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Yamaha DIC183 Offroad Vehicle User Manual

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1. 7 26 Checking and lubricating the throttle grip and cable 7 27 Checking and lubricating the brake and shift pedals 7 27 Checking and lubricating the brake and clutch levers 7 28 Checking and lubricating the centerstand and sidestand 7 28 Checking the front fork 7 29 Checking the steering 7 30 Checking the wheel bearings 7 30 Battery cuo geredet 7 30 Replacing the fuses 7 32 Replacing a headlight bulb 7 33 Replacing the tail brake light DUID i ocio tte ette 7 34 Replacing a turn signal light bulb eet etn 7 34 Replacing the license plate light DUID iei 7 35 Front wheel eeen 7 36 Rear wheel 7 37 Troubleshooting 7 39 Troubleshooting charts 7 40 MOTORCYCLE CARE AND STORAGE 3 doch 8 1 Matte color caution 8 1 p 8 1 Storage ucc 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YAMAHA EXTENDED
2. Engine trouble warning light 4 5 EXUP system sese 4 21 F Front and rear brake pads checking 7 23 Front fork adjusting Front fork checking 2 FUG Fuel tank breather overflow hose 4 13 Fuel tank Fuses replacing Handlebar switches 4 9 Hazard switch 4 10 Headlight bulb 7 33 High beam indicator light 4 2 Horn switch niisiis 4 9 Identification numbers 10 1 Ignition circuit cut off system 4 22 Indicator and warning lights 4 2 K Key identification number 10 1 L Labels location License plate light bulb replacing n Luggage strap holders M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emission control system 7 3 Maintenance 10 5 Matte color 8 1 Model label 10 2 Multi function meter unit 4 5 N Neutral indicator light 4 2 Noise regulation
3. EAU10042 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 A Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha FZS10Z C 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 If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most
4. 1 Fuel There is enough fuel Check the compression Check the fuel level in the fuel tank TR imm EE engine does not start j There is no fuel Supply fuel Check the compression 2 Compression There is compression t Check the ignition Operate the electric starter There is no compression Hava Yamaha dealer check the vehicle 3 Ignition Wipe off with a dry cloth and correct the Wet spark plug gaps or replace the spark plugs Remove the spark plugs i and check the electrodes Operate the electric starter The engine does not start Check the battery Dry Have a Yamaha dealer check the vehicle 4 Battery m gt he engine turns over e The battery is good quickly The engine does not start Operate the electric starter Have a Yamaha dealer The engine turns over Check the battery lead connections check the vehicle slowly and charge the battery if necessary 7 40 PERIODIC MAINTENANCE AND ADJUSTMENT Engine overheating 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 Place a thick rag like a towel over the radiator cap and then slowly rotate
5. 10 4 Oil level warning light 4 2 Panels removing and installing 7 9 Parking 2 Part locations reme 3 1 S Safety defects reporting 10 3 Safety 2 1 4 15 Shifting we 6 2 Shift 4 10 Shock absorber assembly adjusting 4 19 Spark plugs checking x Starting the Start SWite hinien e Steering Checking Storage Ss Storage compartment Tail brake light bulb replacing 7 34 Throttle cable free play checking 7 18 Throttle grip and cable Troubleshooting Troubleshooting charts INDEX Turn signal light bulb replacing 7 34 Turn signal switch ss 4 9 V Valve clearance 7 18 Vehicle Emission Control Information 10 2 Vehicle identification number 10 1 Ww Warranty Warranty limited Wheel bearings
6. Ignition circuit cut off system FOR YOUR SAFETY PRE OPERATION CHECKS OPERATION AND IMPORTANT RIDING POINTS Starting the engine Shifting rer Done Engine break in Parking renes PERIODIC MAINTENANCE AND ADJUSTMENT Owner s tool kit Periodic maintenance chart for the emission control system General maintenance and lubrication chart Removing and installing panels Checking the spark plugs Canister for California only Engine oil and oil filter cartridge Cola Ni aici dine Replacing the air filter element Checking the engine idling Speed ene eae Checking the throttle cable free play i unies Pee RES Valve clearance 7 18 7 18 Cast wheels 7 21 Adjusting the clutch lever free play 7 21 Checking the brake lever free play x ete dieci 7 22 Brake light switches 7 22 Checking the front and rear brake Dads iua eie 7 23 Checking the brake fluid level 7 23 Changing the brake fluid 7 24 Drive chain slack 7 25 Cleaning and lubricating the drive chain 7 26 Checking and lubricating the cables
7. 6 2 ECA10260 NOTICE e Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16681 To start out and accelerate 1 2 Pull the clutch lever to disengage the clutch Shift the transmission into first gear The neutral indicator light should go out Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 25 km h 16
8. 1 Fuel injection system fuse 2 Fuel injection system spare fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire wisis Specified fuses Main fuse 50 0A Headlight fuse 20 0A Signaling system fuse 10 0A Ignition fuse 15 0A Fuel injection system fuse 15 0A Radiator fan fuse 10 0A x2 Backup fuse 10 0A Turn the key to ON and turn on the electrical circuit in question to check if the device operates If the fuse immediately blows again have a Yamaha dealer check the electrical system Install the battery cover and then hook the battery band onto the holder PERIODIC MAINTENANCE AND ADJUSTMENT EAU23932 Replacing a headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows ECA10650 NOTICE Take care not to damage the follow ing parts e Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner e Headlight lens Do not affix any type of tinted film or stickers
9. while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EWA10061 EAU10683 LOCK The steering is locked and all electrical systems are off The key can be re moved 4 1 To lock the steering 1 Push 2 Turn 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering 2 Turn Push the key in and then turn it to OFF while still pushing it EAU11004 Indicator and warning lights Left turn signal indicator light lt p Right turn signal indicator light 5 gt Neutral indicator light IN High beam indicator light ZO Engine trouble warning light iz Oil level warning light Coolant temperature warning light EAU11030 Turn signal indicator lights lt and gt The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light This indicator light comes on when the transmission is in the neutral position 4 2 EAU11080 High beam indicator light zo This indicator light comes on when the high beam of the headlight is switched on EAU11254 Oil level warning
10. EWA10821 1 Loosen the axle nut 1 Axle nut 2 Brake caliper bracket 3 Brake caliper 2 Place the vehicle on the center stand 3 Remove the axle nut 4 Loosen the locknut on each side of the swingarm PERIODIC MAINTENANCE AND ADJUSTMENT NOTICE Do not apply the brake after the wheel has been re moved together with the brake disc otherwise the brake pads will be forced shut ica 1 Slot 2 Retainer 1 Drive chain slack adjusting bolt 2 Locknut 2 Install the drive chain onto the rear sprocket 3 Install the axle nut 5 Turn the drive chain slack adjust ing bolts fully in direction a and push the wheel forward 6 Remove the drive chain from the E 4 Lower the rear wheel so that it is rear sprocket NS on the ground and then put the TIP To install the rear wheel sidestand down e If the drive chain is difficult to re 1 Installthewheelandthebrakecal 5 Adjust the drive chain slack See move remove the wheel axle first iper bracket by inserting the wheel page 7 25 i axle from the left hand side 6 Tighten the axle nut to the speci and then lift the wheel upward enough to remove the drive chain TIP from the rear sprocket Make sure that the slot in the brake Tightening torque The drive chain cannot be disas caliper bracket is fit over the retain Axle nut sembled er on the swingarm 150 Nm 15 m kgf 108 ft Ibf Make sure that there is enough space be
11. PRE OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspected by a Yamaha dealer EWA11151 Before using this vehicle check the following points CHECKS Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 12 4 13 Check the fuel tank breather overflow hose for obstructions cracks or damage and check the hose connection Check oil level in engine Engine oil If necessary add recommended oil to specified level Check vehicle for oil leakage Check coolant level in reservoir Coolant If necessary add recommended coolant to specified level Check cooling system for leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Front brake Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage FOR YOUR SAFETY PRE OPERATION CHECKS ITEM CHECKS P
