Yamaha FAZER FZS600, Owner'S Manual

Page 1: ...5RT 28199 E0 FZS600 OWNER S MANUAL ...

Page 2: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 3: ...o enjoy all advantages of your FZS600 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha deale...

Page 4: ...be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informati...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5rt book Page 2 Wednesday October 3 2001 10 55 AM ...

Page 6: ...NUAL 2001 by Yamaha Motor Co Ltd 1st edition July 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5rt book Page 3 Wednesday October 3 2001 10 55 AM ...

Page 7: ...NT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 8: ...E_5rt book Page 2 Wednesday October 3 2001 10 55 AM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 10: ...even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however should...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 12: ...element page 6 17 4 Fuses page 6 36 5 Storage compartment page 3 13 6 Grab bar 7 Luggage strap holder page 3 15 8 Seat lock page 3 12 9 Rear shock absorber spring preload adjusting ring page 3 14 10 Shift pedal page 3 9 11 Throttle stop screw page 6 20 12 Engine oil drain bolt page 6 10 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 13: ...bar 16 Rear brake fluid reservoir page 6 27 17 Radiator cap page 6 14 18 Front brake master cylinder page 6 27 19 Engine oil level check window page 6 9 20 Engine oil filler cap page 6 9 21 Brake pedal page 3 10 22 Coolant reservoir page 6 12 E_5rt book Page 2 Wednesday October 3 2001 10 55 AM ...

Page 14: ... handlebar switches page 3 7 3 Speedometer unit page 3 4 4 Main switch steering lock page 3 1 5 Tachometer page 3 5 6 Fuel gauge page 3 7 7 Right handlebar switches page 3 8 8 Brake lever page 3 9 9 Throttle grip page 6 20 E_5rt book Page 3 Wednesday October 3 2001 10 55 AM ...

Page 15: ... Fuel gauge 3 7 Handlebar switches 3 7 Clutch lever 3 9 Shift pedal 3 9 Brake lever 3 9 Brake pedal 3 10 Fuel tank cap 3 10 Fuel 3 11 Starter choke lever 3 12 Seat 3 12 Storage compartment 3 13 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 14 Luggage strap holders 3 15 Sidestand 3 15 Ignition circuit cut off system 3 16 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 16: ...d and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK while the motorcycle is movin...

Page 17: ...y lights are 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 ECA00043 CAUTION _ Do not use the parking position for an extended length of time other wise the battery may discharge _ E_5rt book Page 2 Wednesday October 3 2001 10 55 AM ...

Page 18: ...ler check the electrical circuit NOTE _ Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function _ EAU04302 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circui...

Page 19: ...otorcycle s total mileage is indicated When set to TRIP 1 or TRIP 2 the motorcycle s mileage since the tripme ter was last reset is indicated The trip meters can be used together with the fuel gauge to estimate the distance that can be traveled on a full tank of fuel This information will enable you to plan future fuel stops To set a mode Push the SELECT button to change between the odometer mode ...

Page 20: ... 1 Push both the SELECT and RESET buttons for at least two seconds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button to change the minutes 4 When the minute digits start flash ing push the RESET button to set the minutes 5 Push the SELECT button to start the clock NOTE _ After setting the clock be sure to push the SELECT button before turning the...

Page 21: ...ays an error code the motorcycle should be checked as soon as possible in order to avoid engine damage _ NOTE _ If the tachometer displays 4 000 r min instead of 3 000 r min the speed sen sor may be disconnected or short cir cuited If this occurs have a Yamaha dealer check the electrical circuit _ EAU00109 Anti theft alarm optional This motorcycle can be equipped with an optional anti theft alarm ...

Page 22: ...l 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 cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03826 Hazard switch With the key in the ON or posi tion use this switch to turn o...

Page 23: ...to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU03898 Light switch Set this switch to to turn on the EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine 1 Engine stop switch 2 Light switch 3 Start switch E_5rt_Functi...

Page 24: ...on with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU00161 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn t...

Page 25: ...l tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make s...

Page 26: ...A00104 CAUTION _ Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fu...

Page 27: ...Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the front of the seat up and then pull the seat off To install the seat 1 Insert the projection on the rear of the seat into the seat holder as shown 2 Push the front of the seat down to lock it in place 3 Remove the key NOTE Make sure that the seat is properly se cured before riding ...

