OWNER’S MANUAL FZS10V FZS10VC LIT-11626-19-79 3C3-28199-10
U3C310E0.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZS10V/FZS10VC. 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.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZS10V/FZS10VC OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, December 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.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 PRE-OPERATION CHECKS ............. 4-1 Pre-operation check list ................. 4-2 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 OPERATION AND IMPORTANT RIDING POINTS ..................
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM 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 .............
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 189 kg (417 lb) (CAL) 190 kg (419 lb) (U49) 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.
U3C310E0.book Page 4 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 5 Wednesday, December 7, 2005 2:31 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U3C310E0.book Page 6 Wednesday, December 7, 2005 2:31 PM SAFETY INFORMATION 1 4 CAUTION 1 Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Shock absorber assembly rebound damping force adjusting screw (page 3-16) 10.Shift pedal (page 3-9) 11.Engine oil drain bolt (page 6-10) 12.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine oil level check window (page 6-10) 10.Brake pedal (page 3-10) 11.Coolant reservoir (page 6-13) 12.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM 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. 3 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. 1. Push. 2.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11003 Indicator and warning lights 1. 2. 3. 4. 5. 6. 7.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS Coolant temperature Display Conditions What to do Under 39 °C (Under 103 °F) Message “Lo” is displayed. OK. Go ahead with riding. 40–116 °C (104–242 °F) Temperature is displayed. OK. Go ahead with riding. 117–139 °C (243–283 °F) Temperature display flashes. Warning light comes on. Stop the vehicle and allow it to idle until the coolant temperature goes down.
U3C310E0.book Page 4 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11530 Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. (See page 3-4 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”.
U3C310E0.book Page 5 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS Tachometer 4. Push the “SELECT” button, and the minute digits will start flashing. 5. Push the “RESET” button to set the minutes. 6. Push the “SELECT” button and then release it to start the clock. Clock Odometer and tripmeter modes 3 1. Tachometer 2. Tachometer red zone 1. Clock 2. Speedometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.
U3C310E0.book Page 6 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS eter display will automatically change to the fuel reserve tripmeter mode “FTRIP” and start counting the distance traveled from that point.
U3C310E0.book Page 7 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS Air intake temperature mode ● When the air intake temperature display is selected, “A” is displayed for one second, and then the air intake temperature is displayed. Self-diagnosis device ECA11590 CAUTION: If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. LCD and tachometer brightness control mode 3 1.
U3C310E0.book Page 8 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS To set the brightness 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” button. 3. Turn the key to “ON”, and then release the “SELECT” button after five seconds. 4. Push the “RESET” button to select the desired brightness level. 5. Push the “SELECT” button to confirm the selected brightness level. The display will return to the odometer or tripmeter mode.
U3C310E0.book Page 9 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10050 CAUTION: EAU12820 EAU12870 Clutch lever Shift pedal 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. The lever should be pulled rapidly and released slowly for smooth clutch operation.
U3C310E0.book Page 10 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU26822 Brake lever EAU12941 Brake pedal EAU13070 Fuel tank cap The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Brake pedal 1. 2. 3. 4. Brake lever Brake lever position adjusting dial “ ” mark Distance between brake lever and handlebar grip The brake pedal is on the right side of the motorcycle.
U3C310E0.book Page 11 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13220 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EWA11090 WARNING 3 EAU13300 Make sure that the fuel tank cap is properly closed before riding.
U3C310E0.book Page 12 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%.
U3C310E0.book Page 13 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS NOTE: Make sure that the seats are properly secured before riding. 3 2. Remove the key. Rider seat To remove the rider seat 1. Remove the passenger seat. 2. Push the rider seat lock lever, located under the back of the rider seat, to the left as shown, and then pull the seat off. 1. Rider seat lock lever To install the rider seat 1.
U3C310E0.book Page 14 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14461 Storage compartment EAU39331 Adjusting the front fork Each front fork leg is equipped with a spring preload adjusting bolt, the right front fork leg is equipped with a rebound damping force adjusting screw and the left front fork leg with a compression damping force adjusting screw. EWA10180 WARNING 1. Storage compartment The storage compartment is located under the passenger seat. (See page 3-12.
U3C310E0.book Page 15 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS Spring preload setting: Minimum (soft): 8 Standard: 5.5 Maximum (hard): 0 3 Rebound damping force NOTE: Be sure to perform this adjustment on the right front fork leg. Rebound damping setting: Minimum (soft): 26 click(s) in direction (b)* Standard: 15 click(s) in direction (b)* Maximum (hard): 1 click(s) in direction (b)* * With the adjusting screw fully turned in direction (a) Compression damping force 1.
U3C310E0.book Page 16 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU39341 NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range.
U3C310E0.book Page 17 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force 3 1. Rebound damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting screw in direction (b).
