lights switch Turning the light switch to “ ”, turns on the auxiliary light, meter lights and taillight. Turning the light switch to “ ” turns the headlight on also. EAU00143 Start switch “ ” The starter motor cranks the engine when pushing the start switch. 1. Engine stop switch 2. Lights switch 3.
E_5dm_Functions.fm Page 11 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Shift pedal EAU00157 Shift pedal This motorcycle is equipped with a constant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 1. 2. 3. a. Front brake lever Lever position adjuster Arrow mark Lever distance 1.
E_5dm_Functions.fm Page 12 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. @ @ EW000023 WARNING Be sure the cap is properly installed and locked in place before riding the motorcycle. @ 1. Lock cover 2. Open EAU02935 @ Fuel tank cap To open Open the lock cover. Insert the key and turn it 1/4 turn clockwise.
E_5dm_Functions.fm Page 13 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. @ @ EAU00191 3 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 20 L Reserve: 3.5 L 1. Filler tube 2. Fuel level EAU01183 Fuel Make sure there is sufficient fuel in the tank.
E_5dm_Functions.fm Page 14 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Starter (choke) “ ” EAU02976 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). 1. Seat lock 2. Open 1. Projection 2. Seat holder EAU01319 Seat To remove Insert the key into the seat lock and turn it counterclockwise.
E_5dm_Functions.fm Page 15 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Helmet holder 1. Storage compartment EAU00263 EAU01688 Helmet holder Storage compartment The helmet holder is under the seat. Remove the seat and hook the helmet on the helmet holder. Then, reinstall the seat and lock it. This compartment is designed to store a genuine Yamaha U-LOCK. (Other locks may not fit.) Be sure the lock is fastened securely with the straps when storing it in the compartment.
E_5dm_Functions.fm Page 16 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Spring preload adjusting bolt EAU00285 Front fork adjustment 1. Setting position 2. Front fork cap EC000013 This front fork is equipped with spring preload adjusting bolts. EW000037 WARNING Each fork leg must be set to the same pressure. Uneven setting can cause poor handling and loss of stability. @ @ Adjust spring preload as follows.
E_5dm_Functions.fm Page 17 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00315 WARNING This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the cylinder assembly.
E_5dm_Functions.fm Page 18 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.) EW000044 WARNING This motorcycle must not be operated with the sidestand in the down position.
E_5dm_Functions.fm Page 19 Saturday, October 16, 1999 1:45 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00332 Sidestand/clutch switch operation check CLUTCH SWITCH IS OK. Check the operation of the sidestand switch and clutch switch against the information below. EW000046 3 @ CD-08E WARNING ● Be sure to use the centerstand during this inspection. ● If improper operation is noted, consult a Yamaha dealer. SIDESTAND IS DOWN. ENGINE WILL STALL. SIDESTAND SWITCH IS OK.
E_5dm_PreopTOC.fm Page 1 Saturday, October 16, 1999 1:46 PM PRE-OPERATION CHECKS Pre-operation check list......................................................................
E_5dm_Preop.fm Page 1 Saturday, October 16, 1999 1:46 PM PRE-OPERATION CHECKS EAU01114 4- Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
E_5dm_Preop.fm Page 2 Saturday, October 16, 1999 1:46 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Center and sidestand pivots • Check for smooth operation. • Lubricate if necessary. Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. Fuel • Check fuel level. • Fill with fuel if necessary. 3-12 ~ 3-13 Lights, signals and switches • Check for proper operation.
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E_5dm_OperationTOC.fm Page 1 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS Starting the engine............................................................................. 5-1 Starting a warm engine ...................................................................... 5-4 Shifting ............................................................................................... 5-4 Recommended shift points (for Switzerland only) ..............................
E_5dm_Operation.fm Page 1 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS 5- EAU00373 @ 5 WARNING ● Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start your engine or let it run for any length of time in a closed area.
E_5dm_Operation.fm Page 2 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS CF-28E TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “ ”. IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, PUSH THE START SWITCH. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START. 5 RETRACT THE SIDESTAND AND PUT TRANSMISSION IN GEAR. MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.
E_5dm_Operation.fm Page 3 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS 1. Turn the main switch to “ON” and the engine stop switch to “ ”. EC000035 CAUTION: If the fuel indicator light comes on, check the fuel level. If necessary, fill the tank with fuel. @ NOTE: If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery.
E_5dm_Operation.fm Page 4 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine The starter (choke) is not required when the engine is warm. @ EC000046 CAUTION: See the “Engine break-in” section prior to operating the motorcycle for the first time. @ @ 1. Shift pedal N. Neutral EAU00423 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc.