Page 28: ...s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the motorcycle be careful not to let any water enter the storage compartment EAU00285 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts EW000035 WARNING Always adjust both fork legs equal ly otherwise poor handling and loss ...

Page 29: ...C000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b NOTE Align the appropriate notch in the ad justing ri...

Page 30: ...re Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU01311 Luggage strap holders There are two luggage strap holders below the rear of the seat which can be turned out for easier access EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it...

Page 31: ...rcuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the run...

Page 32: ...e clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shoul...

Page 33: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 34: ...ngine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to speci...

Page 35: ... shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 31 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessa...

Page 36: ...ction can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 WARNING If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle E_5rt book Page 3 Wednesday October 3 2001 10 55 AM ...

Page 37: ... Starting a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 38: ...ransmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sid estand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 16 Never ride with the sidestand down _ 1 Turn the key to ON and make sure that the engine stop switch is set to ECA00108 CAUTION...

Page 39: ...lant level and the vehicle for coolant leakage If necessary add coolant and then check the warning light again If when the key is turned to ON the warn ing light does not come on for a few seconds then go off or if it does not go off after starting with sufficient coolant have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine a...

Page 40: ...n press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmi...

Page 41: ...ft ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km For this rea son you should read the following ma terial ca...

Page 42: ... CAUTION _ Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle _ EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children a...

Page 43: ...he brake fluid level 6 27 Changing the brake fluid 6 28 Drive chain slack 6 28 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 30 Checking and lubricating the throttle grip and cable 6 30 Checking and lubricating the brake and shift pedals 6 31 Checking and lubricating the brake and clutch levers 6 31 Checking and lubricating the centerstand and sidestand 6 31 Lubricating th...

Page 44: ...cycle maintenance work have a Yamaha dealer do it for you EAU01299 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 12 for seat removal procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever ad...

Page 45: ...NCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on ...

Page 46: ...ding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand centerstand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assembly Check oper...

Page 47: ...d Replace the brake hoses every four years and if cracked or damaged _ 23 Engine oil Change Check oil level and vehicle for oil leakage 24 Engine oil filter cartridge Replace 25 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Lights signals and switches Check operation A...

Page 48: ...ibed in this chapter Refer to this section each time a panel needs to be removed and installed EAU00491 Panel A C To remove the panel Remove the bolt and then pull the pan el off as shown To install the panel Place the panel in the original position and then install the bolt 1 Panel A 2 Panel B 1 Panel C 1 Panel A 2 Bolt E_5rt book Page 5 Wednesday October 3 2001 10 55 AM ...

Page 49: ... Panel B To remove the panel Remove the screws and then take the panel off To install the panel Place the panel in the original position and then install the screws 1 Panel C 2 Bolt 1 Panel B 2 Screw 3 E_5rt book Page 6 Wednesday October 3 2001 10 55 AM ...

Page 50: ...k plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a ...

Page 51: ...s 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque 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 speci fied torque as soon as possible 4 Install the spark plug cap a Spark plug gap Spark plug gap 0 7 0 8 mm...

Page 52: ...everal minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change...

Page 53: ...emove the oil filter cartridge with an oil filter wrench 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 car tridge NOTE _ Make sure that the O ring is properly seated _ 1 Engine oil drain bolt Left 1 Oil filter wrench 2 Oil filter cartridge 1 O ring 2 Oil filter cartridge E_5rt book Page 10 Wednesday October 3 200...

Page 54: ...tion do not use oils labeled ENERGY CON SERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficie...

Page 55: ...ition NOTE _ The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Remove panel A See page 6 5 for panel removal and installation procedures 3 Check the coolant level in the coolant reservoir NOTE _ The coola...

Page 56: ...eck the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ 5 Install the panel NOTE _ The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 44 for further instruc...

Page 57: ...ater pump housing 10 Make a guide using paper or card board or some other type of mate rial hold it under the coolant drain hole and then remove the radiator cap to drain the remaining coolant EW000067 WARNING Never attempt to remove the radia tor cap when the engine is hot 11 Remove the coolant reservoir cap 12 Disconnect the radiator overflow hose from the top of the radiator 1 Hose 2 Fuel cock ...