12. ant must be changed at the intervals specified in the periodic maintenance and lubrication chart To check the coolant level 1 Place the vehicle on the center stand TIP e The coolant level must be checked on a cold engine since the level varies with engine temperature e Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in an incorrect reading 2 Checkthe coolant level in the cool ant reservoir TIP The coolant should be between the minimum and maximum level marks 7 14 B u Ex e 1 Coolant reservoir 2 Maximum level mark 3 Minimum level mark 3 If the coolant is at or below the minimum level mark remove pan el C to access the coolant reser voir See page 7 9 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot tewatsie NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with cool ant as soon as possible other wise the cooling system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the anti
13. freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced Eca10472 x 1 Coolant reservoir cap Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt 5 Install the panel PERIODIC MAINTENANCE AND ADJUSTMENT EAU33031 Changing the coolant The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant WARNING Never attempt to remove the radiator cap when the engine is hot EWA10381 7 15 EAU40053 Replacing the air filter element The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the rider seat See page 4 15 2 Remove panels A and B See page 7 9 3 Remove the cowling bolts and then pull the cowling off 1 Cowling 2 Bolt 4 Remove the fuel tank bolts 1 Bolt 5 Lift the front of the fuel tank and PERIODIC MAINTENANCE AND ADJUSTMENT Remove the air filter case cover by removing the screws NOTICE 1 Air filter element 2 Air intake manifold carefully tilt it back and away from When removing the air filter 8 Insert a new air filter element into the air filter case but do not di
14. 14B 21668 00 LOCATION OF IMPORTANT LABELS LOCATION OF IMPORTANT LABELS 1 California only EMISSION HOSE ROUTING EE o C ARCOAL NISTER H THROTTLE BODY 5SL 21686 00 A SAFETY INFORMATION EAU10283 Be a Responsible Owner As the vehicle s owner you are respon sible for the safe and proper operation of your motorcycle Motorcycles are single track vehicles Their safe use and operation are de pendent 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 e Obtain thorough instructions from a competent source on all aspects of motorcycle operation Observe the warnings and mainte nance requirements in this Own er s Manual e Obtain qualified training in safe and proper riding techniques e Obtain professional technical ser vice as indicated in this Owner s Manual and or when made neces sary by mechanical conditions Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks e This motorcycle is designed to car ry the operator and a passenger e The failure of motorists to detect and recognize motorcycles in traf fic is
15. To change the engine oil with or without oil filter cartridge replace ment 1 Place the vehicle on a level sur face 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase 1 Engine oil drain bolt 2 Gasket TIP Skip steps 5 7 if the oil filter cartridge is not being replaced 5 Remove the oil filter cartridge with an oil filter wrench 7 12 1 Oil filter wrench 2 Oil filter cartridge TIP An oil filter wrench is available at a Yamaha dealer 6 Apply a thin coat of clean engine oil to the O ring of the new oil filter cartridge 1 O ring TIP Make sure that the O ring is properly seated 7 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench PERIODIC MAINTENANCE AND ADJUSTMENT 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 16 8 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft Ibf 9 Refill with the specified amount of the recommended engine oil and then install and tighten the oil filler cap 7 13 Recommended
16. b With the adjusting screw fully turned in direction a Compression damping force 1 Compression damping force adjusting screw The compression damping force is ad justed on the left front fork leg only To increase the compression damping force and thereby harden the compres sion damping turn the adjusting screw in direction a To decrease the com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b TIP Be sure to perform this adjustment on the left front fork leg Compression damping setting Minimum soft 26 click s in direction b Standard 5 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in direction a TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary EAU39344 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and a rebound damping force adjusting screw ECA10101 NOTICE To avoid damaging the mechanism do not attempt
17. E Empty F Full and symbol gs will flash eight times then go off for approxi mately 3 seconds If this occurs have a Yamaha dealer check the electrical cir cuit 4 7 Coolant temperature mode 1 Sg mS L b 75s RESET SELECT 1 Coolant temperature display The coolant temperature display indi cates the temperature of the coolant TIP When the coolant temperature display is selected C is displayed for one second and then the coolant tempera ture is displayed ECA10021 NOTICE Do not continue to operate the en gine if it is overheating INSTRUMENT AND CONTROL FUNCTIONS Air intake temperature mode em reb f RESET SELECT 1 Air intake temperature display The air intake temperature display indi cates the temperature of the air drawn into the air filler case Turn the key to ON and push the RESET button to switch the coolant temperature display to the air intake temperature display Push the RESET button again to re turn to the coolant temperature display TIP e Even if the air intake temperature is set to be displayed the coolant temperature warning light comes on if the engine overheats e When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to turning the key to OFF e When the air i
18. Recommended engine oil grade API service SG type or higher JASO standard MA Engine 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 Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 25 L 2 38 US qt 1 98 Imp qt Air filter Air filter element Oil coated paper element 9 1 Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve amount 3 4 L 0 90 US gal 0 75 Imp gal Fuel injection Throttle body ID mark FZS10Z 2D11 20 FZS10ZC 3C35 10 Spark plug s Manufacturer model NGK CR9EK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 65 43 1 512 Secondary reduction system Chain drive Secondary reduction ratio 45 17 2 647 Transmission type Constant mesh 6 speed Operation Left foot operation Gear ratio 1st 38 15 2 533 2nd 33 16 2 063 3rd 37 21 1 762 Ath 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 29 in Front tire Type Tubeless Size 120 70 ZR17M C 58W Manufacturer model DUNLOP D221FA Rear tire Type Tubeless Si
19. SERVICE 10 9 TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS EAU10384 Read and understand all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer LOCATION OF IMPORTANT LABELS NOTICE AWARNING A BEFORE YOU OPERATE THIS VEHICLE READ E BE Si THE OWNER S MANUAL AND ALL LABELS solvent will 9 ALWAYS WEAR AN APPROVED MOTORCYCLE windshield HELMET eye protection and protective clothing GK K e Use neutral detergent 5GK 2118K 00 4B5 2815K 0 WARNING LOAD LIMIT 3 kg 7 lbs 3TB 24877 A0 Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 TIRE INFORMATION Cold tire normal pressure should be set as follows e Up to 90 kg 198 Ibs load WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open FRONT 250 kPa 2 50 kgf cm 36 psi REAR 290 kPa 2 90 kgf cm 42 psi 4AA 22259 80 90kg 198 Ibs maximum load FRONT 250 kPa 2 50 kgf cm 36 psi REAR 290 kPa 2 90 kgf cm 42 psi
20. adjustment range may not exactly match the spec ifications listed due to small differences in production This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance EWA10221 e Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service 4 20 EAU15151 Luggage strap holders 1 Luggage strap holder There is a luggage strap holder on each passenger footrest EAU41941 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the inner diameter of the exhaust pipe The EXUP system valve is con stantly adjusted in accordance with the engine speed by a computer controlled servomotor ECA15610 NOTICE The EXUP system has been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or
21. breather hose except for Califor nia 2 Original position paint mark 3 Fuel tank overflow hose 11 Install the fuel tank bolts 12 Place the cowling in the original position and then install the bolts 13 Install the panels 7 17 PERIODIC MAINTENANCE AND ADJUSTMENT 21383 Checking the throttle cable free play 1 Throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the inner edge of the throttle grip Periodi cally check the throttle cable free play and if necessary have a Yamaha deal er adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 7 18 EAU21752 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e Thetire air pressure must b
22. canister to prevent the discharging of fuel vapor into the atmosphere Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged e Make sure that the canister breath er is not blocked and if necessary clean it 7 11 EAU19879 Engine oil and oil filter car tridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on the center stand A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the engine oil level check window located at the bottom right side of the crankcase TIP The engine oil should be between the minimum and maximum level marks PERIODIC MAINTENANCE AND ADJUSTMENT 1 Engine oil filler cap 2 Engine oil level check window 3 Maximum level mark 4 Minimum level mark 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level