U3C310E0.book Page 18 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15150 Luggage strap holders EAU15281 Sidestand This model is equipped with Yamaha’s EXUP (EXhaust Ultimate Power valve) system. This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe. The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer-controlled servomotor. The sidestand is located on the left side of the frame.
U3C310E0.book Page 19 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 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.
U3C310E0.book Page 20 Wednesday, December 7, 2005 2:31 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-11 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-10 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-17, 6-27 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.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU40190 Starting the engine EWA10270 WARNING ● ● ● 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.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM OPERATION AND IMPORTANT RIDING POINTS ECA15490 CAUTION: ● ● 5 ● If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 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 distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U3C310E0.book Page 4 Wednesday, December 7, 2005 2:31 PM OPERATION AND IMPORTANT RIDING POINTS EAU16841 5 ECA10301 EAU17212 Engine break-in CAUTION: Parking There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi).
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 4 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart 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 1 * Air filter element • Replace. 2 * Clutch • Check operation. • Adjust or replace cable.
U3C310E0.book Page 5 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Drive chain • Check chain slack, alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 11 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 10000 mi (16000 km) or 18 months.
U3C310E0.book Page 6 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL 6 ITEM 18 * Shock absorber assembly • Check operation and for oil leakage. • Replace if necessary. 19 * Rear suspension link pivots • Check operation. • Correct if necessary. 20 Engine oil • Change (warm engine before draining). √ 21 * Engine oil filter cartridge • Replace. √ 22 * Cooling system ROUTINE 600 mi (1000 km) or 1 month No.
U3C310E0.book Page 7 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM 26 * Lights, signals and switches ROUTINE • Check operation. • Adjust headlight beam.
U3C310E0.book Page 8 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel C EAU40030 Panels A and B To remove one of the panels Remove the bolts and the screws, and then pull the panel off as shown. 6 1. Panel A 2.
U3C310E0.book Page 9 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19651 Checking the spark plugs 1. Panel C 2. Screw To install the panel Place the panel in the original position, and then install the screw. The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer.
U3C310E0.book Page 10 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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. Canister (for California only) EAU19871 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
U3C310E0.book Page 11 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 1. Oil filter wrench 2. Oil filter cartridge 1. 2. 3. 4. Engine oil filler cap Engine oil level check window Maximum level mark Minimum level mark 4.
U3C310E0.book Page 12 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.90 L (3.07 US qt) (2.55 Imp.qt) With oil filter cartridge replacement: 3.10 L (3.28 US qt) (2.73 Imp.qt) ECA11620 1. O-ring NOTE: Make sure that the O-ring is properly seated. 6 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.
U3C310E0.book Page 13 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. Coolant CAUTION: The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
U3C310E0.book Page 14 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. EWA10380 WARNING Never attempt to remove the radiator cap when the engine is hot. 1. Coolant reservoir cap Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.
U3C310E0.book Page 15 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU40050 Replacing the air filter element The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the rider seat. (See page 3-12.) 2. Remove panels A and B. (See page 6-8.) 3. Remove the cowling bolts, and then pull the cowling off.
U3C310E0.book Page 16 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA11360 WARNING ● 1. Air filter element 8. Insert a new air filter element into the air filter case. ECA10480 CAUTION: 6 ● ● 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. 9.
U3C310E0.book Page 17 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21381 Checking the throttle cable free play 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.
U3C310E0.book Page 18 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) 90–189 kg (198–417 lb) (CAL) 90–190 kg (198–419 lb) (U49): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.
U3C310E0.book Page 19 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10580 WARNING ● ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
U3C310E0.book Page 20 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 “broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions.
U3C310E0.book Page 21 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. EAU40080 Adjusting the clutch lever free play 1. Clutch lever free play adjusting bolt 2. Clutch lever free play The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows.
U3C310E0.book Page 22 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22270 Adjusting the rear brake light switch EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. EAU36890 Front brake pads 1. Locknut (under fuel tank) 2. Clutch lever free play adjusting nut (under fuel tank) 6 8. Tighten the locknut. 9.
U3C310E0.book Page 23 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR the point that a wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set. EAU22571 Checking the brake fluid level Front brake EAU22500 Rear brake pads 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.
U3C310E0.book Page 24 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● ● 6 Be careful that water does not enter the brake fluid reservoir 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. As the brake pads wear, it is normal for the brake fluid level to gradually go down.
U3C310E0.book Page 25 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR Drive chain slack: 25.0–35.0 mm (0.98–1.38 in) Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle nut: 150 Nm (15.0 m·kgf, 110 ft·lbf) 5. If the drive chain slack is incorrect, adjust it as follows. EAU34311 To adjust the drive chain slack 1. Loosen the axle nut and the locknut on each side of the swingarm. 2.
U3C310E0.book Page 26 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23022 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.
