Yamaha FZS10VC manual

3C3-28199-10 FZS10V FZS10VC OWNER’S MANUAL LIT-11626-19-79[...]

EAU10041 U3C310E0.book Page 1 Wednesday, December 7, 2005 2:31 PM[...]

INTRODUCTION EAU10080 Cong ratul atio ns on you r purcha se of the Yamah a FZS10 V/FZ S10VC. This mo del i s the res ult of Yama ha’s vast ex perie nce in the p roduc tion of f ine spo rting , touri ng, an d paces etting racing m achin es. It repres ents the high degree of craf tsmans hip and re liabilit y tha t have mad e Yama ha a le ader in th[...]

IMPORTANT MANUAL INFORMATION EAU1013 1 Parti cular ly impo rtant in for mation is disti nguis hed in th is manua l by the foll owi ng nota tions: NOTE: ● This ma nual should b e cons idere d a per manent part of this m otor cycle and sh ould r emain w ith i t even if the m otor cycle is subs eque ntly sold. ● Yamaha cont inually s eeks a dvanc [...]

IMPORTANT MANU AL INFORMATION AND UNTIL YOU HAVE BEEN TRAIN ED IN S AFE AND PROP ER RIDIN G TECHNIQUE S. REGULAR I NSPECTIONS AND CAREFUL MAINTENAN CE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPAB ILITIES A ND THE RE LIABILITY OF THIS MOT ORCYCLE. *Pro duct a nd spe cif icati ons ar e sub ject to chan ge wi thout n oti[...]

IMPORTANT MANUAL INFORMATION EAU10192 FZS10V/FZS10VC OW N E R ’ S MANU AL ©2005 by Y amaha Motor Corpora tion, U. S.A. 1st edit ion, Decembe r 2005 All rights reserved. Any reprinting or unauthorized use without th e written permission of Y amaha Motor Corporation, U. S.A. is expressl y pr ohibited. Printed in Japan. P/N LIT -11626-19- 79 AFFIX [...]

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 a nd instrum ents ........... ..... 2-3 INSTRUMENT AND CONTROL FUNCT[...]

TABLE OF CONTENTS Replaci ng the license plate light bulb ........ ...................... .............6-35 Front wheel ........... ...................... .. 6-35 Rear wheel ................ ................. .. 6-37 Troublesh ooting .... ...................... .. 6-38 Troublesh ooting charts ............... .. 6-39 MOTORCYCLE CARE AND STORAGE ....[...]

1-1 1 SAFETY INFORMATION EAU10281 MOT ORCYC LES A RE SIN GLE TRACK VEHICLES. THEIR SAFE USE AND OPER ATI ON AR E DEPE ND ENT UPON THE USE OF PROPER RIDING TECH NIQ UES AS WEL L AS TH E EX- PERTISE OF THE OPERATOR. EV- ERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RID ING THIS MO TOR- CYCL E. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRU[...]

SAFETY INFORMATION 1-2 1 due to EXCESSIVE SPE ED or un- derc orneri ng (in suffic ient l ean an- gle fo r th e spee d). • Alway s obey the s peed lim it and never trav el f aster than w arr ant- ed by ro ad an d traffi c con dition s. • Alway s signa l befor e turnin g or chan ging lane s. M ake su re tha t othe r motorists can see you. ● The[...]

SAFETY INFORMATION 1-3 1 Loadin g The to tal weig ht of the ope rator, pas- senger, acce ssories an d cargo must not exce ed the maximum load li mit. When lo ading with in this weig ht limit, keep the f ollowing in mind: ● Cargo and a cces sory we igh t shoul d be kept as l o w and cl ose to the mo torcycle as possibl e. Make sure t o dist ribu t[...]

SAFETY INFORMATION 1-4 1 tor an d may limi t control abi lity, therefo re, such acce ssories are not re comm ende d. ● Use ca utio n whe n addi ng el ectr i- cal accesso ries. If el ectric al acces- sories e xceed the capacit y of the motor cycle ’ s elec trical syst em, an elec tric fa ilure could res ult, which could cause a dang erous loss o[...]

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Plea se re ad the f oll owing i mport ant lab els c arefu lly b efor e oper ating this vehi cle. U3C310E0.book Page 5 Wednesday, December 7, 2005 2:31 PM[...]