23. checking T Wheel front sese Wheel rear eese Wheels eene eee hte ehe See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2009 12 0 3x1 CR E
24. it if necessary INSTRUMENT AND CONTROL FUNCTIONS Make sure that the end of the fuel tank breather overflow hose is po Catalytic converters NOTICE sitioned inside of the clamp This vehicle is equipped with catalytic Use only unleaded gasoline The use converters in the exhaust DL M of leaded gasoline will cause unre pairable damage to the catalytic converter The exhaust system is hot after op eration To prevent a fire hazard or burns e Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn e Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system e Make sure that the exhaust sys tem has cooled down before do ing any maintenance work e Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat 4 14 EAU39322 Seats Passenger seat To remove the passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 1 Passenger seat lock 2 Unlock 2 Pull the passenger seat forward and then lift it up To install the passenger seat 1 Place the passenger seat in the original position and then push the rear of the seat down to lock it in place INSTRUMENT AND CONTROL FUNCTIONS 2 Remove the key Rider seat To remove the rider seat 1 Remove
25. lithium soap based grease lightly Clutch lever pivot shaft Apply lithium soap based grease lightly Shift pedal pivot shaft Apply lithium soap based grease lightly Centerstand and sidestand pivots Check operation Apply lithium soap based grease lightly Sidestand switch Check operation and replace if necessary PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READINGS ROUTINE INITIAL 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Front fork Check operation and for oil leak age Replace if necessary Shock absorber as sembly Check operation and for oil leak age Replace if necessary Rear suspension link pivots Check operation Correct if necessary Engine oil Change warm engine before draining Engine oil filter car tridge Replace Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Front and rear brake switches Check operation Control cables Apply Yamaha chain and cable lube or engine oil thoroughly Throttle grip hous ing and cable Check operation and free play Adjus
26. mi h If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle OPERATION AND IMPORTANT RIDING POINTS 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Shift up points 1st 2nd 20 km h 12 2nd 3rd 30 km h 19 mi h 4th 40 km h 25 mi h 4th 5th 50 km h 31 mi h 5th gt 6th 60 km h 37 mi h Shift down points 6th 5th 25 km h 16 mi h 5th gt 4th 25 km h 16 mi h 4th gt 3rd 25 km h 16 mi h 2nd 25 km h 16 mi h 2nd 1st 25 km h 16 mi h 6 3 EAU16841 Engine break in 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 follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17093 0 1000 km 0 600 mi Avoid prolonged operation above 6000 r min NOTICE After 10
27. motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack with in the specified limits caos 7 25 TIP Using the alignment marks on each side of the swingarm make sure that both drive chain pullers are in the same position for proper wheel alignment 1 Axle nut 2 Drive chain slack adjusting bolt 3 Locknut 4 Drive chain puller 5 Alignment marks 3 Tighten the axle nut then the lock nuts to their specified torques Tightening torques Axle nut 150 Nm 15 m kgf 108 ft Ibf Locknut 16 Nm 1 6 m kgf 12 16 PERIODIC MAINTENANCE AND ADJUSTMENT EAU23025 Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows ECA10583 NOTICE The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ic 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants
28. motorcycle is changed To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Operation of an overloaded vehicle could cause an accident Maximum load FZS10Z 190 kg 419 Ib FZS10ZC 189 kg 417 Ib When loading within this weight limit keep the following in mind e Cargo and accessory weight should be kept as low and close to the motorcycle as possible Se curely pack your heaviest items as close to the center of the vehicle as possible and make sure to distrib ute the weight as evenly as possi ble on both sides of the motorcycle to minimize imbalance or instabili ly e Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires 2 3 Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleep
29. on each side by removing the bolts NOTICE Do not apply the brake after the brake calipers have been re moved otherwise the brake pads will be forced shut ics Brake hose holder Bolt and nut Brake caliper bolt Brake caliper Reflector 5 Pull the wheel axle out and then remove the wheel EAU40211 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 TIP Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 4 Install the brake hose holder on each side by installing the bolt and nut 5 Take the vehicle off the center stand so that the front wheel is on the ground and then put the side stand down 6 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torques Wheel axle 72 Nm 7 2 m kgf 52 Front wheel axle pinch bolt 23 Nm 2 3 m kgf 17 Brake caliper bolt 40 Nm 4 0 m kgf 29 ft Ibf 7 Push down hard on the handlebar several times to check for proper fork operation 7 37 EAU25080 Rear wheel EAU40022 To remove the rear wheel To avoid injury securely support the vehicle so there is no danger of it falling over
30. the passenger seat 2 Push the rider seat lock lever lo cated under the back of the rider seat to the right as shown and then pull the seat off 4 15 1 Rider seat lock lever To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown and then push the rear of the seat down to lock it in place ES 1 Projection 2 Seat holder 2 Install the passenger seat INSTRUMENT AND CONTROL FUNCTIONS EAU14462 TIP Storage compartment Make sure that the seats are properly secured before riding 1 Storage compartment The storage compartment is located under the passenger seat See page 4 15 e Do not exceed the load limit of 3 kg 7 Ib for the storage com partment e Do not exceed the maximum load of FZS10Z 190 kg 419 Ib FZS10ZC 189 kg 417 Ib for the vehicle EWA10961 When storing the Owners Manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet 4 16 When washing the vehicle be careful not to let any water enter the storage compartment EAUS9333 Adjusting the front fork Always adjust the spring preload on both fork legs equally otherwise poor handling and loss of stability may result EWA14670 Each front fork leg is equipped with a spring preload adjusting bolt the right front fork leg is equipped with a re bound damping force adjusting
31. to turn beyond the maximum or minimum settings Spring preload 1 Spring preload adjusting ring 2 Special wrench 3 Extension bar 4 Position indicator INSTRUMENT AND CONTROL FUNCTIONS To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench and the extension bar included in the own ers tool kit to make the adjust ment Spring preload setting Minimum soft 1 Standard 3 Maximum hard 7 4 19 Rebound damping force 1 Rebound damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b Rebound damping setting Minimum soft 12 click s in direction b Standard 8 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in direction a INSTRUMENT AND CONTROL FUNCTIONS TIP To obtain a precise adjustment it is ad visable to check the actual total number of clicks or turns of the damping force adjusting mechanism This
32. warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit INSTRUMENT AND CONTROL FUNCTIONS EAU40179 Multi function meter unit 65 4 1 Coolant temperature display air intake tem perature display 2 Speedometer 3 Tachometer 4 Odometer tripmeter fuel reserve tripmeter 5 SELECT button 6 RESET button 7 Clock 8 Fuel meter EWA12422 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident 4 5 The multi function meter unit is equipped with the following a speedometer a tachometer an odometer two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled since the left segment of the fuel meter started flashing a clock a fuel meter a coolant temperature display an air intake temperature display a self diagnosis device an LCD and tachometer bright ness control mode TIP e Be sure to turn the key to ON be fore using the SELECT and RE SET buttons e To switch the speedometer and odometer tripmeter displays be tween kilometers and miles press the SELECT button for at least
33. 0 90 US gal 0 75 Imp gal ECA11400 NOTICE Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi INSTRUMENT AND CONTROL FUNCTIONS um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems 4 13 EAU48790 Fuel tank breather overflow hose 1 Fuel tank breather hose 2 Original position paint mark 3 Fuel tank overflow hose TIP For California See page 7 11 for breather hose information Before operating the motorcycle Check the fuel tank breather over flow hose connection Check the fuel tank breather over flow hose for cracks or damage and replace it if damaged e Make sure that the end of the fuel tank breather overflow hose is not blocked and clean