U3C310E0.book Page 27 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23111 Checking and lubricating the throttle grip and cable EAU23131 Checking and lubricating the brake and shift pedals Recommended lubricant: Lithium-soap-based grease (all-purpose grease) The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
U3C310E0.book Page 28 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23211 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the centerstand and sidestand Brake lever The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
U3C310E0.book Page 29 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
U3C310E0.book Page 30 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU33650 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Positive battery terminal 2. Negative battery terminal 3.
U3C310E0.book Page 31 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc.
U3C310E0.book Page 32 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU38371 Replacing the fuses The main fuse, the fuel injection system fuse, and the fuse box, which contains the fuses for the individual circuits, are located under the rider seat. (See page 3-12.) 6 1. 2. 3. 4. Main fuse Fuse box Fuel injection system fuse Fuel injection system spare fuse 1. 2. 3. 4. 5. 6. 7. 8.
U3C310E0.book Page 33 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU23930 Replacing a headlight bulb This model is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Disconnect the headlight coupler, and then remove the bulb cover. 1. Headlight bulb holder EWA10790 WARNING 1. Headlight coupler 2. Headlight bulb cover 2. Unhook the headlight bulb holder, and then remove the defective bulb. Headlight bulbs get very hot.
U3C310E0.book Page 34 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the headlight bulb cover, and then connect the coupler. 5. Have a Yamaha dealer adjust the headlight beam if necessary. EAU24112 Replacing the tail/brake light bulb 1. Remove the passenger seat. (See page 3-12.) 2. Remove the socket (together with the bulb) by turning it counterclockwise. EAU24202 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 1.
U3C310E0.book Page 35 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24310 Replacing the license plate light bulb 1. Remove the license plate light unit by removing the screws. 3. Remove the defective bulb by pulling it out. 4. Insert a new bulb into the socket. 5. Install the socket (together with the bulb) by pushing it in. 6. Install the license plate light unit by installing the screws.
U3C310E0.book Page 36 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the brake hose holder on each side by removing the bolt and nut. 4. Remove the brake caliper (together with the reflector) on each side by removing the bolts. EAU40210 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle. 3. Install the brake caliper (together with the reflector) on each side by installing the bolts.
U3C310E0.book Page 37 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 Rear wheel EAU40020 To remove the rear wheel EWA10820 WARNING ● ● 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. 3. Remove the axle nut. 4. Loosen the locknut on each side of the swingarm. 5. Turn the drive chain slack adjusting bolts fully in direction (a) and push the wheel forward.
U3C310E0.book Page 38 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Make sure that there is enough space between the brake pads before installing the wheel. 1. Slot 2. Retainer 6 2. Install the drive chain onto the rear sprocket. 3. Install the axle nut, and then lower the rear wheel so that it is on the ground. 4. Adjust the drive chain slack. (See page 6-24.) 5. Tighten the axle nut to the specified torque.
U3C310E0.book Page 39 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 40 Wednesday, December 7, 2005 2:31 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26011 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.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM MOTORCYCLE CARE AND STORAGE ● ● 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. EAU26180 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
U3C310E0.book Page 4 Wednesday, December 7, 2005 2:31 PM MOTORCYCLE CARE AND STORAGE 7 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.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM SPECIFICATIONS Dimensions: Overall length: 2140 mm (84.3 in) Overall width: 770 mm (30.3 in) Overall height: 1205 mm (47.4 in) Seat height: 815 mm (32.1 in) Wheelbase: 1460 mm (57.5 in) Ground clearance: 135 mm (5.31 in) Minimum turning radius: 3000 mm (118.1 in) Weight: With oil and fuel: 220.0 kg (485 lb) (U49) 221.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM SPECIFICATIONS 2nd: 33/16 (2.063) 3rd: 37/21 (1.762) 4th: 35/23 (1.522) 5th: 27/20 (1.350) 6th: 29/24 (1.208) Chassis: Frame type: Diamond Caster angle: 25.00 ° Trail: 109.0 mm (4.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM SPECIFICATIONS Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: AC magneto Battery: Model: YTZ14S Voltage, capacity: 12 V, 11.2 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 60 W/55.0 W × 2 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, 21.0 W × 2 License plate light: 12 V, 5.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-12.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U3C310E0.book Page 3 Wednesday, December 7, 2005 2:31 PM 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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U3C310E0.book Page 5 Wednesday, December 7, 2005 2:31 PM 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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U3C310E0.book Page 7 Wednesday, December 7, 2005 2:31 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U3C310E0.book Page 9 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 10 Wednesday, December 7, 2005 2:31 PM 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.
U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM INDEX A F Accessories and replacement parts...... 6-20 Air filter element, replacing ................... 6-15 B Battery................................................... 6-30 Brake and clutch levers, checking and lubricating ..................... 6-28 Brake and shift pedals, checking and lubricating ..................... 6-27 Brake fluid, changing ............................ 6-24 Brake fluid level, checking .................... 6-23 Brake lever.
U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM INDEX Turn signal light bulb, replacing............ 6-34 Turn signal switch................................... 3-8 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) .........................................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.12-0.
