TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-12
Handlebar switches ......................3-13
Clutch lever ...................................3-14
Shift pedal .....................................3-14
Brake lever ...................................3-15
Brake pedal ..................................3-15
ABS (for ABS models) ..................3-15
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather hose ................3-18
Catalytic converters ......................3-18
Seat ..............................................3-18
Helmet holder ...............................3-19
Storage compartment ...................3-19
Adjusting the shock absorber
assembly ...................................3-20
Sidestand ......................................3-21
Ignition circuit cut-off system ........3-22PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing
the panel ..................................... 6-6
Checking the spark plugs ............... 6-6
Engine oil and oil filter cartridge ..... 6-7
Coolant ......................................... 6-10
Replacing the air filter element ..... 6-13
Adjusting the engine idling
speed ........................................ 6-15
Checking the throttle cable free
play ........................................... 6-16
Valve clearance ............................ 6-16
Tires ............................................. 6-16
Cast wheels .................................. 6-19Adjusting the clutch lever free
play ........................................... 6-19
Rear brake light switch ................ 6-20
Checking the front and rear brake
pads .......................................... 6-20
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-22
Drive chain slack .......................... 6-22
Cleaning and lubricating the drive
chain ......................................... 6-24
Checking and lubricating
the cables ................................. 6-24
Checking and lubricating
the throttle grip and cable ......... 6-25
Checking and lubricating
the brake and shift pedals ........ 6-25
Checking and lubricating
the brake and clutch levers ...... 6-26
Checking and lubricating
the sidestand ............................ 6-26
Lubricating the swingarm
pivots ........................................ 6-27
Checking the front fork ................. 6-27
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-28
Battery ......................................... 6-29
Replacing the fuses ..................... 6-30
Replacing the headlight bulb ....... 6-32
Replacing the tail/brake light
bulb ........................................... 6-33U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM
PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-17
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20, 6-21
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20, 6-21
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-19
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU1770A
Periodic maintenance and lubrication chart NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*Fuel lineCheck fuel hoses for cracks or
damage.√√√√√
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km (24000 mi)
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
NOTE:If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internalclutch mechanism.
EAU36501
Rear brake light switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, have a Yamaha dealer ad-
just the 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 spec-
ified in the periodic maintenance and
lubrication chart.
EAU36890
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn to1. Brake pad wear indicator
U5S5E1E0.book Page 20 Friday, June 22, 2007 1:03 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6 the point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU40260
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
Use only the recommended quality
brake 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 or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
U5S5E1E0.book Page 21 Friday, June 22, 2007 1:03 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.Drive chain slack:
45.0–55.0 mm (1.77–2.17 in)
U5S5E1E0.book Page 22 Friday, June 22, 2007 1:03 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU44790
Front wheel (FZ6-NHG)
WARNING
EWA14840
For the ABS model, have a Yamahadealer remove and install the wheel.
EAU24490
To remove the front wheel
WARNING
EWA10820
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.2. Lift the front wheel off the ground
according to the procedure on
page 6-35.
3. Remove the brake caliper on each
side by removing the bolts.
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
4. Pull the wheel axle out, and then
remove the wheel.
EAU43370
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Install the brake calipers by install-
ing the bolts.NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brakediscs.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
1. Wheel axle
2. Front wheel axle pinch bolt
1. Brake caliper
2. Brake caliper bolt
U5S5E1E0.book Page 36 Friday, June 22, 2007 1:03 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
NOTE:A rubber mallet may be useful to tap thewheel axle out.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the rear wheel.
7. Remove the wheel.CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU32941
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the right-hand side.
NOTE:
Make sure that the slot in the brake
caliper bracket is fit over the retain-
er on the swingarm.
Make sure that there is enough
space between the brake pads be-fore installing the wheel.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-22.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
1. Locknut
2. Drive chain slack adjusting bolt
3. Wheel axle
4. Brake caliper bracket
5. Brake caliper
1. Retainer
2. Slot
U5S5E1E0.book Page 38 Friday, June 22, 2007 1:03 PM