SAFETY INFORMATION 1-6 1 1 3 2 5 4 6 7 CA UTION Cleaning with alkaline or acid cleaner , gasoline or solvent will damage windshield. Use neutral detergent. 5JW-00 California onl y U3C310E0.book Page 6 Wednesday, December 7, 2005 2:31 PM[...]

DESCRIPTI ON 2-1 2 EAU10410 Left view 1. F ront fork spr ing preload adjusting bo lt (page 3-14) 2. F ront fork compression damping force adjusting scre w (page 3-14) 3. Air filter element (page 6-15) 4. Main fuse (p age 6-32) 5. Fuel injection system fuse (page 6-32) 6. Storage compar tment (page 3-14) 7. P assenger seat lock (page 3-12) 8. Shock [...]

DESC RIPTION 2-2 2 EAU1042 0 Right view 1. Owner ’ s tool kit (page 6-1) 2. Rider seat lock le ver (page 3- 12) 3. Fuse box (page 6-32) 4. Batter y (page 6-30) 5. Rear brake fluid reser voir (page 6-23) 6. Engine oil filler cap (page 6-10) 7. Front brak e fluid reser voir (page 6-23) 8. Front fork rebound damping force adjusting scre w (page 3-14[...]

DESCRIPTI ON 2-3 2 EAU10430 Controls and instruments 1. Clutch lev er (page 3-9) 2. Left handlebar switches (page 3-8) 3. Main s witch/steering lock (page 3-1) 4. Multi-function meter u nit (page 3-4) 5. Right handlebar s witches (page 3-8) 6. Throttle grip (page 6-17) 7. Brake lev er (page 3-10) U3C310E0.book Page 3 Wednesday, December 7, 2005 2:3[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-1 3 EAU10460 Main s wit ch/s teeri ng lo ck The mai n switch/ st eering lock controls the ig nition and li ghting system s, and is used to lo ck the s teerin g. The v ariou s positi ons are describ ed below. EAU26900 ON All el ectric al circuits are s upplied with power, and the m eter l ightin g, taill ight, lic[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The c orrespondi ng indica tor light fl ash- es when the tur n sign al swit ch is pushe d to th e le ft or ri ght. EAU11060 Neutral indicator light “” This i ndica tor li ght co mes on when the trans miss ion is i[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-3 3 Coolant temp er ature Dis pla y Condi tions What to do Under 39 ° C (Under 103 ° F) Mess age “ Lo ” is display ed. OK. Go ahead with riding. 40 – 116 ° C (104 – 242 ° F) T emperature is displa yed. OK. Go ahead with riding. 117 – 139 ° C (243 – 283 ° F) T emperature displa y flashes. W ar ni[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 EAU11530 Engine trouble warning light “” This wa rning light comes on or fla shes when an elec trical circui t monit oring the engine is defe ctive. When th is occurs, have a Yamaha deale r check the s elf- diagno sis system. (See page 3-4 fo r an expl anatio n of th e se lf-di agno sis de- vice.) The el e[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-5 3 Tachometer The electric t achomet er allows the ride r to mon itor the engi ne speed an d keep it within the idea l power r ange. When th e key is turne d to “ ON ” , the ta- chomet er needle wi ll sweep on ce across the r/ min ra nge a nd then retur n to zer o r/m in in or der to test t he el ectri - cal[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 3 eter displ ay will a utomaticall y change to the fu el reserve tr ipmet er mode “ F- TRIP ” and start c ount ing t he dist ance trav eled fr om that poin t. In t hat cas e, push t h e “ SELECT ” button to s witch the disp lay betw een th e vario us tripm eter and od omet er mod es in the f ollowi ng or[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-7 3 Air intake temperature mode The ai r intak e temperat ure display in di- cates th e temperat ure of the air dr awn int o the ai r filter c ase. Push the “ RE- SET ” butt on to s witch the co olan t tem - peratu re di splay t o the air i ntake temper ature dis play. NOTE: ● Even if the air intak e tem pe[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 To set the brigh tness 1. Tur n the k ey to “ OFF ” . 2. Pu sh an d hold the “ SELECT ” bu t- ton. 3. Tur n the key to “ ON ” , and then re- lease th e “ SELE C T ” butt on after five se conds. 4. Pu sh the “ RESET ” button to se lec t the de sired brightne ss level. 