E_5dm_Operation.fm Page 5 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS EAU02937 Tips for reducing fuel consumption The recommended shift points are shown in the table below. Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: ● Warm up the engine before riding. ● Turn off the starter (choke) as soon as possible. ● Shift up swiftly and avoid high engine speeds during acceleration.
E_5dm_Operation.fm Page 6 Saturday, October 16, 1999 1:46 PM OPERATION AND IMPORTANT RIDING POINTS EAU01329 0 ~ 1,000 km Avoid operation above 5,000 r/min. 1,000 ~ 1,600 km Avoid cruising speeds in excess of 6,000 r/min. EC000052 CAUTION: After 1,000 km of operation, be sure to replace the engine oil and oil filter. @ @ EAU00460 Parking When parking the motorcycle, stop the engine and remove the ignition key. EW000058 WARNING The exhaust system is hot.
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E_5dm_PeriodicTOC.fm Page 1 Saturday, October 16, 1999 1:46 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit...................................................................6-1 Periodic maintenance and lubrication...................6-2 Panel removal and installation ..............................6-5 Panel A, C.............................................................6-5 Panel B .................................................................6-6 Spark plugs............................................
E_5dm_Periodic.fm Page 1 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
E_5dm_Periodic.fm Page 2 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION CP-01E EVERY NO. ITEM CHECKS AND MAINTENANCE JOBS 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Check condition. • Replace if necessary. 3 4 Spark plugs * Valves 5 6 7 Clutch • Check operation. • Adjust or replace cable.
E_5dm_Periodic.fm Page 3 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. 11 12 13 6 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) • Check bearing for looseness or damage. • Replace if necessary. √ √ Swingarm • Check swingarm pivoting point for play. • Correct if necessary. • Lubricate with molybdenum disulfide grease every 24,000 km or 24 months (whichever comes first). √ √ Drive chain • Check chain slack.
E_5dm_Periodic.fm Page 4 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. ITEM CHECKS AND MAINTENANCE JOBS √ √ √ • Check oil level and vehicle for oil leakage. • Correct if necessary. • Change. (Warm engine before draining.) √ √ √ * Carburetors 22 Engine oil 23 Engine oil filter cartridge • Replace. * Cooling system 12,000 km or 12 months (whichever comes first) • Check engine idling speed, synchronization and starter operation. • Adjust if necessary.
E_5dm_Periodic.fm Page 5 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 2. Panel B 1. Panel C 1. Panel A 2. Bolt EAU01122 6 EAU00491 Panel removal and installation Panel A, C The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. To remove Remove the bolt and pull outward on the areas shown.
E_5dm_Periodic.fm Page 6 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel C 2. Bolt 1. Panel B 2. Screw (× 3) EAU01315 Panel B To remove Remove the screws. 6 To install Place the panel in the original position and install the screws.
E_5dm_Periodic.fm Page 7 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR ly remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. 1. Spark plug cap 1. Spark plug wrench EAU01485* Spark plugs 6 Removal 1. Remove the spark plug caps. 2.
E_5dm_Periodic.fm Page 8 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the spark plug and tighten it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kg) NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. @ a. Spark plug gap Installation 1.
E_5dm_Periodic.fm Page 9 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover. NOTE: Wait a few minutes until the oil level settles before checking. @ @ 1. Oil level check window 2. Maximum level mark 3. Minimum level mark EAU01717 Engine oil 6 Oil level inspection 1. Place the motorcycle on the centerstand. Warm up the engine for several minutes. 3.
E_5dm_Periodic.fm Page 10 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt 3. Remove the drain bolt and drain the oil. NOTE: When draining the engine oil, use a funnel or similar device to keep oil away from the exhaust pipe. @ 1. Oil filter wrench 2. Oil filter cartridge 1. O-ring NOTE: An oil filter wrench is available at a nearby Yamaha dealer. @ @ @ 6. Apply a light coat of engine oil to the O-ring of the new oil filter. 4.
E_5dm_Periodic.fm Page 11 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Torque wrench 7. Install the new oil filter and tighten it to the specified torque with an oil filter wrench. 6 @ @ @ CAUTION: ● Do not put in any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. ● Be sure no foreign material enters the crankcase. @ 8. Fill the engine with sufficient oil to reach the specified level.
E_5dm_Periodic.fm Page 12 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR Reservoir tank capacity: 0.61 L EC000080 CAUTION: Hard water or salt water is harmful to the engine. You may use distilled water if you can’t get soft water. @ @ 1. Reservoir tank 2. Maximum level mark 3. Minimum level mark NOTE: ● If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. ● The radiator fan operation is completely automatic.