34. 00 km 600 mi of operation the engine oil must be changed and the oil filter car tridge or element replaced ico 1000 1600 km 600 1000 mi Avoid prolonged operation above 7200 r min OPERATION AND IMPORTANT RIDING POINTS 1600 km 1000 mi and beyond The vehicle can now be operated nor mally ECA10310 NOTICE Keep the engine speed out of the tachometer red zone e If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17213 Parking When parking stop the engine and then remove the key from the main switch e Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned e Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire e Do not park near grass or other flammable materials which might catch fire EWA10311 6 4 EAU17232 Periodic inspection adjustment and lu brication will keep your vehicle in the safest and most efficient condition pos sible Safety is an obligation of the vehi cle owner operator The most important points of vehicle inspection adjust ment and lubrication are explained on the following pages Failure to properly maintain the ve hicle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during
35. 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA11131 WARNING Contaminants the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires e If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering behavior ECA10800 NOTICE e Apply spray oil and wax spar ingly and make sure to wipe off any excess e Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product e Avoid using abrasive polishing compounds as they will wear away the paint TIP e Consult a Yamaha dealer for ad vice on what products to use e Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens 8 3 EAU26181 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 NOTICE e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust e To prevent corrosion avoid damp cellars
36. A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 CONSUMER INFORMATION PO PO gt gt WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters Spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation a
37. AGE Rear brake Check 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 7 28 7 23 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 7 21 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 7 18 7 27 Control cables Make sure that operation is smooth Lubricate if necessary 7 26 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 7 25 7 26 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 18 7 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 28 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 7 28 FOR YOUR SAFETY PRE OPERATION CHECKS ITEM CHECKS Chassis fasteners Make sur
38. B in the following order TRIP A gt TRIP B ODO gt TRIP A When the fuel amount in the fuel tank decreases to 3 4 L 0 90 US gal 0 75 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter m mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the display between the various tripmeter and odometer modes in the following order F TRIP TRIP A gt TRIP ODO F TRIP To reset a tripmeter select it by push ing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter LoF 1 5 teb TRIPA RESET SELECT 1 Fuel meter INSTRUMENT AND CONTROL FUNCTIONS The fuel meter indicates the amount of fuel in the fuel tank The display seg ments of the fuel meter disappear to wards E Empty as the fuel level decreases When the last segment on the left starts flashing refuel as soon as possible TIP This fuel meter is equipped with a self diagnosis system If a problem is de tected in the electrical circuit the follow ing cycle will be repeated until the malfunction is corrected
39. and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the products warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts c Abnormal strain neglect or abuse d Lack of proper maintenance e Accident or collision damage f Modification to original parts SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be inspected and registered for warranty by an authorized Ya
40. become ineffective PERIODIC MAINTENANCE AND ADJUSTMENT 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 TIP The rear brake fluid reservoir is located behind panel C See page 7 9 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 Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance e Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock e 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 ualy go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause 7 24 EAU22731 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the inte
41. brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the A mark on the brake lever INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 4 11 EAU13074 Fuel tank cap le 2 1 Fuel tank cap lock cover 2 Unlock To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover INSTRUMENT AND CONTROL FUNCTIONS TIP The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard EWA11091 EAU13221 Fuel Make sure there is sufficient gasoline in the tank Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when ref
42. ce it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 2 Ifthe battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 7 31 4 After installation make sure that the battery leads are properly con nected to the battery terminals ECA16530 NOTICE Always keep the battery charged Storing a discharged battery can cause permanent battery damage PERIODIC MAINTENANCE AND ADJUSTMENT EAU43011 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 4 15 1 Main fuse 2 Fuse box 3 Fuel injection system fuse 4 Fuel injection system spare fuse Fuse box Headlight fuse Ignition fuse Signaling system fuse Backup fuse for clock Right radiator fan fuse Left radiator fan fuse 8 Spare fuse If a fuse is blown replace it as follows TIP Include steps 2 and 6 only for the fuel injection system fuse 1 Turn the key to OFF and turn off the electrical circuit in question 2 Unhook the battery band and then remove the battery cover 7 32 EF Battery band Battery cover N
43. checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit ECA10021 NOTICE Do not continue to operate the en gine if it is overheating 4 3 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 117 134 C 243 274 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 7 40 Above 135 Above 275 F 4 4 Message flashes Warning light comes on Stop the engine and allow it to cool See page 7 40 EAU11534 Engine trouble warning light This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine If this oc curs have a Yamaha dealer check the self diagnosis system See page 4 8 for an explanation of the self diagnosis device The electrical circuit of the warning light can be checked by turning the key to ON The
44. ctric failure could result which could cause a dangerous loss of lights or engine power Aftermarket Tires and Rims The tires and rims that came with your motorcycle were designed to match the performance capabilities and to provide the best combination of handling brak ing and comfort Other tires rims siz es and combinations may not be appropriate Refer to page 7 18 for tire specifications and more information on replacing your tires DESCRIPTION Left view Air filter element page 7 15 Main fuse page 7 32 Fuel injection system fuse page 7 32 Storage compartment page 4 16 Passenger seat lock page 4 15 Front fork spring preload adjusting bolt page 4 17 Front fork compression damping force adjusting screw page 4 17 Shock absorber assembly spring preload adjusting ring page 4 19 EAU10410 ZS BAK AL S EE ong S EES I RO e C 10 9 87 9 Shock absorber assembly rebound damping force adjusting screw page 4 19 10 Shift pedal page 4 10 11 Engine oil drain bolt page 7 11 12 Engine oil filter cartridge page 7 11 DESCRIPTION Right view Owner s tool kit page 7 2 9 Brake pedal page 4 11 Rider seat lock lever page 4 15 10 Coolant reservoir page 7 14 Fuse box page 7 32 11 Rear brake light switch page 7 22 Battery page 7 30 12 Luggag
45. cur rent product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If there is any question concerning this manual please consult a Yamaha dealer E Please read this manual and the YOU AND YOUR MOTORCYCLE RIDING TIPS booklet carefully before operating this motorcycle Do not attempt to operate this motorcycle until you have attained adequate knowledge of its con trols and operating features Regular inspections and careful maintenance along with good operating techniques will help ensure that you safely enjoy the capabilities and reliability of this motorcycle EWA10011 IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations NOTICE TIP This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer IMPORTANT MANUAL INFORMATION EAU10193 FZS10Z C OWNER S MANUAL 2009 by Yamaha Motor Corporation U S A 1st edition November 2009 All ri
46. d move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty e In addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is flexible You choose the plan that s right for you 12 months 24 months 36 months or on certain models even 48 months beyond your warranty period e Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects j
