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1. 15 69 Ignitor 06 Rear turn signal light lead right 67 Taillight lead 68 Rear turn signal light lead left 09 Taillight bracket 69 Starter motor lead 6 Starter relay 62 Relay 63 Relay assembly 64 Wire harness 65 Fuel pump lead coupler Ignition coil 62 Clutch cable 68 Starter cable 69 Ground lead Box Fan motor lead 42 Rectifier regulator lead Handlebar switch lead left Main switch lead Wire harness 46 To taillight 2 Rear fender Clamp 36 42 43 CABLE ROUTING SPEC ve Tighten the ground lead and the thermostat housing together with a bolt Pass the reservoir hose left side of thermo stat housing Do not fasten the high tension cord 4 with locking tie Use plastic band to fasten the high tension cord 3 4 Fuel pump lead comes over Pass the rear brake switch lead and battery negative lead under NS r eo the coolant reservoir tank be tween the reservoir hose and the battery then are connected at the right side of the battery Pass the rear flasher lead through the rear fender Pass the rear flasher lead L through the2. Wire harness 65 Relay 86 Fuse box 82 To front brake switch 68 To battery negative lead To starter relay Starter motor lead Pickup coupler 42 Sidestand switch coupler Oil level neutral switch coupler AC magneto coupler CABLE ROUTING SPEC ve Oil level neutral switch lead gt Use a plastic clamp to fasten the handlebar switch lead left main switch lead clutch cable and starter cable to the frame Pass the fan motor lead through the guide gear then into the box C Use a plastic clamp to fasten the horn lead and air guide plate to the frame 00 E 11 42 13 When installing the plug cap the high tension code should be fac ing the inside of the body Pass the wire harness starter motor lead AC magneto lead sidestand switch lead and oil neutral switch lead over the cross tube Use a plastic clamp to fasten to gether the wire harness and the frame m ID 14 15 Use a plastic clamp to fasten to gether the wire harness and the frame Push couplers into the lock stay of the frame after connecting wires Use a plastic band to fasten to gether wireharness starte
3. CABLE ROUTING SPEC ve Use a steel holder to fasten to gether the speed sensor lead and outer tube Use a plastic clamp to fix the speed sensor lead at 3 points af ter running the lead along the outside of the brake hose First Fasten the bottom end of the speed sensor lead without loosening Second Fasten the lead several E 11 42 13 lt times from the bottom end by running along the brake hose Pass the hom lead under the horn bracket then connect it at the back of the horn Pass only the starter lead through the bottom of the joint of wire harness ID 14 15 1 Rear brake switch lead 2 Battery 8 Reservoir tank over flow hose 4 Cross tube 5 Battery negative lead 6 Reservoir tank hose 7 Air filter To fuel tank 9 Fuel tank breather hose Fuel tank drain hose 8 T P S lead 2 Box 3 Speed sensor lead CABLE ROUTING SPEC ve Handlebar switch lead right 5 Throttle cable 9 Brake hose 2 Guide wire 9 Headlight lead Main switch lead 69 Reservoir tank Air filter box bracket 62 Swingarm bracket 23 Engine bracket 12 Pass the fuel tank
4. hose fuel tank breather hose and res ervoir tank over flow pipe be tween the rear arm and the en gine crankcase Pass the fuel tank drain hose and fuel tank breather hose be tween air filter joint and 4 After installing the fuel tank pull it down toward the air filter joint so that there will be no bend of loosening between them O Pass the T P S lead as shown then install cover to the air filter case Use a plastic clamp to fasten to gether the throttle cables head light lead handlebar switch right and speed sensor lead Use a plastic locking tie to fasten the handlebar switch right and brake hose to the right front fork inner tube CABLE ROUTING SPEC ve Pass the throttle cable with the pull side up through the center of the clamp Pass the throttle cable through the guide wire installed to the handle crown To front cowling Pass the main switch lead under the throttle cables headlight lead handlebar switch lead right and speed sensor lead then insert it right side of the box 2241225 J K Pass the throttle cable under the box Pass the reservoir tank over flow hose and fuel tank drain hose through the cable holder To coolant reservoir tank Pass the battery negative