E_5dm_Periodic.fm Page 13 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (× 2) EAU01719* Changing the coolant 6 1. Place the motorcycle on the centerstand. 2. Remove the seat. 3. Remove the fuel tank bolts. 1. Hose 2. Fuel cock 3. Fuel level sensor connector 1. Coolant drain bolt 2. Sidestand switch lead 3. Plastic holder 7. Remove the sidestand switch lead from its holder. 8.
E_5dm_Periodic.fm Page 14 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Radiator cap 2. Overflow hose 1. Plastic holder EW000067 WARNING Do not remove the radiator cap when the engine is hot. 12. Remove the hose holder from the frame. @ @ 10. Remove the coolant reservoir tank cap. 11. Remove the radiator overflow hose from the top of the radiator. 13. Pull the hose all the way down and to the outside while making sure to keep the end up.
E_5dm_Periodic.fm Page 15 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 15. Replace the coolant drain bolt washer if it is damaged and tighten the coolant drain bolt to the specified torque. Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kg) 16. Install the radiator overflow hose. Make sure it is properly routed. 17. Pour the recommended coolant into the radiator until it is full.
E_5dm_Periodic.fm Page 16 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Rubber cover 2. Holder 1. Air filter case cover 2. Screw (× 4) 5. Remove the screws holding the air filter case cover. 4. Remove the rubber cover from its holders by pushing it downward. Then pull it upward and back as shown, away from the air filter case.
E_5dm_Periodic.fm Page 17 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000072 @ 1. Air filter element 6. Pull out the air filter element. 7. Tap the air filter element lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air from the mesh side of the air filter element. If it is damaged, replace it. 8. Install by reversing the removal procedure. 6 EC000085 @ CAUTION: ● Make sure the air filter is properly seated in the filter case.
E_5dm_Periodic.fm Page 18 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00630 Carburetor adjustment The carburetors are important parts of the engine and require very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idle speed may be adjusted by the owner as part of routine maintenance. EC000095 CAUTION: The carburetors were set at the Yamaha factory after many tests.
E_5dm_Periodic.fm Page 19 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 EAU00658 Valve clearance adjustment Tires The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician.
E_5dm_Periodic.fm Page 20 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR CE-33E Maximum load* Cold tire pressure Up to 90 kg load* EW000083 187 kg Front Rear 225 kPa 250 kPa (2.25 kg/cm2, (2.50 kg/cm2, 2.25 bar) 2.50 bar) 225 kPa 290 kPa 90 kg Maximum load* (2.25 kg/cm2, (2.90 kg/cm2, 2.25 bar) 2.90 bar) High speed riding 225 kPa 290 kPa (2.25 kg/cm2, (2.90 kg/cm2, 2.25 bar) 2.90 bar) * Load is the total weight of cargo, rider, passenger and accessories.
E_5dm_Periodic.fm Page 21 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000095 EW000080 WARNING Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician. WARNING ● After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd.
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E_5dm_Periodic.fm Page 23 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If proper adjustment cannot be obtained or the clutch does not work correctly, ask a Yamaha dealer to inspect the internal clutch mechanism. @ @ 1. Locknut 2. Adjusting bolt c. Free play a. Pedal height EAU00712* Rear brake pedal height check EAU00692 The top of the brake pedal should be positioned 36.6 mm below the top of the footrest. If not, ask a Yamaha dealer to adjust it.
E_5dm_Periodic.fm Page 24 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000109 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary. @ @ 1.
E_5dm_Periodic.fm Page 25 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Wear indicator groove 1. Wear indicator groove 1. Minimum level mark EAU01314 6 EAU00731 Checking the front and rear brake pads Inspecting the brake fluid level Each brake pad is provided with a wear indicator groove, which allows checking the brake pad for wear without disassembling the brake.
E_5dm_Periodic.fm Page 26 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. ● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● Have a Yamaha dealer check the cause if the brake fluid level goes down. ● 1.
E_5dm_Periodic.fm Page 27 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000096 CAUTION: Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. @ @ a. Chain slack EAU00745 Drive chain slack check NOTE: Spin the wheel several times and find the tightest position of the chain. Check and/or adjust the chain slack while it’s in this tightest position.
E_5dm_Periodic.fm Page 28 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 Drive chain lubrication The chain consists of many parts which work with each other. If the chain is not maintained properly, it will wear out quickly. Therefore, the chain must be serviced regularly. This service is especially necessary when riding in dusty areas. This motorcycle is equipped with a sealed type chain.