5. Pu sh t he “ SELE [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-9 3 CAUTION: ECA10050 See page 5-1 for sta rting in stru c- tions prior to s tarting the engine. EAU12764 Haz ard s witch “” With the key in t he “ ON ” positio n, turn this s witch to “” to turn on th e hazar d ligh ts (simulta neous fla shing of al l turn sign al l ights). The h azard ligh ts are us[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 EAU26822 Brake le ver The brak e lever is locate d at the right handle bar grip. T o apply the front brak e, pull th e lev er towar d the hand le- bar gri p. The brake leve r is equipp ed wi th a po - siti on adju sting dial . To a djust the dis - tanc e betw een the br ake leve r and the handle bar grip, t u[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-11 3 NOTE: The fu el tank cap c annot be clos ed un- less th e key i s in the lo ck. In addition , the key cannot be r emove d if the c ap is not pr operl y clo sed an d lo cked. W ARNING EWA11090 Make su re tha t the f uel t ank ca p is properly closed before riding. EAU13220 Fuel Make s ure th at th ere is s uf[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 3 knocking (or pinging) occurs, use a gasolin e of a diff erent bran d or premi- um unl eaded fuel. Us e of unlea ded fuel will ex tend spark plu g life and red uce mainte nance costs . Gasohol There are two type s of g asoho l: ga so- hol cont aining ethan ol and that cont ain- ing met hanol . Gaso hol co ntai[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-13 3 2. Remove t he key. Rider seat To remove t he rider seat 1. Remove the passe nger seat. 2. Push the rid er seat lock l e ver, lo- cated unde r the b ack of the ri der seat, to the l eft as shown, a nd th en pull th e seat off. To ins tall the rid er se at 1. In sert t he pro jecti on on the front of the r id[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-14 3 EAU14461 Storage compart ment The stor age compa rtment is located under the passe nger seat. (See pag e 3-12. ) W ARNING EWA10961 ● Do not exceed the l oad limit of 3 kg (7 lb) for the storage com- partment. ● Do n ot ex ceed t he maximu m loa d of 18 9 kg (4 17 lb) (CA L) 190 kg (419 lb) (U49) for th e [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-15 3 Rebound damping force The re bound damp ing force i s adjusted on the righ t fron t fork leg only. To in- crea se the reboun d dampin g force and ther eby har den the rebo und damp ing, turn the adjusting screw in direction (a). To dec reas e the re bound dampin g force and there by softe n the rebo und damp[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-16 3 NOTE: Altho ugh the tota l nu mber o f cli cks o f a dampin g force adjus ting mecha nism may not e xactly match the ab ove spec- ific ations due t o smal l di fferen ces in produ ctio n, the actual nu mber of cli cks alway s rep resents the entire adjus ting rang e. To o btain a p recis e adj ust ment , it w[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-17 3 Rebound damping force To inc rease the re bound dam ping force and ther eby ha rden th e rebou nd dam p- ing, turn th e adj usting scre w in d irect ion (a). To de cre ase the r eboun d damp ing force and there by softe n the rebo und dampi n g, tu rn the ad justing screw in di- rection (b). NOTE: Althou gh [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-18 3 EAU15150 Luggage strap holders There is a luggage s trap holde r on each passeng er footrest. EAU15281 EXUP system This m odel is eq uipped wit h Yama ha ’ s EXUP (EXhau st Ultimat e Power valv e) system. Th is system boosts engine power b y means of a valve t h at r egu- lates t he diamet er of the exhaus [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-19 3 below and have a Yamaha dealer re- pair it if it does not func tion proper- ly. EAU15321 Ignit ion ci rcuit cu t-off sy stem The ign ition circuit cu t-off system (c om- prisi ng the si destand swi t ch, cl utch switch a n d neut ral switch ) has the fol- lowing functi ons. ● It pre vent s star tin g when [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-20 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T urn the key on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep the c[...]

PRE-OPERATION CH ECKS 4-1 4 EAU15591 The con diti o n of a vehicl e is the owner ’ s r espons ibility. V ital compon ents can start to de teriorate quickly and unexpecte dly, even if th e vehicle r emain s unused (f or example , as a resu lt of exposu re to the elem ents ). Any damage, flui d leakage or los s of tir e air p ressur e cou ld ha ve [...]