47. damage to the engine INSTRUMENT AND CONTROL FUNCTIONS EAU15303 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 22 for an explanation of the ignition circuit cut off system The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described EWA10240 4 21 below and have a Yamaha dealer re pair it if it does not function proper ly INSTRUMENT AND CONTROL FUNCTIONS EAU44902 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions e It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled EN e It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is s
48. e Replace brake pads if necessary EI Brake hoses Check for cracks or damage EI EI Replace Every 4 years Wheels Check runout and for damage Replace if necessary EI Check tread depth and for dam age Replace if necessary Check air pressure Correct if necessary Wheel bearings Check bearings for smooth oper ation Replace if necessary Swingarm pivot bearings Check bearing assemblies for looseness 7 5 ROUTINE INITIAL PERIODIC MAINTENANCE AND ADJUSTMENT 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Drive chain Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 600 mi 1000 km and after washing the motorcycle riding in the rain or riding in wet areas Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease Every 12000 mi 19000 km Chassis fasteners Check all chassis fitting and fas teners Correct if necessary Brake lever pivot shaft Apply silicone grease lightly Brake pedal pivot shaft Apply
49. e ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EWA10501 Tire air pressure measured on cold tires 0 90 kg 0 198 Ib Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi PERIODIC MAINTENANCE AND ADJUSTMENT Tire inspection EWA10580 e It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace FZS10Z 90 190 kg 198 419 Ib 2 the tire immediately FZS10ZC 90 189 kg 198 417 Ib The replacement of all wheel Front and brake related parts includ kPa 2 50 kgf cm 36 psi W ing the tires should be left to a 290 kPa 2 90 kgf cm2 42 psi 1 Tire sidewall Yamaha dealer who has the High speed riding 2 Tire wear indicator necessary professional knowl Front 3 Tire tread depth edge and experience AR Always check the tires before operating Rear 290 kPa 2 90 kgf cm 42 psi the motorcycle If a tire tread shows Tire information Maximum load crosswise lines minimum tread depth 1 FZS10Z 190 kg 419 Ib FZS10ZC 189 kg 417 Ib Total weight of rider passenger car go and accessories A WARNING Minimum tire tread depth front and Never overload your vehicle Opera rear tion of an overloaded vehicle could 1 0 mm 0 04 in cause an accident if the tire has a nail or gla
50. e strap holder page 4 20 Rear brake fluid reservoir page 7 23 Engine oil filler cap page 7 11 Front fork rebound damping force adjusting screw page 4 17 Engine oil level check window page 7 11 3 2 EAU10420 DESCRIPTION EAU10430 Controls and instruments 1 2 4 5 6 CLA ALD SE 2 SOLES dica o Lr QA AOA eRe ib Fe S S v9 N Clutch lever page 4 10 Left handlebar switches page 4 9 Main switch steering lock page 4 1 Multi function meter unit page 4 5 Front brake fluid reservoir page 7 23 Right handlebar switches page 4 9 Throttle grip page 7 18 Brake lever page 4 11 3 3 EAU10460 Main switch steering lock The main switch steering lock controls the ignition and lighting systems and is used to lock the steering The various positions are described below EAU26900 ON All electrical circuits are supplied with power and the meter lighting taillight license plate light and position lights come on and the engine can be start ed The key cannot be removed TIP The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stalls INSTRUMENT AND CONTROL FUNCTIONS EAU10661 OFF All electrical systems are off The key can be removed Never turn the key to OFF or LOCK
51. e that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle EAU15951 Read the Owner s Manual carefully to become familiar with all controls If there is a control or function you do not understand ask your Yamaha dealer EWA10271 A WARNING Failure to familiarize yourself with the controls can lead to loss of con trol which could cause an accident or injury OPERATION AND IMPORTANT RIDING POINTS EAU48020 TIP This model is equipped with a lean an gle sensor to stop the engine in case of a turnover In this case the multi func tion display indicates error code 30 but this is not a malfunction Turn the key to OFF and then to ON to clear the er ror code Failing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch 6 1 EAU40198 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up See page 4 22 for more informa tion 1 Turn the key to ON and make sur
52. e that the engine stop switch is set to O The following warning lights should come on for a few seconds then go off Oillevel warning light e Coolant temperature warning light e Engine trouble warning light ECA15484 NOTICE If a warning light does not come on initially when the key is turned to ON or if a warning light remains on see page 4 2 for the correspond ing warning light circuit check tral position See page 6 2 The neutral indicator light should come on If not ask a Yamaha dealer to check the electrical circuit Start the engine by pushing the start switch NOTICE For maxi mum engine life never acceler ate hard when the engine is cold jEca11041 If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one at tempt OPERATION AND IMPORTANT RIDING POINTS 2 Shift the transmission into the neu EAU16671 Shifting s 1 Shift pedal 2 Neutral position Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it
53. engine oil See page 9 1 Oil quantity Without oil filter cartridge replace ment 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 TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down ECA11620 NOTICE In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase PERIODIC MAINTENANCE AND ADJUSTMENT 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause TIP After the engine is started the engine oil level warning light should go off if the oil level is sufficient ECA10401 NOTICE If the oil level warning light flickers or remains on even if the oil level is correct immediately turn the engine off and have a Yamaha dealer check the vehicle 11 Turn the engine off wait a few min utes until the oil settles and then check the oil level and correct it if necessary EAU20070 Coolant The coolant level should be checked before each ride In addition the cool
54. ers your legs ankles and feet The engine or exhaust sys tem become very hot during or af ter operation and can cause burns 2 2 A passenger should also observe the above precautions Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide a deadly gas Breathing car bon monoxide can cause headaches dizziness drowsiness nausea confu sion and eventually death Carbon Monoxide is a colorless odor less tasteless gas which may be present even if you do not see or smell any engine exhaust Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symptoms of carbon monoxide poison ing leave the area immediately get fresh air and SEEK MEDICAL TREAT MENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open windows and doors carbon monoxide can rap idly reach dangerous levels A SAFETY INFORMATION e Do not run engine in poorly venti lated or partially enclosed areas such as barns garages or car ports e Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors Loading Adding accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the
55. ever free play turn the clutch lever free play adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 7 21 TIP 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 internal clutch mechanism PERIODIC MAINTENANCE AND ADJUSTMENT braking performance which may re ee Checking the brake lever free ult in loss of control an acci Brake light switches play dent 1 No brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the EWA14211 7 22 1 Rear brake light switch 2 Rear brake light switch adjusting nut The brake light which is activated by the brake pedal and brake lever should come on just before braking takes ef fect If necessary adjust the rear brake light switch as follows but the front brake light switch should be adjusted by a Yamaha dealer Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light co
56. for the drive chain as they may contain substances that could damage the O rings ECA11111 7 26 EAU23093 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 Recommended lubricant Yamaha Chain and Cable Lube or engine oil EAU23112 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart PERIODIC MAINTENANCE AND ADJUSTMENT EAU44272 Checking and lubricating the brake and shift pedals Brake pedal The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary 7 27 Recommended lubricant Lithium soap based grease PERIODIC MAINTENANCE AND ADJUSTMENT EAU23142 Checking and lubricating the Recommended lubricants Brake lever brake and clutch levers Silicone grease Clu
57. ghts reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 23 58 TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS nene pete 1 1 SAFETY INFORMATION 2 1 DESCRIPTION 3 1 Left view 3 1 Right view 3 2 Controls and instruments 3 3 INSTRUMENT AND CONTROL FUNCTIONS 4 1 Main switch steering lock 4 1 Indicator and warning lights 4 2 Multi function meter unit 4 5 Handlebar switches 4 9 Clutch lever 4 10 Shift 4 10 Brake lever 4 11 Brake pedal 4 11 Fuel tank cap 4 11 4 12 Fuel tank breather overflow NOSE c ced aceti ieee 4 13 Catalytic converters 4 14 Seals cete emet ne 4 15 Storage compartment 4 16 Adjusting the front fork 4 17 Adjusting the shock absorber assembly 4 19 Luggage strap holders 4 20 EXUP system Sidestand