5. Br O Br R G O R G Green White Green Yellow Blue Black Blue Red Blue White Blue Yellow Red Black R W R Y WIB W G WR ss UR Q Red White Red Yellow White Black White Green White Red Yellow Black Yellow Red D A C magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse back up 6 Fuse main 7 Starter relay Starter motor 9 Starting circuit cut off relay Fuel pump relay 1 Ignitor unit 2 Ignition coil 3 Spark plug Pick up coil 9 Throttle position sensor Neutral switch 12 Speed sensor Fuel sender Thermo switch engine temperature 60 Diode Fuel pump 02 Sidestand switch 03 Speedometer 02 Tachometer 65 Fuel meter 06 Fuel level warning light Engine temperature warning light Neutral indicator light 09 Oil level warning light High beam indicator light 8 Turn indicator light 62 Meter light 63 Clutch switch 62 Oil level switch 65 Flasher relay 86 Horn 62 Pass switch 68 Dimmer switch 69 Horn switch Turn switch Hazard switch 4 Front turn signal light Rear turn signal light Headlight 45 Tail Brake light Auxiliary light 4 Fan motor Thermo switch fan motor Fuse fan motor Fuse head light 63 Rear brake switch 62 Fuse signal 63 Front brake switch Light switch 65 Engine stop switch Starter switch 62 Fuse Alarm Fuse parking Relay 2
6. lead inside of the reservoir hose Use the plastic clamp to fasten together the rear brake switch lead and the frame The latch of the clamp must face the outside of the body CABLE ROUTING SPEC ve O Pass the battery negative lead and rear brake switch lead inside the air filter bracket of the frame gt Pass the reservoir tank over flow pipe between the air filter case and cross tube and then outside of engine bracket o Use a clamp to fasten together the coolant reservoir hose and the bracket rear arm 14 1 Throttle cable 2 Speed sensor lead 8 Handlebar switch lead right 4 Headlight lead 5 Thermostat housing 6 Carburetor heater hose 7 Reservoir tank hose Throttle cable 9 Fuel pump Fuel filter 1 Fuel tank breather hose 12 Fuel tank drain hose 36 42 43 CABLE ROUTING SPEC ve 3 Pipe Fuel hose 9 T P S lead 16 Fuel pipe 2 Fuel sender coupler 8 Battery negative lead Battery Rear brake hose 61 Rear brake reservoir tank 62 Rear brake switch lead 3 Fuse box 64 Seat lock cable 28 r eo
7. Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet Starter jet Throttle valve size Fuel level N J P 0 P A J 1 130 P O P J B P 1 B P 2 B P 3 P S V S G S 1 G S 2 TH V F L with pecial tool Engine idle speed 1 150 1 250 r min Intake vacuum 30 7 33 3 kPa 230 250 mmHg 2 wm o MAINTENANCE SPECIFICATIONS ve CHASSIS Standard Front suspension Front fork travel 120 mm Fork spring free length 316 8 mm Fitting length 309 8 mm Collar length 183 mm Spring Rate 7 35 N mm 0 75 kg mm 13 72 N mm 1 4 kg mm Stroke 0 70 mm 70 120 mm Optional spring No Oil capacity 465 cm Oil level 132 mm Oil grade Fork oil 10W or equivalent Drive chain Type manufacturer 50VA7 DAIDO No of links 110 Chain free play 30 45 mm TIGHTENING TORQUES CHASSIS Tightening Part to be tightened Thread size torque Remarks Holder clutch lever 1 M6 x 1 0 De MAINTENANCE SPECIFICATIONS ELECTRICAL Ignition system Ignition timing B T D C Advanced timing B T D C Advance type Ti Pickup coil resistance T C I unit model manufacturer Charging system Type Model manufacturer Standard output Stator coil resistance Starter motor Model manufacturer 1 0 number Output Armature coil resistance Brush overall length Brush