PRE-OPERATION CHE CKS 4-2 4 EAU15603 Pre-operation check list ITEM CHECKS P A GE Fuel • Check fuel le vel in fuel tank. • Refuel if necessar y . • Check fuel line for leakage. 3-11 Engine oil • Check oil le vel in engine. • If necessar y , add recommended oil to specified le vel. • Check vehicle f or oil leakage. 6-10 Coolant • Check [...]

PRE-OPERATION CH ECKS 4-3 4 Thr ottle grip • Make sure that oper at ion is smooth. • Check cable free pla y . • If necessar y , have Y amaha dealer adjust cable free play and lubricate cable and grip housing. 6-17, 6-27 Contr ol cables • Make sure that oper at ion is smooth. • Lubricate if nece ssar y . 6-26 Drive chain • Check chain sl[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-1 5 EAU15950 W ARNING EWA10270 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it i n a closed area for an y length of tim[...]

OPERATION AND IM PORTANT RIDING POINTS 5-2 5 CAUTION: ECA15490 ● If the oil level war ning light flick- ers or rema ins on after startin g, immediately stop the engine, and then check the e ngine oil level and the veh icle f or oil leak - age. If ne cess ary, add e ngine oil, and then check th e warnin g light again . ● If the coolan t temp era[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-3 5 CAUTION: ECA10260 ● Even wi th the tr ansmi ssion i n the neutral position, do not coast for long periods of time with the engine off, a nd do not tow the motorcycle for long dis - tances. The transmission is properly lubricated only when the engine is running. Inade - quate lubrication m ay damage the[...]

