OWNER’S MANUAL FZS6V(C) LIT-11626-19-76 5VX-28199-12
U5VX12E0.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZS6V(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM IMPORTANT MANUAL INFORMATION EAU10131 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.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. *Product and specifications are subject to change without notice.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZS6V(C) OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, October 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM TABLE OF CONTENTS Replacing the license plate light bulb ....................................6-35 Front wheel ...................................6-35 Rear wheel ...................................6-37 Troubleshooting ............................6-38 Troubleshooting charts .................6-39 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage .......................
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM SAFETY INFORMATION EAU10281 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.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM SAFETY INFORMATION 1 ● ● 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.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: FZS6V 190 kg (419 lb) FZS6VC 189 kg (417 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.
U5VX12E0.book Page 4 Monday, October 17, 2005 9:58 AM SAFETY INFORMATION 1 ● 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.
U5VX12E0.book Page 5 Monday, October 17, 2005 9:58 AM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U5VX12E0.book Page 6 Monday, October 17, 2005 9:58 AM SAFETY INFORMATION 1 4 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 1 5JW-00 2 5 WARNING Improper loading can cause loss of control. Read owner’s manual for proper loading.
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U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10660 OFF All electrical systems are off. The key can be removed. To unlock the steering EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. 3 1. Push. 2. Turn.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11003 Indicator and warning lights 3 1. 2. 3. 4. 5. Oil level warning light “ ” Engine trouble warning light “ ” Neutral indicator light “ ” High beam indicator light “ ” Turn signal indicator lights “ ” and “ ” EAU11030 Turn signal indicator lights “ ” and “ ” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU32922 LCD tachometer ECA10031 EAU33672 Multi-function display CAUTION: Do not operate the engine in the tachometer red zone. Red zone: 14000 r/min and above EWA12311 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 3 1. LCD tachometer 2.
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U5VX12E0.book Page 5 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS Air intake temperature mode The temperature displayed may vary from the outside temperature depending on engine conditions. To switch the clock to the air intake temperature mode, first set the display to the odometer or tachometer mode, and then push the “RESET” button for at least two seconds.
U5VX12E0.book Page 6 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12344 Handlebar switches Left EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. ECA10050 CAUTION: See page 5-1 for starting instructions prior to starting the engine. 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 released, the switch returns to the center position.
U5VX12E0.book Page 7 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12870 Shift pedal EAU26822 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever.
U5VX12E0.book Page 8 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13070 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 tank cap EWA11090 WARNING 3 Make sure that the fuel tank cap is properly closed before riding. 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
U5VX12E0.book Page 9 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13220 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole and to fill the tank to the bottom of the filler tube as shown.
U5VX12E0.book Page 10 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13431 Catalytic converter This model is equipped with a catalytic converter in the exhaust system. EWA10860 WARNING 3 EAU32980 Seat To remove the seat 1. Insert the key into the seat lock, and then turn it counterclockwise. The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. 1. Projection 2.
U5VX12E0.book Page 11 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14451 Storage compartment When washing the vehicle, be careful not to let any water enter the storage compartment. EAU36461 Adjusting the shock absorber assembly 3 1. Storage compartment 1. Spring preload adjusting ring 2. Special wrench 3. Position indicator The storage compartment is located under the seat. (See page 3-10.
U5VX12E0.book Page 12 Monday, October 17, 2005 9:58 AM INSTRUMENT AND CONTROL FUNCTIONS 2. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b). 3 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.
U5VX12E0.book Page 13 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 14 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-9 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-11 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU16370 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.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM OPERATION AND IMPORTANT RIDING POINTS ECA11130 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, always warm the engine up before starting off. 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.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U5VX12E0.book Page 4 Monday, October 17, 2005 9:58 AM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17212 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EWA10310 WARNING ● ECA10310 CAUTION: ● ● Keep the engine speed out of the tachometer red zone.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE 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 motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary.
U5VX12E0.book Page 4 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL No. 1 * ITEM Air filter element ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ • Check condition and damage. √ √ • Replace if necessary. 2 * Clutch • Check operation.
U5VX12E0.book Page 5 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 9 * 10 11 * ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack, alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. Steering bearings 6 • Check bearing assemblies for looseness.
U5VX12E0.book Page 6 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 17 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 18 * Shock absorber assembly • Check operation and for oil leakage.
U5VX12E0.book Page 7 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17630 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid.
U5VX12E0.book Page 8 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 9 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33020 EAU19651 Checking the spark plugs Panel C To remove the panel 1. Remove the seat. (See page 3-10.) 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.
U5VX12E0.book Page 10 Monday, October 17, 2005 9:58 AM 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. EAU19681 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.
U5VX12E0.book Page 11 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32852 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. 4. Remove the engine oil dipstick and wipe it clean, insert it back into the hole (without screwing it in), and then remove it again to check the oil level. 1.
U5VX12E0.book Page 12 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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. 1. Engine oil drain bolt 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) NOTE: Skip steps 4–6 if the oil filter cartridge is not being replaced. 4. Remove the oil filter cartridge with an oil filter wrench. 7.