E_5dm_Periodic.fm Page 29 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02984 6 EAU02985 EAU02965 Brake and shift pedal lubrication Brake and clutch lever lubrication Center and sidestand lubrication Lubricate the pivoting parts. Lubricate the pivoting parts. Recommended lubricant: Engine oil Recommended lubricant: Engine oil Lubricate the pivoting and mating joints. Check to see that the center and sidestand move up and down smoothly.
E_5dm_Periodic.fm Page 30 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00790 EAU02939 Rear suspension lubrication Front fork inspection Lubricate the pivoting parts. Visual check EW000115 Recommended lubricant: Molybdenum disulfide grease WARNING Securely support the motorcycle so there is no danger of it falling over. @ @ Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. Operation check 1.
E_5dm_Periodic.fm Page 31 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 Battery If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings. This motorcycle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or fill the battery with distilled water. ● If the battery seems to have discharged, consult a Yamaha dealer.
E_5dm_Periodic.fm Page 32 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000116 WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. ANTIDOTE: ● EXTERNAL: Flush with water. ● INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately.
E_5dm_Periodic.fm Page 33 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 CAUTION: Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire. @ @ 6 1. 2. 3. 4. 5. 6. 7. 8.
E_5dm_Periodic.fm Page 34 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000104 CAUTION: To prevent damage to the following: ● Headlight bulb Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and illuminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
E_5dm_Periodic.fm Page 35 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Socket 1. Screw EAU00858 Taillight bulb replacement 6 1. Remove the seat. 2. Remove the tool kit. 3. To remove the socket, turn it counterclockwise. 4. To remove the defective bulb, turn it counterclockwise. 5. Push a new bulb into the socket and turn it clockwise. 6. Install the socket and turn it clockwise. 7. Install the tool kit and seat. EAU01095 Turn signal light bulb replacement 1.
E_5dm_Periodic.fm Page 36 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. Brake hose holder Plastic clamp Caliper bolt (× 2) Speed sensor 4. Remove the brake hose holders and calipers. 5. Remove the plastic clamp holding the speed sensor lead to the brake cable. NOTE: Do not depress the brake lever when the calipers are off the discs as the brake pads will be forced shut. 1. Speed sensor 1. Stopper EAU01309 Front wheel installation 1.
E_5dm_Periodic.fm Page 37 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the wheel axle, pinch bolt and caliper bolts to the specified torques. Tightening torque: Wheel axle: 67 Nm (6.7 m·kg) Pinch bolt: 20 Nm (2.0 m·kg) Caliper bolt: 40 Nm (4.0 m·kg) 1. Axle nut 2. Chain adjusting nut 3. Locknut 1. Caliper bolt (× 2) 2. Brake torque rod nut EAU01318 Rear wheel removal EW000122 6 @ WARNING It is advisable to have a Yamaha dealer service the wheel.
E_5dm_Periodic.fm Page 38 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Tighten the axle nut, caliper bolts and the brake torque rod nut to the specified torques. NOTE: ● Do not depress the brake pedal when the caliper is off the disc as the brake pads will be forced shut. ● You do not have to disassemble the chain in order to remove or install the rear wheel. @ @ EAU01317 Rear wheel installation 1. Install the caliper bracket and wheel assembly, then insert the axle. 2.
E_5dm_Periodic.fm Page 39 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting 6 Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer.
E_5dm_Periodic.fm Page 40 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02990* Troubleshooting chart EW000125 WARNING Never check the fuel system while smoking or in the vicinity of an open flame. @ @ 1. Fuel Enough fuel. Go to compression check. No fuel. Supply fuel. Check if there is fuel in the fuel tank. Engine doesn’t start, go to compression check. 2. Compression There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect.
E_5dm_Periodic.fm Page 41 Saturday, October 16, 1999 1:47 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Engine overheating EW000070 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. Open the radiator cap as follows. Wait until the engine has cooled. Remove the radiator cap stopper by removing the screw.
E_5dm_CleaningTOC.fm Page 1 Saturday, October 16, 1999 1:47 PM MOTORCYCLE CARE AND STORAGE Care ................................................................................................... 7-1 Storage...............................................................................................
E_5dm_Cleaning.fm Page 1 Saturday, October 16, 1999 1:47 PM MOTORCYCLE CARE AND STORAGE EAU01516 7- Care 7 The exposure of its technology makes a motorcycle charming but also vulnerable. Although high-quality components are used, they are not all rust-resistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Frequent and proper care, however, will keep your motorcycle looking good, extend its life and maintain its performance.
E_5dm_Cleaning.fm Page 2 Saturday, October 16, 1999 1:47 PM MOTORCYCLE CARE AND STORAGE ECA00010 @ CAUTION: ● Avoid using strong acidic wheel cleaners, especially on spoked wheels. If you do use such products for hard-to-remove dirt, do not leave it on any longer than instructed, then thoroughly rinse it off with water, immediately dry the area and apply a corrosion protection spray. ● Improper cleaning can damage windshields, cowlings, panels and other plastic parts.