OPERATION AND IM PORTANT RIDING POINTS 5-4 5 EAU16841 Engine break-in There is never a more im portant p eriod in the l ife o f your engine than the pe riod betw een 0 and 16 00 km (100 0 mi). For this r eason, you s h ould r ead th e follow- ing mater ial care fully. Since the engi ne i s brand ne w, do n ot put an excessive lo ad on it for the fi[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-1 6 EAU17231 Safety is an obliga tion of th e owner. P e - riod ic ins pecti on, ad just ment an d lubr i- cation will keep your vehicle in t he safest and most eff icient condit ion pos- sible. The most im portan t points of motor cycle inspecti on, adj ustmen t , and lubri cation are e xplained o n the fo[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-2 6 W ARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor- mance, excess ive e missi ons, and render the ve hicle u nsaf e for us e. Consult a Yamaha dealer before at- tem pting any ch ange s. U3C310E0.book Page 2 Wednesday, December 7, 2005 2:31 PM[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-3 6 EAU17600 Periodi c mainte nance c hart fo r the em ission c ontrol sy stem * Since t hese it ems req uire s pecial to ols, data and tech nical s kills, hav e a Yama ha dea ler perf orm the servic e. No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 800[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-4 6 EAU32183 General maintenance and lubrication chart No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 mo nths 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter eleme[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-5 6 10 Drive chain • Check chain slack, ali gnment and condition. • Adjust and lubr icate chain with a special O-ring c hain lubricant thoroughly . Every 600 mi (1000 km) and after washing the m otorcycle or riding in the rain 11 * Steeri ng bearings • Check bearing assemblies f or looseness. • Mode[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-6 6 18 * Shock absorber as- semb ly • Check operation and for oil leak- age. • Replace if necessar y . √√√√√ 19 * Rear suspension link pi vots • Check operation. • Correct if necessar y . √√ 20 Engine oi l • Change (warm engine before draining). √√√√√√ 21 * Engine oil fil[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-7 6 * Since t hese it ems req uire s pecial to ols, data and tech nical s kills, hav e a Yama ha dea ler perf orm the servic e. NOTE: From 24 000 mi (3700 0 km) or 36 mon ths, re peat th e mainte nanc e inter vals st arting from 8000 mi ( 13000 km ) or 12 m onths . EAU17650 NOTE: ● Air f ilte r • This m[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-8 6 EAU18771 Removing and installing panels The p a nel s show n need to be rem oved to pe rform some of the mai ntenance jobs de scri bed in th is ch apte r. Refer to this s ection ea ch time a panel ne eds to be rem oved and i nstal led. EAU40030 Panels A and B To remo ve one of t he p anel s Remov e the [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-9 6 To instal l the panel Plac e the pa nel i n the o rigi nal pos ition , and the n instal l the screw. EAU19651 Checking the spark plugs The s park p lugs ar e impo rtan t engine compon ents, which sho uld be che cked perio d ical ly, preferab ly by a Yamaha deal er. Sin ce heat and depo sits will caus e [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-10 6 NOTE: If a torque wrench is no t avai lable whe n insta lling a s park pl ug, a go od esti mate of the correct to rq ue is 1/4 – 1/2 turn past fi nger tight . Howev er, the spar k plug s hou ld be tigh tened to the sp eci- fied to rque a s soo n as p ossi ble. CAUTION: ECA10840 Do not use any tools t[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-11 6 NOTE: The e ngi ne oil shou ld b e bet ween the mini mum a nd m aximu m le vel m arks . 4. If th e engine oil is be low the mini - mum le vel mark, ad d sufficient oil of the re comm ended ty pe to raise it to the co rrec t le vel. To change the engine oil (with or without oil filter cartri dge replace[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-12 6 N O TE: Make su re that the O-ri ng is proper ly seate d . 6. Instal l the new oil fi lter ca rtrid g e with a n oil filter wr ench, and t hen tight en it to the specifie d torque with a torqu e wren ch. 7. Insta ll the engine oil drain bo lt, and then ti ghte n it to the s pecif ied torqu e. 8. A dd t[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-13 6 NOTE: After the e ngi ne is star ted, th e en gine oil level warning ligh t should go of f if th e oil lev el is su ffici ent. CAUTION: ECA10400 If the oil lev el warning light flickers or remains on, i mmediately turn the engine off and have a Yamaha dealer check the ve hicl e. 10. Turn th e en gine o[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-14 6 CAUTION: ECA10470 ● If coolant is not available, use distilled water or s oft tap water instead. Do not use har d water or sal t water sinc e it is harmf ul to the engine. ● If wat er ha s been used ins tead of coolant, replace it with cool- ant as soon as possible, other- wise the engine ma y not [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-15 6 EAU40050 Replaci ng the a ir filte r ele ment The air fi lter elem ent shou ld be re- placed a t the inter val s specified in t he peri odic ma inte nanc e and lubr icati on char t. Repl ace t he ai r fi lter e lemen t more freque ntly if you are ri ding i n un- usually w et or dust y areas. 1. Remo ve[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-16 6 8. Inser t a new air filter element int o the air filter case. CAUTION: ECA10480 ● Make sure th at the a ir filt er ele- ment is properly seated in the air fi lter case. ● The engine should never be op- erated without the air filter ele- ment installe d, otherwise the piston(s) and/or c ylinder(s) [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-17 6 EAU21381 Checking the throttle ca ble free play The th rottl e cable free pl ay shoul d mea - sure 3. 0 – 5.0 mm (0.12 – 0.2 0 in) at the thrott le grip . Periodica lly check th e thro ttle ca ble free play and, if neces- sary, hav e a Yama ha de aler adju st it. EAU21401 Valve cl earance The val v[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-18 6 W ARNING EWA10510 Proper loading of yo ur vehicle is im- porta nt for sev eral c harac teris tics of your vehicle, such as handling, braking, performance and safety . Do not ca rry loos ely pa cked items t hat can shift. Securely pack your heavi- est item s cl ose to the ce nter of the vehicle, and dis[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-19 6 W ARNING EWA10580 ● It is dangerous to r ide with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the ti re imm ediat ely. ● The repl aceme nt of all whee l- and brake-related parts, includ- ing the tires, should be left to a Yamaha dealer, who has th[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-20 6 “ broken in ” . There fore, it is ad - visable before doing any high- speed riding to ride conserva- tivel y for ap proxima tely 100 km (60 mi) after installing a new tire. ● The tires must be warmed up before a high-spee d run. ● Always adjust the tire ai r pres- sure ac cording t o the o p er[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-21 6 any consequences caused by the use of items which have not been approved by Yamaha. EAU40080 Adjusti ng the clutch le ver fr ee play The c lutch leve r free play s hould m ea- sure 10. 