8. spring pressure Commutator dia Mica undercut depth Mica undercut width Starter relay Model manufacturer Amperage rating Coil winding resistance Horn Type Quantity Model manufacturer Maximum amperage Performance Coil winding resistance Flasher hazard relay Type Model manufacturer Self cancelling device Hazard flasher device Flasher frequency Wattage Standard 10 1 250 r min 50 4 500 r min Digital type 189 231 Q Y L J4T095 MITSUBISHI A C magneto F4T359 MITSUBISHI 14 V 18 A at 5 000 r min 0 36 0 44 at 20 C W W SM 13 MITSUBA SM 13 0 7 kW 0 0015 0 0025 Q at 20 C 10 mm 7 64 10 00 N 779 1 020 gf 28 mm 0 7 mm 0 8 mm MS5F 631 JIDECO 180A 4 18 4 62 Q at 20 C Plane type 1 pcs YF 12 NIKKO 3 0A 105 113 db 2m 1 15 1 25 Q at 20 C Full transistor type FE246BH DENSO No Yes 75 95 cyl min 21W 2 3 4W MAINTENANCE SPECIFICATIONS SPEC g Starting circuit cut off relay Model manufacture G8R 30Y B OMRON Coil winding resistance 202 5 247 5 at 20 C Fuel pump relay Model manufacture G8R 30Y B OMRON Coil winding resistance 202 5 247 5 at 20 C Amperage for individual circuit Main Headlight Signal Ignition Fan Parking Hazard Back up Reserve CABLE ROUTING SPEC ve EB205000 CABLE ROUTING 1 Throttle cable Use a plastic band to fasten to D Pass the brake ho
9. 4 YAMAHA 119000 SUPPLEMENTARY SERVICE MANUAL FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the FZS600 2000 For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual FZS600 SERVICE MANUAL 5DM1 AE1 FZS600 2000 SUPPLEMENTARY SERVICE MANUAL 01999 by Yamaha Motor Co Ltd First Edition June 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual So it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair Repairs attempted by anyone without this knowledge are likely to render the scooter unfit for use Yamaha Motor Company Ltd is continually striving to improve all its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important informati
10. Chocolate lead or Dark green lead on the bulb socket connector 30 The wiring circuit from the left handlebar switch to the bulb socket connector is faulty MEETS repair it SPECIFICATION This circuit is not faulty CLOCK 500805 The clock fails to come on 1 Voltage e Connect the pocket tester DC 20 V to the clock coupler Tester read Brow 1 Tester read Frame ground e Turn the main switch to Check the voltage 12 V on the Brown D lead at the clock terminal MEETS ll SPECIFICATION 2 Clock OUT OF SPECIFICATION e Check that the clock is operating properly eWhen setting the clock after its power source has been disconnected e g when the battery is removed first set the clock to 1 00 AM and then to the correct time MEETS ll SPECIFICATION This circuit is not faulty 31 FZS600 2000 WIRING DIAGRAM COLOR CODE Bus Black Br Brown Ch Chocolate Dg Dark green 3 nivis Green Gy Gray E s Blue 5 23 ETE l 04451 UR UR 36 Nw Ee ug 4 Poo Pink B L Lg uus Light green B R Orange B W Red BLY s Sb Sky blue Br L sns White Br W Moss Yellow G R Black Blue Black Red Black White Black Yellow Brown Blue Brown White Green Red G W G Y LI Bes 222 LIR us L W LIY uus R B
11. EC ve SPECIFICATIONS GENERAL SPECIFICATIONS 725600 Model code Fuel Type Fuel tank capacity Fuel reserve amount Tire pressure Maximum load except motorcycle Loading condition A front rear Loading condition B front rear High speed riding front rear Bulb voltage wattage x quantity Headlight Marker light Brake tail light Front turn signal light Rear turn signal light Meter light Indicator light Neutral indicator light High beam indicator light Oil level warning light Turn indicator light Fuel level warning light Engine temperature warning light Regular unleaded gasoline 20 L 3 5L 187 kg 0 90 kg 225 kPa 2 25 kg cm 2 25 bar 250 kPa 2 5 kg cm 2 5 bar 90 187 kg 225 kPa 2 25 kg cm 2 25 bar 290 kPa 2 9 kg cm2 2 9 bar 225 kPa 2 25 kg cm2 2 25 bar 290 kPa 2 9 kg cm2 2 9 bar 12 V 60 W 55 W x 1 12V5W x 1 12V21W 5W x2 12V21W x2 12V21W x2 12V2W x 3 14 V 1 4 W x 1 14 V 1 4 W x 1 14 V 1 4 W x 1 14V1 4W x 2 12V2W x 1 LED Load is the total weight of cargo rider passenger and accessories MAINTENANCE SPECIFICATIONS ve MAINTENANCE SPECIFICATIONS ENGINE Valve spring Free length 40 09 mm Set length valve closed 34 5 mm Compressed pressure 131 4 153 0 N 13 4 15 6 kg Tilt limit eee Direction of winding Clockwise Carburetor 1 0 mark 5DM1 01 GB N SF DK D NL Main jet M J Main air jet M A J Jet needle J N Needle jet