U5VX12E0.book Page 13 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 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) ECA11620 CAUTION: ● 6 ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U5VX12E0.book Page 14 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 1. Maximum level mark 2. Minimum level mark 3. Coolant reservoir 3. If the coolant is at or below the minimum level mark, remove the seat. (See page 3-10.) 4. Remove the fuel tank bolts, and then lift the fuel tank away from the coolant reservoir cap. (See page 6-15.) 5. Open the coolant reservoir cap. 1. Coolant reservoir cap 6.
U5VX12E0.book Page 15 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33030 EAU32885 Replacing the air filter element Changing the coolant EWA10380 WARNING Never attempt to remove the radiator cap when the engine is hot. The coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer change the coolant.
U5VX12E0.book Page 16 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10480 EAU21381 Checking the throttle cable free play CAUTION: ● ● 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.
U5VX12E0.book Page 17 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21401 EAU21750 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.
U5VX12E0.book Page 18 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR est items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle.
U5VX12E0.book Page 19 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 20 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 21 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22080 Adjusting the clutch lever free play 6 EAU36500 NOTE: If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. Adjusting the rear brake light switch 1. Clutch lever free play adjusting bolt 2. Clutch lever free play 1. Rear brake light switch 2.
U5VX12E0.book Page 22 Monday, October 17, 2005 9:58 AM 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. Rear brake pads EAU22390 EAU36470 Checking the brake fluid level Front brake EAU22500 EAU22420 Front brake pads 1.
U5VX12E0.book Page 23 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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. NOTE: The rear brake fluid reservoir is located under the fuel tank. (See page 6-15.
U5VX12E0.book Page 24 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. Drive chain slack: 45.0–55.0 mm (1.77–2.17 in) 5. If the drive chain slack is incorrect, adjust it as follows. EAU22791 To check the drive chain slack 1. Place the motorcycle on the centerstand. 2. Shift the transmission into the neutral position. 3.
U5VX12E0.book Page 25 Monday, October 17, 2005 9:58 AM 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) Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
U5VX12E0.book Page 26 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23111 Checking and lubricating the cables 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. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
U5VX12E0.book Page 27 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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 clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U5VX12E0.book Page 28 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23211 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.
U5VX12E0.book Page 29 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 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. 1. Place a stand under the engine to raise the front wheel off the ground.
U5VX12E0.book Page 30 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU34371 EWA10760 Battery WARNING 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. Positive battery terminal 2.
U5VX12E0.book Page 31 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● 6 KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation. 4.
U5VX12E0.book Page 32 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23740 1. 2. 3. 4. 5. 6. 7. 8. Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse (for odometer and clock) Fuel injection system fuse Spare fuse Taillight fuse If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage.
U5VX12E0.book Page 33 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 34 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32822 Replacing the tail/brake light bulb 1. Remove the seat. (See page 3-10.) 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.
U5VX12E0.book Page 35 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24310 EAU24360 Replacing the license plate light bulb Front wheel EAU33681 1. Remove the license plate light unit by removing the screws. To remove the front wheel EWA10820 WARNING ● ● 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.
U5VX12E0.book Page 36 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the brake hose holder and reflector on each side by removing the bolt. 4. Remove the brake caliper on each side by removing the bolts. EAU33691 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle. 3. Install the brake calipers by installing the bolts.
U5VX12E0.book Page 37 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 NOTE: The drive chain does not need to be disassembled in order to remove and install the rear wheel. Rear wheel EAU32872 To remove the rear wheel EWA10820 WARNING ● ● 6 It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Loosen the axle nut. 2. Place the motorcycle on the centerstand. 3. Remove the axle nut. 4.
U5VX12E0.book Page 38 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11070 EAU25870 CAUTION: Troubleshooting Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
U5VX12E0.book Page 39 Monday, October 17, 2005 9:58 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 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.
U5VX12E0.book Page 40 Monday, October 17, 2005 9:58 AM 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.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26041 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM MOTORCYCLE CARE AND STORAGE ECA10800 CAUTION: ● ● ● Apply spray oil and wax sparingly and make sure to wipe off any excess. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use.
U5VX12E0.book Page 4 Monday, October 17, 2005 9:58 AM MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 6.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM 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: FZS6V 207.0 kg (456 lb) FZS6VC 208.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM SPECIFICATIONS 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.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM 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/position light: 12 V, 21 W/5.0 W × 2 Rear turn signal light: 12 V, 21.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION EAU26540 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U5VX12E0.book Page 3 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U5VX12E0.book Page 5 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U5VX12E0.book Page 7 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U5VX12E0.book Page 9 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U5VX12E0.book Page 10 Monday, October 17, 2005 9:58 AM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
U5VX12E0.book Page 1 Monday, October 17, 2005 9:58 AM INDEX A Front fork, checking...............................6-28 Fuel .........................................................3-9 Fuel tank cap...........................................3-8 Fuses, replacing....................................6-31 Accessories and replacement parts ..... 6-20 Air filter element, replacing ................... 6-15 B Battery ..................................................
U5VX12E0.book Page 2 Monday, October 17, 2005 9:58 AM INDEX Turn signal switch ................................... 3-6 V Valve clearance .................................... 6-17 Vehicle identification number .................. 9-1 W Warranty, extended................................. 9-9 Warranty, limited ..................................... 9-7 Wheel bearings, checking..................... 6-30 Wheel (front) ......................................... 6-35 Wheel (rear) ..................................
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.11-3.