Page 58: ...tap water 16 Install the coolant drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary 17 Connect the radiator overflow hose and make sure that it is prop erly routed 18 Pour the recommended coolant into the radiator until it is full 1 Hose holder Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf Recommended antifreeze High quality ...

Page 59: ...lace the fuel tank in the original position EW000072 WARNING Before installing the fuel tank make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched 20 Start the engine let it idle for sev eral minutes turn it o...

Page 60: ...he coolant section on page 6 13 for the fuel tank removal procedure EW000071 WARNING Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage 3 Remove panels A B and C See pages 6 5 and 6 6 for panel re moval and installation proce dures 4 Remove the rubber cover from its holders by pushing it d...

Page 61: ...d air from the mesh side of the air filter element If it is damaged replace it 8 Install by reversing the removal procedure EC000085 CAUTION Make sure the air filter is prop erly seated in the filter case The engine should never be run without the air filter installed Excessive pistons and or cylin ders wear may result 1 Air filter case cover 2 Screw 4 1 Air filter element 1 Air filter element E_5...

Page 62: ...d expe rience The adjustment described in the following section however may be serviced by the owner as part of routine maintenance EC000095 CAUTION The carburetors have been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU00632 Adjusting the engine idling speed The engine...

Page 63: ...hrottle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance 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 ...

Page 64: ...teris tics of your motorcycle you should keep the following precautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift d...

Page 65: ...8E NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations EW000079 WARNING Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be ...

Page 66: ...he valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride CE 10E CE 14E 1 Tire air valve 2 Tire air valve core 3 Tire air valve cap with seal FRONT Manufacturer Size Type Bridgestone 110 70 ZR17 54W BT 57F 110 70 ZR17 M C 54W Dunlop 110 70 ZR17 54W D207F 110 70 ZR17 M C 54W REAR Manufa...

Page 67: ...ge be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at modera...

Page 68: ...ootrest as shown Peri odically check the brake pedal position and if necessary have a Yamaha dealer adjust it EW000109 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydraulic system will diminish the braking perform...

Page 69: ... EAU01314 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad ...

Page 70: ...ake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lo...

Page 71: ... Oil seals Replace every two years Brake hose Replace every four years EAU00745 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shift the transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measu...

Page 72: ...this from occurring keep the drive chain slack within the specified limits _ 3 Tighten the locknuts and then tighten the axle nut to the specified torque EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Serv...

Page 73: ...le ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 WARNING Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU04034 Checking and lubricating the throttle grip and cable The ope...

Page 74: ... lever pivots should be lu bricated if necessary EAU03371 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EW000114 WARNING If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pa...

Page 75: ...ng points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease E_5rt book Page 32 Wednesday October 3 2001 10 55 AM ...

Page 76: ...n 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be che...

Page 77: ...a dealer check or repair the steer ing EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion 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 E_5rt book Page 34 Wednesday October 3 2001 10 55 AM ...

Page 78: ...ian EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the motorcycle will not be used for more than one month rem...

Page 79: ...han recommended to avoid causing extensive damage to the electrical system and possibly a fire _ 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 1 Main fuse 2 Spare fuse 4 3 Ignition fuse 4 Signaling system fuse 5 Headlight fuse 6 Radiator fan fuse 7 Backup fus...

Page 80: ...bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 3 Place a new bulb into position and then secure it with the bulb holder 1 Headlight bulb cover 2 Headlight coupler 1 Headlight bulb holder 1 Do not touch t...

Page 81: ...of a wattage higher than speci fied 4 Install the bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU00858 Replacing the tail brake light bulb 1 Remove the seat See page 3 12 for seat removal and installation procedures 2 Remove the owner s tool kit 3 Remove the socket together with the bulb by turning it counter clockwise 4 Remove the defectiv...

Page 82: ...WARNING It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Place the motorcycle on the cen terstand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 3 Remove the brake hose holders by removing the bolts 4 Remove the brake calipers by re moving the bolts ECA00047 CAUTION D...

Page 83: ... aligned with the notches in the wheel hub and that the slot in the speed sensor fits over the re tainer on the fork leg _ 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground 5 Push down hard on the handlebar several times to check for proper fork operation 6 Install the brake calipers by install ing the bolts NOTE _ Make sure that there is enough space between the brake pa...