58. h to turn on the hazard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard ECA10061 NOTICE Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever EAU12870 Shift pedal 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 4 22 4 10 1 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU26823 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip 1 Brake lever 2 Brake lever position adjusting dial 3 A mark 4 Distance between brake lever and handlebar grip The brake lever is equipped with a brake lever position adjusting dial To adjust the distance between the
59. he owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 7 2 TIP PERIODIC MAINTENANCE AND ADJUSTMENT EAU48490 From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months e Items marked with an asterisk require special tools data and technical skills have a Yamaha dealer perform the service Periodic maintenance chart for the emission control system ROUTINE INITIAL ODOMETER READINGS EAU17601 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Fuel line Check fuel hoses for cracks or damage Replace if necessary Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km Crankcase breather system Check breather hose for cracks or damage Replace if necessary Fuel injecti
60. herefore it is ad visable before doing any high EWA10600 7 20 speed riding to ride conserva tively 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 pres sure according to the operating conditions EAU21960 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels e The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced e The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life e Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics PERIODIC MAINTENANCE AND ADJUSTMENT EAU22081 Adjusting the clutch lever free play 1 Clutch lever free play adjusting bolt 2 Clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch l
61. ight unit by 24818 installing the screw NOTICE Do Replacing the license plate not overtighten the screw oth light bulb erwise the lens may break 1 Remove the license plate light unit by removing the screws ECA11191 1 Turn signal light bulb socket 3 Remove the burnt out bulb by pull ing it out 1 License plate light unit 2 Screw 2 Remove the license plate light bulb socket together with the bulb by pulling it out 1 Turn signal light bulb 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by turning it clockwise 7 35 PERIODIC MAINTENANCE AND ADJUSTMENT 1 License plate light bulb 3 Remove the burnt out bulb by pull ing it out Insert a new bulb into the socket Install the socket together with the bulb by pushing it in Install the license plate light unit by installing the screws EAU24360 Front wheel EAU40201 To remove the front wheel To avoid injury securely support the vehicle so there is no danger of it falling over EWA10821 1 Place the vehicle on the center stand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 1 Front wheel axle pinch bolt 2 Wheel axle 3 Brake caliper bolt 7 36 3 Remove the brake hose holder on each side by removing the bolt and nut 4 Remove the brake caliper togeth er with the reflector
62. ing bags duffel bags or tents can create unstable han dling or a slow steering re sponse This vehicle is not designed to pull a trailer or to be attached to a sidecar Genuine Yamaha Accessories Choosing accessories for your vehicle is an important decision Genuine Yamaha accessories which are avail able only from a Yamaha dealer have been designed tested and approved by Yamaha for use on your vehicle Many companies with no connection to Yamaha manufacture parts and acces Sories or offer other modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies produce Therefore Yamaha can neither en dorse nor recommend the use of ac cessories not sold by Yamaha or modifications not specifically mended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket Parts Accessories and Modifications While you may find aftermarket prod ucts similar in design and quality to genuine Yamaha accessories recog nize that some aftermarket accessories or modifications are not suitable be cause of potential safety hazards to you or others Installing aftermarket prod ucts or having other modifications per formed to your vehicle that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the f
63. lastic parts cannot be thor oughly cleaned with water di luted mild detergent with water may be used Be sure to rinse off any detergent residue using plenty of water as it is harmful to plastic parts Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield MOTORCYCLE CARE AND STORAGE Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound _ after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off
64. light This warning light comes on if the en gine oil level is low The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit TIP e Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a malfunction e This model is also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection INSTRUMENT AND CONTROL FUNCTIONS circuit the following cycle will be repeated until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle TIP e For radiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator e If the engine overheats see page 7 40 for further instructions EAU11427 Coolant temperature warning light This warning light comes on if the en gine overheats If this occurs stop the engine immediately and allow the en gine to cool The electrical circuit of the warning light can be
65. maha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehicle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty 10 7 Engine Displacement Period Under 50cc 6 000 km 3 750 miles or five years whichever occurs first 50cc to 169cc 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc and over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR
66. me on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22392 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 1 Brake pad wear indicator 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 to PERIODIC MAINTENANCE AND ADJUSTMENT the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU46291 Rear brake pads 1 Brake pad wear indicator groove Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that a wear indicator groove almost appears have a Yamaha dealer replace the brake pads as a set 7 23 Checking the brake fluid level Front brake 1 Minimum level mark Rear brake 1 Minimum level mark Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to
67. more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads 8 2 TIP Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled down NOTICE Do not use warm water since it increases the corrosive action of the salt ca10791 2 Apply a corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing MOTORCYCLE CARE AND STORAGE 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc
68. moved and installed 1 PanelA 2 Panel B PERIODIC MAINTENANCE AND ADJUSTMENT 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 1 PanelA 2 Screw 3 Bolt 7 9 To install the panel Place the panel in the original position and then install the screws and the bolts EAU19281 Panel C To remove the panel Remove the screw and then pull the panel off as shown PERIODIC MAINTENANCE AND ADJUSTMENT 1 Panel C 2 Screw To install the panel Place the panel in the original position and then install the screw EAU19652 Checking the spark plugs The spark plugs are important engine components which should be checked periodically preferably by a Yamaha dealer Since heat and deposits will cause any spark plug to slowly erode they should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yo
69. nd or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring Special tools or equipment be done by a Yamaha motorcycle dealer Q Will the warranty be void or cancelled if do not operate or maintain my new motorcycle exactly as specified in the Owners Manual A No The warranty on a new motorcycle cannot be voided or cancelled However Po PO if a particular failure is caused by operation or maintenance other than as described in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satisfaction at the time of sale and upon your request at any later date 3 Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the
70. ntake temperature display is selected A is displayed for one second and then the air in take temperature is displayed Self diagnosis device RESET SELECT 916 1 Error code display This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display will indi cate an error code 4 8 If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle ECA11590 NOTICE 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 1 Tachometer panel 2 Tachometer needle 3 LCD 4 Brightness level This function allows you to adjust the brightness of the LCD and the tachom eter panel and needle to suit the out side lighting conditions To set the brightness 1 Turn the key to OFF 2 Push and hold the SELECT but ton 3 Turn the key to and then re lease the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to con firm the selected brightness level The display will return to the odom eter or tripmeter mode INSTRUMENT AND CONTROL FUNCTIONS EAU12348 Handleba