12. Loosen Refer to REMOVING Loosen INSTALLING THE FRONT Loosen FORK LEGS section Refer to REMOVING INSTALLING THE FRONT FORK LEGS section For installation reverse the removal procedure FRONTFORK CHAS Job name Part name Remarks Disassembling the front fork Disassembly the parts in the order listed Cap bolt O ring Spacer Washer Front fork spring Dust seal Oil seal clip Bolt Gasket Damper rod rebound spring Inner tube Inner tube bushing Oil seal Washer Refer to ASSEMBLING THE FRONT FORK LEGS section e L 5 Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS section 9 99 69 Cc669 9 O 23 FRONTFORK CHAS Job name Part name Remarks Outer tube bushing 1 Refer to ASSEMBLING THE FRONT Oil flow stopper FORK LEGS section For assembly reverse the disassembly procedure 24 25 FRONT FORK CHAS CHECKING THE FRONT FORK LEGS 1 Check bolt O ring 1 Damage wear Replace EB703700 ASSEMBLING THE FRONT FORK LEGS 1 Fill e front fork leg with the specified amount of the recom mended fork oil X Quantity each front fork leg 0 465 L Yamaha fork and shock oil 10 W or equivalent X Front fork leg oil level 3 from the top of the inner tube with the inner tube fully compressed and without the fork spring 132 mm NOTE e While filling
13. NUITY 28 SIGNAL SYSTEM ELEC 4 Voltage e Connect the pocket tester DC 20 V to the flasher relay coupler Tester lead Brown terminal 1 Tester lead Frame ground e Turn the main switch to OUT OF SPECIFICATION e Check the voltage 12 V of the Brown 1 lead at the flasher relay terminal MEETS TENERE The wiring circuit from the main switch to the JL SPECIFICATION flasher relay connector is faulty repair it e Connect the pocket tester DC 20 V to the flasher relay coupler 5 Voltage Tester lead Brown White terminal Tester lead Frame ground e Turn the main switch to ON OUT OF SPECIFICATION e Turn the turn switch to L R or push the hazard switch eCheck the voltage 12 V on the Brown White 1 lead at the flasher relay terminal MEETS SPECIFICATION 29 SIGNAL SYSTEM 6 Voltage e Connect the pocket tester DC 20 V to the bulb socket connector AJ Flasher light Turn indicator light At the flasher light left Tester lead Chocolate lead 1 Tester lead Frame ground At the flasher light right Tester lead Dark green lead 2 Tester lead Frame ground OUT OF SPECIFICATION Turn the main switch to ON e Turn the turn switch to L R or push the hazard switch Check the voltage 12 V of the
14. ase 63 Apply molybdenum disulfide grease Symbols 62 to 69 in the exploded diagrams indi cate the following 62 Apply locking agent LOCTITE 65 Use new one CONTENTS GENERAL INFORMATION FEATURES 1 SPEEDOMETER NES HENE EAS DAR 1 SPECIFICATIONS GENERAL SPECIFICATIONS 2 MAINTENANCE SPECIFICATIONS 3 ENGINE Enna a ERES 3 CHASSIS EN ERR E He pd 4 CABLE ROUTING A RR REOR ARRIERE I TR 7 PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE LUBRICATION INTERVALS 19 CHASSIS 24200358 Ree d a ec d dca 21 ADJUSTING THE FRONT FORK LEGS 21 CHASSIS 5252265 RE Rd EE 22 CHECKING THE FRONT FORK LEGS 59 RR RR 23 ASSEMBLING THE FRONT FORK LEGS 2e vows en 23 ELECTRICAL SIGNAL SYSTEM o 26 CIRCUIT DIAGRAM ER Ato 26 SIGNAL SYSTEM CHECK cvesvia eed bauwunthowued ex 28 31 25600 2000 WIRING DIAGRAM GENERAL INFORMATION FEATURES SPEEDOMETER D Speedometer 2 Odometer Tripmeter Clock 3 SELECT button 4 RESET button This speedometer is equipped with an odometer two tripmeters a clock Odometer and tripmeter modes W
15. e exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a disassembly step Symbols indicate parts to be lubricated or replaced see SYMBOLS 7 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc Jobs requiring more information such as special tools and technical data are described sequentially cLuTcH ENG CLUTCH REMOVING THE CLUTCH Se 1 Straighten the lock washer tab 2 Loosen clutch boss nut While holding the clutch boss 2 with the uni versal clutch holder 9 loosen the clutch boss nut Universal clutch holder 3 90890 04086 3 Remove spacer 1 bearing 2 NOTE Insert two M6 mm bolts into the spacer and then remove the spacer by pulling on the bolts CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set NOTES Measure the friction plate at four places Job name Part name Remarks Friction plate thickness Removing the clutch Remove the parts in the order listed 290 306 mm Compress