Page 84: ...e caliper bolts 2 Disconnect the brake torque rod from the brake caliper by removing the nut and the bolt 3 Place the motorcycle on the cen terstand 4 Remove the axle nut and the brake caliper by removing the bolts ECA00082 CAUTION _ Do not apply the brake after the brake caliper has been removed otherwise the brake pads will be forced shut _ Tightening torques Wheel axle 67 Nm 6 7 m kgf Front whe...

Page 85: ...in onto the rear sprocket and then adjust the drive chain slack See page 6 28 for drive chain slack adjustment procedures 3 Connect the brake torque rod to the brake caliper bracket by in stalling the bolt and the nut 4 Install the brake caliper by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc 5 Take ...

Page 86: ...troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi...

Page 87: ...starter 2 Compression There is compression No compression Go to ignition check Ask a Yamaha dealer to inspect Remove spark plugs and check electrodes 3 Ignition Wet Dry Wipe clean with dry cloth and correct spark gap or replace spark plugs Ask a Yamaha dealer to inspect Engine doesn t start ask a Yamaha dealer to inspect Engine doesn t start go to battery check Open throttle half way and start the...

Page 88: ...pe When the hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Level is OK Level is low check the c...

Page 89: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 90: ...ctrical couplers and connectors including the spark plug caps are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners es...

Page 91: ...ld Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing 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 i...

Page 92: ... systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er 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 EWA00...

Page 93: ...corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the ...

Page 94: ...bles and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent mo...

Page 95: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 96: ... Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 5 L With oil filter cartridge replacement 2 7 L Total amount dry engine 3 5 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do n...

Page 97: ...m Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 708 Secondary reduction system Chain drive Secondary reduction ratio 3 200 Number of drive chain sprocket teeth rear front 48 15 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 846 2nd 1 947 3rd 1 545 4th 1 333 5th 1 190 6th 1 074 Chassis Frame type Double cradle C...

Page 98: ...kPa 2 25 kgf cm2 2 25 bar Rear 290 kPa 2 90 kgf cm2 2 90 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3 00 17 M C MT 3 00 Rear Type Cast wheel Size 17 MT 5 00 17 M C MT 5 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingar...

Page 99: ... light 12 V 5 21 W 2 Turn signal light 12 V 21 W 4 Meter lighting 14 V 1 4 W 3 Neutral indicator light 14 V 1 4 W 1 High beam indicator light 14 V 1 4 W 1 Oil level warning light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 4 W 2 Fuel level warning light 12 V 2 W 1 Coolant temperature warning light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 10 A Radiator fan fuse 10 A Ig...

Page 100: ...MPERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous k...

Page 101: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_5rt book Page 1 Wednesday October 3 2001 10 55 AM ...

Page 102: ...1E EAU01041 Key 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 EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The vehicle identification number is used to identify yo...

Page 103: ...under the passenger seat See page 3 12 for seat removal and instal lation procedures Record the informa tion on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_5rt book Page 2 Wednesday October 3 2001 10 55 AM ...

Page 104: ...g 3 13 Front fork checking 6 33 Fuel 3 11 Fuel consumption tips for reducing 5 4 Fuel gauge 3 7 Fuel level warning light 3 4 Fuel tank cap 3 10 Fuses replacing 6 36 H Handlebar switches 3 7 Hazard switch 3 7 Headlight bulb replacing 6 37 High beam indicator light 3 3 Horn switch 3 7 I Identification numbers 9 1 Idling speed adjusting 6 19 Ignition circuit cut off system 3 16 Indicator and warning ...

Page 105: ...ting 6 20 Throttle grip and cable checking and lubricating 6 30 Tires 6 21 Tool kit 6 1 Troubleshooting 6 43 Troubleshooting charts 6 44 Turn signal indicator lights 3 3 Turn signal light bulb replacing 6 39 Turn signal switch 3 7 V Valve clearance adjusting 6 20 Vehicle identification number 9 1 W Wheel bearings checking 6 34 Wheel front 6 39 Installing 6 40 Removing 6 39 Wheel rear 6 41 Installi...

Page 106: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 107: ...E_5GK_Consumer fm Page 11 Wednesday June 13 2001 1 03 PM ...

Page 108: ...PRINTED IN JAPAN 2001 8 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...