71. number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area CONSUMER INFORMATION EAU26470 Model label 1 Model label The model label is affixed to the frame under the rider seat See page 4 15 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label cS JB I gt 1 Vehicle Emission Control Information label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 10 2 CONSUMER INFORMATION EAU26551 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 If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A T
72. o contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov 10 3 CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Muffler Exhaust pipe Silencer Intake system Air cleaner case Air cleaner element ntake duct 10 4 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 emis
73. ollowing guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground A SAFETY INFORMATION clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may cause instability when passing or being passed by large vehicles Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera 2 4 tor and may limit control ability therefore such accessories are not recommended Use caution when adding electri cal accessories If electrical acces sories exceed the capacity of the motorcycle s electrical system an ele
74. on Check and adjust engine idle speed and synchronization Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary PERIODIC MAINTENANCE AND ADJUSTMENT 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Evaporative emis sion control system for California only Check control system for dam age Replace if necessary Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts General maintenance and lubrication chart PERIODIC MAINTENANCE AND ADJUSTMENT ROUTINE INITIAL ODOMETER READINGS EAU32186 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Air filter element Replace Every 24000 mi 37000 km Clutch Check operation Adjust or replace cable EI EI Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary Rear brake Check operation fluid level and for fluid leakag
75. one second INSTRUMENT AND CONTROL FUNCTIONS Tachometer 1 Tachometer 2 Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit ECA10031 NOTICE Do not operate the engine in the ta chometer red zone Red zone 12000 r min and above Clock LoF teb TRIPA RESET SELECT 1 Clock The clock displays when the key is turned to ON In addition the clock can be displayed for 10 seconds by pushing the SELECT button when the main switch is in the OFF or LOCK position To set the clock 1 Turn the key to ON 2 Push the SELECT button and RESET button together for at least two seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 4 6 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock Odometer and tripmeter modes LoF teb TRIPA CO 1 Odometer tripmeter fuel reserve tripmeter Push the SELECT button to switch the display between the odometer mode ODO and the tripmeter modes TRIP A and TRIP
76. onth in order to prevent the tires from becoming degraded in one spot Cover the muffler outlet with a plastic bag to prevent moisture from entering it Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 For more information on storing the battery see page 7 30 TIP Make any necessary repairs before storing the motorcycle spark plug caps 8 4 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 FZS10Z 220 kg 485 Ib FZS10ZC 221 kg 487 Ib Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Forward inclined parallel 4 cylinder Displacement 998 cm Bore x stroke 77 0 x 53 6 mm 3 03 x 2 11 in Compression ratio 11 50 1 Starting system Electric starter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 10W 30 10W 40 10W 50 15W 40 20W 40 or 20W 50 0 10 30 50 70 90 110130 F 1 1 1 1 1 1 1 1 i ISAE10W 30 10W 40 SAE 10W 50 SAE 15W 40 SAE 20W 40 TE SAE 20W 50 1 1 1 1 1 1 1 20 10 0 10 20 30 40 50 C
77. r switches Left 1 Dimmer switch 20 20 2 Turn signal switch lt a c gt 3 Horn switch pes 4 Hazard switch A Right 1 Engine stop switch 7 5 2 Start switch 4 9 EAU12400 Dimmer switch 20 20 Set this switch to zo for the high beam and to zo for the low beam EAU12460 Turn signal switch lt gt To signal a right hand turn push this switch to c gt To signal a left hand turn push this switch to lt When re leased the switch returns to the center position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch O R Set this switch to before starting the engine Set this switch to g to stop the engine in case of an emergen Cy Such as when the vehicle overturns or when the throttle cable is stuck INSTRUMENT AND CONTROL FUNCTIONS EAU12711 Start switch Push this switch to crank the engine with the starter See page 6 1 for start ing instructions prior to starting the en gine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12765 Hazard switch A With the key in the ON position use this switc
78. re turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator foot rests during operation to main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs A SAFETY INFORMATION e This motorcycle is designed for on road use only It is not suitable for off road use Protective apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The use of a safety helmet is the single most critical factor in the preven tion or reduction of head injuries e Always wear an approved helmet e Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard e The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations e Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Always wear protective clothing that cov
79. rosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your mo torcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod 8 1 ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and de greaser off with water Cleaning ECA10772 NOTICE e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray e Improper cleaning can damage plastic parts such as cowlings panels windshields headlight lenses meter lenses etc and the mufflers Use only a soft clean cloth or sponge with wa ter to clean plastic However if the p
80. rvals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the master cylinders and calipers as well as the brake hoses re placed at the intervals listed below or whenever they are damaged or leak ing Oil seals Replace every two years e Brake hoses Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22793 To check the drive chain slack 1 Place the motorcycle on the cen terstand 2 Shiftthe transmission into the neu tral position 3 Spin the rear wheel several times to locate the tightest portion of the drive chain 4 Measure the drive chain slack as shown INR Yo SS S gt 1 Drive chain slack PERIODIC MAINTENANCE AND ADJUSTMENT Drive chain slack 20 0 30 0 mm 0 79 1 18 in 5 If the drive chain slack is incorrect adjust it as follows EAU34315 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the drive chain slack adjusting bolt on each side of the swingarm in direc tion a To loosen the drive chain turn the adjusting bolt on each side of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the
81. s case cover be careful not to al the air filter case NOTICE Make connect the fuel hoses low foreign objects to drop into sure that the air filter element is WARNING Make sure that the the air intake manifold properly seated in the air filter fuel tank is well supported Do case The engine should never not tilt or pull the fuel tank too be operated without the air filter much otherwise the fuel hoses element installed otherwise the may come loose which could piston s and or cylinder s may cause fuel leakage and a fire become excessively worn hazard EWA10411 ECA10481 9 Install the air filter case cover by in stalling the screws 10 Place the fuel tank in the original position Make sure that the fuel 1 Screw 2 Air filter case cover hoses are properly connected and routed and not pinched Be sure 7 16 PERIODIC MAINTENANCE AND ADJUSTMENT hose and the fuel tank overflow 14 Install the rider seat Checki h idli EAUAATSA hose in the original position ecking the engine idling WARNING Before placing the speed fuel tank in the original position Check the engine idling speed and if make sure that the fuel hoses necessary have it corrected by a are not damaged If any fuel Yamaha dealer hose is damaged do not start E the engine but have a Yamaha Engine tallng speed dealer replace the hose other ICM wise fuel may leak creating a fire hazard 1 1 Fuel tank