E_5dm_Cleaning.fm Page 3 Saturday, October 16, 1999 1:47 PM MOTORCYCLE CARE AND STORAGE 1. Clean your motorcycle with cold water and soap after the engine has cooled down. ECA00012 CAUTION: Do not use warm water since it increases the corrosive action of the salt. @ @ 2. Be sure to apply a corrosion protection spray on all (even chromeand nickel-plated) metal surfaces to prevent corrosion. 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2.
E_5dm_Cleaning.fm Page 4 Saturday, October 16, 1999 1:47 PM MOTORCYCLE CARE AND STORAGE ECA00013 @ CAUTION: ● Apply spray oil and wax sparingly and wipe off any excess. ● Never apply oil or wax on rubber and plastic parts, but treat them with a suitable care product. ● Avoid using abrasive polishing compounds as they wear away the paint. Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
E_5dm_Cleaning.fm Page 5 Saturday, October 16, 1999 1:47 PM MOTORCYCLE CARE AND STORAGE 7. Check and, if necessary, correct the tire air pressure, then raise the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover up the muffler outlet with a plastic bag to prevent moisture from entering. 9. Remove the battery and fully charge it.
E_5dm_SpecTOC.fm Page 1 Saturday, October 16, 1999 1:47 PM SPECIFICATIONS Specifications ..................................................................................... 8-1 HOW TO USE THE CONVERSION TABLE .......................................
E_5dm_Spec.
E_5dm_Spec.fm Page 2 Saturday, October 16, 1999 1:48 PM SPECIFICATIONS Cooling system total amount 1.95 L Air filter Dry type element Fuel Type Regular unleaded gasoline Fuel tank capacity 20 L Fuel reserve amount 3.
E_5dm_Spec.fm Page 3 Saturday, October 16, 1999 1:48 PM SPECIFICATIONS Rear Rear Type Tubeless Type Cast Size 160 / 60 ZR17 (69W) Size 17 × MT 5.00 Manufacturer/ model Bridgestone / BT-57R Brakes Front Dunlop / D207J Metzeler / MEZ1 Michelin / MACADAM 90X Maximum load* 187 kg Up to 90 kg load* 225 kPa (2.25 kg/cm2, 2.25 bar) Rear 250 kPa (2.50 kg/cm2, 2.
E_5dm_Spec.fm Page 4 Saturday, October 16, 1999 1:48 PM SPECIFICATIONS Electrical system Ignition system Fuses T.C.I. (digital) Charging system Main fuse 30 A Headlight fuse 20 A Type A.C.
E_5dm_Spec.fm Page 5 Saturday, October 16, 1999 1:48 PM SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CS-02E CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER METRIC TO IMPERIAL Metric unit IMPERIAL **mm × 0.03937 = **in 2 mm × 0.03937 = 0.08 in 8 8-5 Multiplier Imperial unit Torque m·kg m·kg cm·kg cm·kg 7.233 86.794 0.0723 0.
E_5dm_ConsumerTOC.fm Page 1 Saturday, October 16, 1999 1:48 PM CONSUMER INFORMATION Identification number records............................................................. 9-1 Key identification number ................................................................... 9-1 Vehicle identification number.............................................................. 9-1 Model label.........................................................................................
E_5dm_Consumer.fm Page 1 Saturday, October 16, 1999 1:48 PM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 1. Key identification number CA-02E 2. VEHICLE IDENTIFICATION NUMBER: CA-02E 1.
E_5dm_Consumer.fm Page 2 Saturday, October 16, 1999 1:48 PM CONSUMER INFORMATION 1. Model label EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-14 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
E_5dmIX.fm Page 1 Saturday, October 16, 1999 1:48 PM INDEX 10- A E Air filter ..................................................6-15 Antitheft alarm (optional) ..........................3-8 Engine break-in ....................................... 5-5 Engine oil ................................................ 6-9 Engine stop switch................................. 3-10 B Battery ...................................................6-31 Brake and clutch lever lubrication...........
E_5dmIX.fm Page 2 Saturday, October 16, 1999 1:48 PM INDEX P Panel A, C ............................................... 6-5 Panel B.................................................... 6-6 Panel removal and installation ................. 6-5 Parking .................................................... 5-6 Pass switch ............................................. 3-9 Periodic maintenance and lubrication ...... 6-2 Pre-operation check list ........................... 4-1 R Rear brake pedal ..................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 · 10 - 0.