16. e rectifier regulator lead fan motor lead handlebar switch lead left main switch lead headlight lead handlebar switch lead right and speed sensor lead through front side of the box then connecte each coupler in the box Use a plastic clamp to fasten the wire harness after passing al ways under the taillight bracket 36 42 43 lt 1 CABLE ROUTING SPEC ve Align the connector position of rear turn signal light leads left and right then bend the rear 2 r eo 18 CHK PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ 9 EB3000000 PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE LUBRICATION INTERVALS 6 000 km 12 000 km INITIAL or or 1 000 km 6 months 12 months whichever whichever comes first comes first CHECKS AND MAINTENANCE JOBS Check fuel hoses for cracks or damage Replace if necessary Check condition Replace if necessary Check condition Y Spark plugs Clean regap or replace if necessary M UC irst Y val Check valve clearance Every 42 000 km or 42 months aves Adjust if necessary whichever comes first Clean or replace if necessary Check operation 4 J Ad
17. hen set to ODO the motorcycle s total mileage is indicated When set to TRIP 1 or TRIP 2 the motorcycle s mileage since the tripmeter was last reset is indi cated Use the tripmeters to estimate how far you can ride on atank of fuel This information will enable you to plan fuel stops in the future Selecting a mode Push the SELECT button 8 to change between the odometer mode ODO the tripmeter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO Resetting a meter To reset either tripmeter 1 or 2 to 0 0 select either by pushing the SELECT button 8 and push the RESET button 4 for at least one second Clock mode To change the display to the clock mode push the SELECT button 3 To change the display back to the odometer mode push the SELECT button 3 To set the clock 1 Push both the SELECT button 3 and RESET button 2 for at least two seconds 2 When the hour digits start flashing push the RESET button 4 to set the hours 3 Push the SELECT button 3 to change the minutes 4 When the minute digits start flashing push the RESET button to set the minutes 5 Push the SELECT button 3 to start the clock NOTE After setting the clock be sure to push the SELECT button before turning the main switch to OFF otherwise the clock will not be set GENERAL SPECIFICATIONS SP
18. ion spring 1 SEI 2 8 m Pressure plate m Short clutch push rod CHECKING THE CLUTCH PLATES O ring The following procedure applies to all of the Bali clutch plates Long clutch push rod Refer to INSTALLING THE CLUTCH 1 pr d Friction plate section pressa Cui pele Damage Replace he clutch pates as a Fricition plate large 2 Measure Clutch spring plate clutch plate Nut Refer to HEMOVING INSTALLING THE with a surface plate and thickness gauge CLUTCH section 3 0 oosoosaoma Out of specification Replace the clutch plates as a set clutch plate warpage limit gt Less than 0 1 mm 003000 SYMBOLS The following symbols are not relevant to every vehicle Symbols to 9 indicate the subject of each chapter D General information 2 Specifications 9 Periodic inspection and adjustment Engine 5 Cooling system 6 Carburetor s 7 Chassis Electrical system 9 Troubleshooting Symbols 9 to 42 indicate the following Serviceable with engine mounted 1 Filling fluid 2 Lubricant 3 Special tool Tightening torque 5 Wear limit clearance Engine speed 17 Electrical data Symbols 8 to 3 in the exploded diagrams indi cate the types of lubricants and lubrication points Apply engine oil Apply gear oil 60 Apply molybdenum disulfide oil Apply wheel bearing grease 62 Apply lightweight lithium soap base gre