0 – 15 .0 mm (0 .39 – 0.5 9 in) as shown. Peri odically check the c lutch le- ver free pl ay an d, if neces sary ,[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-22 6 8. Tight en the lo cknut. 9. P lace th e fuel tan k in the or igina l positio n, and then inst all the bolts. 10. In sta ll the cowli ng. 11. I nsta ll t he pane ls. 12. I nsta ll the rid er se at. EAU22270 Adjustin g the re ar brak e light switch The re ar brake li ght swit ch, which is ac - tivate d [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-23 6 the poi nt that a wear indicator almost touc hes the br ake disc, have a Yam aha deale r replac e the b rake pa ds as a set. EAU22500 Rear b rake pads Check each rear brak e pad for damage and mea sure the linin g thickness. I f a brak e pad i s dama ged o r if th e lini ng thickne ss is less tha n 1.0[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-24 6 ● Be care ful th at wate r does not en - ter t he br ake flui d reservo ir when refilli ng. Water will si gnificantly lower the boili ng po int of the fl uid and may resul t in vapor lock. ● Brake fl uid may deterio rate paint- ed su rfac es or plas tic p art s. A l- ways clea n up spilled flu id i[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-25 6 5. If th e dri ve chai n slack is inc orrec t, adjust it a s fol lows. EAU34311 To ad just t he dr ive c hain slack 1. Lo osen the ax le nu t an d the lock - nut on e ach side of th e swin garm. 2. T o tighte n the dri ve cha in, turn the adju stin g bolt on ea ch side of the swingarm in direction (a).[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-26 6 EAU23022 Cleaning and lubricating the drive chain The dr ive ch ain must be cle aned and lubri cated at the int ervals speci fied i n the pe riodic ma intena nce and lubri ca- tion c hart, othe rwise it w ill q uic kly w ear out, especially when riding in dusty or wet ar eas. Servi ce the drive ch ain [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-27 6 EAU23111 Checking and lubricating the thro ttle gri p and cab le The op eratio n of the thr ottle gr ip shou ld be check ed before each ride. In add i- tion, th e cabl e shoul d be lub ricated at the inte rvals specified in the periodic mainte nance chart . EAU23131 Checking and lubricating the brake a[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-28 6 EAU23140 Checking and lubricating the brake and clutch levers Brake l ever Clutch lever The o perat ion of t he brake an d clutch levers sh ould be checked b e fore each ride, and the lev er pivots shou ld b e lu - bricate d if nec essar y. EAU23211 Checking and lubricating the centerstand and sidestan[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-29 6 EAU23271 Checking the front fork The c ondit ion a nd op erat ion of the f ront fork must be c hec ked as fol lows a t the inter vals speci fied in the peri odic ma in- ten ance and lu bri catio n char t. To check the condition W ARNING EWA10750 Securely support the vehicle so that there is no danger o[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-30 6 EAU23290 Checki ng the wheel bearings The f ront and r ear wheel be arings must be chec ked a t the i nter vals spec ifie d in the pe riodic maint enance and lu brica- tion ch art . If ther e is pla y in th e whee l hub or if th e wheel do es not turn smoot hly, have a Yamaha dealer check the w heel be[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-31 6 working near batteries. In case of contact, administer the fol- lowing FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: D rink large quan- tities of water or milk and im- medi ately call a phys ician . • EYES: Flush with water for 15 minutes and seek prompt medical attention. ● Ba[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-32 6 EAU38371 Replaci ng the fuse s The ma in fuse, th e fuel injectio n system fuse, and the fuse bo x, which co ntai ns the f u ses for t he i ndivi dual cir cuits, ar e locat ed u nder t he r ider seat. (See pag e 3-12.) If a fuse is blow n, repla ce it as follo ws. 1. Turn the key t o “ OFF ” and tu[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-33 6 EAU23930 Replacing a headlight bulb This model i s equi pped w ith quar tz bulb headli ghts. If a headlight bul b burn s out , repl ace it as follow s. 1. Di sco nnect t he he adli ght co upler , and th en remove the bu lb cover. 2. Unho ok the headl ight bulb ho lder, and the n re move t he de fecti v[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-34 6 4. Instal l the headlight bulb cove r, and the n connect the couple r. 5. Have a Ya maha deal er adjust the headli ght beam if nec essary. EAU24112 Replacing the tail /brake light bulb 1. Remove the pa ssenger seat. (See page 3 -12.) 2. Remove the socket ( toget her with the bul b) by tur ning i t coun[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-35 6 EAU24310 Replacing the license plate light bulb 1. Rem ove the licens e p late ligh t uni t by rem oving the scr ews. 2. Remove t he socket (toget her with the bu lb) by pulling it out. 3. Rem ove the def ecti ve bulb by pu ll- ing it out. 4. Ins ert a new bulb i nto the sock et. 5. Inst all the socket[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-36 6 3. Remove the br ake hose ho lder on each sid e by r e moving the bolt and nut. 4. Remove the brak e caliper (togeth- er wi th the ref lector) on e ach si de by rem oving the b olts. CAUTION: ECA11050 Do not apply the brake after the brake calipers have be en removed, otherwise the brake pads will be f[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-37 6 EAU25080 Rear whee l EAU40020 To remo ve the re ar wheel W ARNING EWA10820 ● It i s adv isable to have a Yamaha deal er service t he wheel. ● Securely support the motor- cycle so that t here is no danger of it falli ng over. 1. Lo osen the ax le nut . 2. Pla ce the ve hicle on the cen ter- stan d. [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-38 6 ● Make s ure th at the re is eno ugh spac e betwe en th e brak e pads be - fore i n stalli ng the whe el. 2. Instal l the drive chain onto the rear sprocket . 3. In sta ll the ax le nut, an d then lower the re ar w heel so that it is on th e groun d. 4. Adjust th e drive chain sl ack. (See page 6- 24[...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-39 6 EAU25911 Troubleshooting charts Starting problems or poor engine performanc e W ARNING EWA10840 Keep away open flames and do not smok e while checking or wor k ing on the fuel s y stem. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply [...]