19. just or replace cable Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary Check balance runout and for damage 4 Rebalance or replace if necessary Check tread depth and for damage Replace if necessary Y Check air pressure Correct if necessary 4 Check bearing for looseness or damage Wheelibearings Replace if necessary y Y Check swingarm pivoting point for play Correct if necessary Lubricate with molybdenum disulfide grease every 24 000 km or 24 months whichever comes first Check chain slack Adjust if necessary Make sure that the rear wheel is properly Every 1 000 km and after washing the aligned motorcycle or riding in the rain Clean and lubricate Check bearing play and steering for roughness ingly Steering bearings Correct accordingly Rear brake Lubricate with lithium soap base grease every 24 000 km or 24 months whichever comes first Make sure that all nuts bolts and screws are properly tightened ug Chassis fasteners s li necessary 19 CHK PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ Q i 6 000 km 12 000 km ITEM CHECKS AND MAINTENANCE JOBS uda or or 1 000 km 6 mon
20. on is distinguished in this manual by the following A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A 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 CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer YP002000 HOW TO USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive explanations of all installation removal disassembly assembly repair and inspection procedures are laid out with the individual steps in sequential order D The manual is divided into chapters An abbreviation and symbol in the upper right corner of each page indicate the current chapter Refer to SYMBOLS on the following page Each chapter is divided into sections The current section title is shown at the top of each page except in Chapter 3 Periodic Inspections and Adjustments where the sub section title s appear In Chapter 3 Periodic Inspections and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there ar
21. r mo tor lead AC magneto lead side stand switch lead and oil lev el neutral switch lead then hold CABLE ROUTING SPEC ve the clamp to the frame bracket Position the band end to out side of chassis Use a plastic locking tie to fasten the starter motor lead AC mag neto lead sidestand switch lead and oil level neutral switch lead to the frame bracket Cut off the excess end of the tie Pass the air cleaner drain hose through the engine clamp E 11 42 13 L z Use a steel holder to fasten to gether the AC magneto lead sidestand lead and oil level neu tral switch lead Pass the air cleaner drain hose in front of the rear arm pivot shaft and back of the cross tube Pass the air cleaner drain hose through the pipe holder of rear shock absorber bracket then draw it out to the left side of the body ID 14 15 O gt o 20 Use plastic clamp to fasten to gether the sidestand switch lead and the frame Pass the sidestand switch lead through the bottom of the coolant pipe Do not loosen the fan motor lead here Pass the clutch cable and starter cable outside of high tension code 1
22. rear fender Pass the wire harness through the groove of the rear fender Wire harness shouldn t come top of the rear fender rib 16 Pass the wire harness inside of the rear fender rib Pass the wireharness under the starter relay Pass the starter motor lead un der the joint of the harness then pull upward Setthe fuel sender coupler in the cross pipe of the frame Use a plastic clamp to fasten to gether the wire harness and cross pipe of the frame 36 42 43 CABLE ROUTING SPEC ve Pass the fuel pump lead be tween the ignition coil and fuel fil ter then push under Use a plastic clamp to fasten to gether the wire harness and stay Pass the carburetor inlet hose un der the high tension cord 2 4 Use a clamp to fasten the clutch cable and starter cable Use a plastic clamp to fasten high tension code 2 and 4 1 eo C lt Set the clamp which is fixed to the wire harness in T stud of the frame Putthe wire harness into the box through the groove at the back then connect it in the box 17 Pass th