PERIODI C MAINTENANCE AND MI NOR REPAIR 6-40 6 Engine overheating W ARNING EWA10400 ● Do not remove the radiator cap when the engine a nd radiator are h ot. Scalding hot fluid and steam ma y be blown out under press ure, which coul d cause serious in jury. Be sure to wait until the engine has cooled. ● After removing the radiator cap retaining [...]

MOTORCYCLE CAR E AND STORAGE 7-1 7 EAU26011 Care While t he open desig n of a motorcycl e reve als th e at tracti venes s of the te ch- nology, it also makes it more vulner a- ble. Ru st an d corr osion can dev elop even if h igh-q uali ty co mpon ents ar e used. A rus ty exha ust p ipe may go un - noti ced on a car , howe ver, it detr acts from th[...]

MOTORCYCLE CARE A ND STORAGE 7-2 7 After normal use Remove dirt with warm water, a mild deterg ent, and a sof t, clea n spong e, and then rins e tho roughl y with clean wate r. Use a toothb rush or bott lebru sh for hard -to-r each a reas . Stubbo rn d irt and in sects wi ll come off more e asily if the ar ea is covered with a wet cl oth for a few [...]

MOTORCYCLE CAR E AND STORAGE 7-3 7 ● Never ap ply oi l or w ax to an y rubber and plastic parts, but treat t hem wit h a sui table ca re product. ● Avoid using abr asive polishing compounds as t hey will we ar away the paint. NOTE: Cons ult a Yamaha dealer for advice on what produ cts t o use. EAU26180 Storage Short-term Always s t ore yo ur mo[...]

MOTORCYCLE CARE A ND STORAGE 7-4 7 4. L ubri cate a ll c ontro l ca ble s and th e pivo ting poin ts of a ll leve rs an d pedals a s well as of th e side- stand/ centerstand . 5. Check and, if necessa ry, corre ct the tir e air pressu re, and the n lift the mot orcycle so that both of its wheel s are of f the gro und. Al terna- tivel y, tur n the w[...]

SPECIFICATIONS 8-1 8 Dimensions: Overall le ngth: 2140 mm (84.3 in) Overall w idth: 770 mm ( 30.3 in) Overall h eight: 1205 mm (47.4 in) Seat height: 815 mm ( 32.1 in) Wheelb ase: 1460 mm (57.5 in) Groun d clearan ce: 135 mm (5.31 in) Minimu m turni ng radi us: 3000 mm (118.1 in ) Weight: With oil an d fuel: 220.0 kg (485 lb ) (U49 ) 221.0 kg (487 [...]

SPECI FI CAT IONS 8-2 8 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 : Diamon d Caster angle: 25.0 0 ° Tra il: 109.0 mm (4. 29 in) Front tire: Type : Tubele ss Size: 120/7 0 ZR17M /C (58W ) Manuf acturer /mode l: MICHELIN/Pilot R oad S Manuf acturer /mode l: DUNLOP/D22 1FA[...]