23. rts of the master cylinder and caliper every two years Replace the brake hoses every four years or if cracked or damaged 20 21 CHK o ADJUSTING THE FRONT FORK LEGS ADJ EAS00152 CHASSIS ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability e Securely support the motorcycle so that there is no danger of it falling over CAUTION Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust e spring preload a Turn the adjusting bolt 1 direction 8 Spring preload is Direction increased suspension is harder Spring preload is Direction decreased suspension is softer MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Adjusting positions Standard 5 Minimum 7 Maximum 1 FRONT FORK Job name Part name Removing the front fork Front wheel Front brake calipers Front fender Bolt upper bracket Cap bolt Bolt lower bracket Front fork assembly left right CHASSIS 22 FRONTFORK CHAS Remarks Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS section Refer to FRONT AND REAR BRAKES section
24. se out side of 2 Clutch cable gether the handlebar switch lead the speed sensor lead then use 8 Handlebar switch left L and the handlebar a plastic clamp to fasten them 4 Starter cable Use a plastic clamp to fasten to 5 Main switch gether the handlebar switch lead 6 Main switch lead left clutch cable and starter 7 Brake hose cable Speed sensor lead C Pass the speed sensor lead in 9 Headlight lead side of the clamp code Handlebar switch right E 2 WS EIE il N 1 Main switch lead 2 Handlebar switch lead left 8 Clutch cable 4 Starter cable 5 Rectifier regulator 6 Horn lead 7 Box Air guide plate 9 Fan motor lead High tension code 1 Relay assembly CABLE ROUTING SPEC ve 2 Flasher leray 13 Battery Starter relay 5 Battery positive lead 8 Seat lock cable 2 Seat lock stay 8 Cross tube AC magneto lead 69 Starter motor lead 61 Air filter drain hose 62 Neutral switch E 11 42 13 63 Sidestand switch lead 62 Neutral switch lead 65 Oil level switch lead 69 Radiator Rectifier regulator lead Horn 09 Speed sensor lead 69 Brake hose 8 Horn lead 62 Horn bracket 63 Rear fender ID 14 15
25. the front fork leg keep it upright e After filling slowly pump the front fork leg up and down to distribute the fork oil EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM SIGNAL SYSTEM ELECTRICAL mes Pex THE B e 28 E 9 0 6 p BLOB 26 3 Main switch 4 Battery 6 Fuse main 65 Flasher relay Turn switch Hazard switch 42 Front turn signal light Rear turn signal light 62 Fuse signal Relay 2 27 SIGNAL SIGNAL SIGNAL SYSTEM CHECK EB806023 1 If the turn signal light and or turn indicator light fails to blink NO CONTINUITY Replace the bulb and or bulb socket 2 Turn switch e Disconnect the left handlebar switch cou plers from the wire harness e Set the hazard switch OFF e Check for continuity as follows Brown White 1 Chocolate Brown White 1 Dark green 3 Ch Bw Dg R j NO CONTINUITY Replace the left handlebar switch 3 Hazard switch Disconnect the left handlebar switch cou plers from the wire harness e Set the turn switch Neutral position e Check for continuity as follows Brown White Chocolate 2 Brown White 1 Dark green 3 Chocolate 0 Dark green 3 p l 8 Rv D lt NO CONTINUITY Replace the left handlebar switch CONTI
26. ths 12 months whichever whichever comes first comes first 4 Check operation un d repair 2 9 Check operation ee Replace 1 necessary Check operation and for oil leakage N 4 Correct accordingly Rear shock absorber Check operation and shock absorber for oil leakage N assembly Replace shock absorber assembly if necessary Check engine idling speed synchronization and starter operation Adjust if necessary Carburetors Rear suspension relay Check operation arm and connecting Lubricate with molybdenum disulfide grease every 24 000 km or arm pivoting points 24 months whichever comes first Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining Engine oil filter Repl cartridge replace Check coolant level and vehicle for coolant leakage Cooling system Correct if necessary N gsy Change coolant every 24 000 km or 24 months whichever comes first Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer NOTE e The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake system When disassembling the master cylinder or caliper always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on the inner pa
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