SPECIFICATIONS 8-3 8 Electrical system: Ignition system: Transisto rized coil ign ition (digital) Chargin g syst em: AC magn eto Battery: Model : YTZ14S Voltag e, capacit y: 12 V, 11.2 Ah Headlight: Bulb type: Halogen bu lb Bulb voltage, wattage × quantity: Headligh t: 12 V, 60 W /55.0 W × 2 Tail/bra ke light: 12 V, 5.0 W/ 21.0 W × 1 Front turn [...]

CONSUMER INFORMA T ION 9-1 9 EAU26351 Identification numbers Record th e key id enti ficatio n numb er, vehicl e ide ntifica tion number and mod- el labe l info rmati on in the spa ces pro - vided be low for assist ance when order ing sp are pa rts fr om a Yam aha dealer or for refer ence in case the veh i- cle is sto len. KEY IDENTIFICATION NUM BE[...]

CONSUMER INFORMATI O N 9-2 9 EAU26470 Model label The mode l labe l is affix ed to the fr ame under the ri der se at. ( See pag e 3-12 .) Rec ord the in form atio n on th is labe l in the space provide d. This inform ation will b e needed when order ing spare parts from a Yamaha de aler. 1. Model label U3C310E0.book Page 2 Wednesday, December 7, 20[...]

CONSUMER INFORMA T ION 9-3 9 EAU26550 Reporting safety defects If you be lieve that you r vehicle has a defec t which could c ause a cra sh or could cause injury or death , you should imme diately infor m the Na tion al Hig hway Tr affic S afety Admi nistra tion ( NHTSA) i n ad dition to noti fying Yamaha Moto r Corpo ration , U.S.A. If NHTSA rec e[...]

CONSUMER INFORMATI O N 9-4 9 EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYS TEM PROHIBITED: Fede ral law proh ibit s the foll owin g act s or the ca using ther eof: (1) The remo val or rende rin g inope rati ve by an y pers on othe r tha n for pur poses of ma intena nce, repair , or r eplace ment of any de vic e or el emen t [...]

CONSUMER INFORMA T ION 9-5 9 EAU26632 Maintenance record Copie s of work orde rs and/or receip ts fo r parts purc hased an d installe d on your vehicle wil l be required to document that mainte nanc e has be en co mple ted in accorda nce with th e emiss ions warran ty. The char t bel ow is pr inted o nly as a remind er that main tena nce work is re[...]

CONSUMER INFORMATI O N 9-6 9 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Maintena nce inter val Date of service Mileage Ser vicing dealer name and address Remarks U3C310E0.book Page 6 Wednesday, December 7, 2005 2:31 PM[...]

CONSUMER INFORMA T ION 9-7 9 EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U3C310E0.book Page 7 Wednesday, December 7, 2005 2:31 PM[...]

CONSUMER INFORMATI O N 9-8 9 U3C310E0.book Page 8 Wednesday, December 7, 2005 2:31 PM[...]

CONSUMER INFORMA T ION 9-9 9 EAU26750 YAMAHA EXTEND ED SERVICE (Y.E.S.) K eep your Y amaha protected ev en after your warranty expires with gen uine Y amaha Extended Service (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co verage f or extra [...]

CONSUMER INFORMATI O N 9-10 9 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage r ight aw ay , and you ’ ll rest easy knowing you ’ ll hav e strong factory-backed protection e ven after your Y amaha Limited W arranty expires . A special note: If visiting your dealer isn ’ t con venient, contact Y amaha with yo[...]

INDEX A Accessories and replacement par ts . ..... 6-20 Air filter element, rep lacing .. ................. 6-15 B Batte r y....... ........ ...... ......... ........ .... ....... .. 6-30 Brake and clut ch levers, checking and lubricating ..................... 6-28 Brake and shif t pedals, checking and lubricating ..................... 6-27 Brake f[...]

INDEX Turn signal light bulb, replacing ............ 6-34 Turn signal switch ................................... 3-8 V Valve cl earan ce ..... ..... ...... ........ ......... ... 6-17 Vehicle identification number . ................ . 9-1 W Warranty, extended ................ ................ 9-9 Warrant y, limit ed ......... .......... ........ ..[...]

PRINTED IN JAPAN 2005.12-0.4 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MOT OR CO . , L TD .[...]