82. screw and the left front fork leg with a com pression damping force adjusting screw ECA10101 NOTICE To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings INSTRUMENT AND CONTROL FUNCTIONS Spring preload 1 Spring preload adjusting bolt To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load thereby soften the suspension turn the adjusting bolt on each fork leg in direction b Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt 4 17 1 Current setting 2 Front fork cap bolt Spring preload setting Minimum soft 8 Standard 5 5 Maximum hard 0 INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force E 1 Rebound damping force adjusting screw The rebound damping force is adjusted on the right front fork leg only To in crease 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 di rection b TIP Be sure to perform this adjustment on the right front fork leg Rebound damping setting Minimum soft 26 click s in direction b Standard 18 click s in direction b Maximum hard 1 click s in direction
83. service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service Turn off the engine when performing maintenance unless otherwise specified EWA10321 EWA15121 PERIODIC MAINTENANCE AND ADJUSTMENT A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide 7 1 EAU17302 Emission controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance In the following periodic maintenance charts the services relat ed to emissions control are grouped separately These services require specialized data knowledge and equipment Maintenance replacement or repair of the emission control devic es and systems may be performed by any repair establishment or individual that is certified if applicable Yamaha dealers are trained and equipped to perform these particular services PERIODIC MAINTENANCE AND ADJUSTMENT EAU17491 Owner s tool kit 1 Owners tool kit The owner s tool kit is located inside the storage compartment under the pas senger seat See page 4 15 The service information included in this manual and the tools provided in t
84. ses and rebounds smoothly 7 29 ECA10590 NOTICE If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it PERIODIC MAINTENANCE AND ADJUSTMENT EAU45511 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance lubrication chart 1 Place the vehicle on the center stand WARNING To avoid inju ry securely support the vehicle so there is no danger of it falling over igwA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23291 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 7 30 EAU33654 Battery 1 Positive battery lead red 2 Negative battery lead black 3 Battery This model is equipped with a VRLA Valve Regulated Lead Acid battery There is no need to check the electro lyte or to add distilled water However the battery lead connections need to be checked and if necessary tightened EWA10760 A WARNING Electroly
85. sions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of Mileage Servicing dealer Remarks interval service name and address 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or 42 months 32000 mi 49000 km or 48 months 10 5 CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service 9 name and address 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months 10 6 CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants that new Yamaha motorcycles will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leasing or other commercial purposes
86. ss fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced EWA10511 1 Tire air valve 2 Tire air valve core 3 Tire air valve cap with seal 7 19 7 PERIODIC MAINTENANCE AND ADJUSTMENT This motorcycle is equipped with cast wheels and tubeless tires with valves EWA10481 A WARNING The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motorcy cle may be different which could lead to an accident Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride After extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd Front tire Size 120 70 ZR17M C 58W Manufacturer model DUNLOP D221FA Rear tire Size 190 50 ZR17M C 73W Manufacturer model DUNLOP D221G FRONT and REAR Tire air valve TR412 Valve core 9100 original This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires e Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds e Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in T
87. stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the MOTORCYCLE CARE AND STORAGE Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every m
88. t the throttle cable free play if necessary Lubricate the throttle grip housing and cable ROUTINE ODOMETER READINGS PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL 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 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months TIP Lights signals and switches Check operation Adjust headlight beam EI EI Y EI EI EI EAU17650 e Air filter This model s air filter is equipped with a disposable oil coated paper element which must not be cleaned with com pressed air to avoid damaging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas e Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 7 8 EAU18771 Removing and installing pan els 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 re
89. tage wattage x quantity Headlight 12 V 60 W 55 W x 2 Tail brake light 12 V 5 0 W 21 0 W x 1 Front turn signal position light 12 21 W 5 0 W x2 Rear turn signal light 12V 210Wx2 License plate light 12V 5 0W x 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Fuses Main fuse 50 0A Headlight fuse 20 0A Signaling system fuse 10 0A Ignition fuse 15 0A Radiator fan fuse 10 0Ax2 Fuel injection system fuse 15 0A Backup fuse 10 0A EAU26352 Identification numbers Record the key identification number vehicle identification number and mod el label information in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER p MODEL LABEL INFORMATION CONSUMER INFORMATION EAU26381 Key identification number EAU26400 Vehicle identification number 1 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key 10 1 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this
90. tch lever Lithium soap based grease Brake lever Clutch lever 7 The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary 7 28 EAU23213 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of control EWA10741 Recommended lubricant Lithium soap based grease PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over ewaio751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compres
91. te is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space e KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories PERIODIC MAINTENANCE AND ADJUSTMENT ECA16520 NOTICE To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a con stant voltage battery charger have a Yamaha dealer charge your battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then pla
92. the cap counterclockwise to the de tent to allow any residual pressure to escape When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap EWAT1040 There is p Have a Yamaha dealer check The coolant level is low leakage and repair the cooling system Check the cooling system for leakage There is Wait until the Check the coolant level in the no leakage Add coolant See TIP engine has cooled reservoir and radiator Y The coolant level Start the engine If the engine overheats again have a is OK Yamaha dealer check and repair the cooling system TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible 7 41 MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 NOTICE Some models are equipped with matte colored finished parts Be sure to consult a Yamaha dealer for advice on what products to use be fore cleaning the vehicle Using a brush harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface Wax also should not be applied to any matte colored fin ished parts EAU26014 Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and cor
93. the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching passing through intersections since in tersections are the most likely places for motorcycle accidents to occur 2 1 Ride where other motorists can see you Avoid riding in another motorist s blind spot Many accidents involve inexperi enced operators In fact many op erators who have been involved in accidents do not even have a cur rent motorcycle license Make sure that you are qualified and that you only lend your mo torcycle to other qualified opera tors Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle where there is no traffic until you have become thoroughly famil iar with the motorcycle and all of its controls Many accidents have been caused by error of the motorcycle opera tor A typical error made by the op erator is veering wide on a turn due to excessive speed or under cornering insufficient lean angle for the speed Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions Always signal befo
94. till down e Itcutsthe running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure 4 22 With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is set to O 3 Turn the key on 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden 4 23 INSTRUMENT AND CONTROL FUNCTIONS e The vehicle must be placed on the center stand during this inspection e If a malfunction is noted have a Yamaha dealer check the system before riding The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer FOR YOUR SAFETY
95. to the headlight lens Do not use a headlight bulb of a wattage higher than specified 7 33 1 Do not touch the glass part of the bulb 1 Disconnect the headlight coupler and then remove the bulb cover e 1 Headlight coupler 2 Headlight bulb cover 2 Unhook the headlight bulb holder and then remove the burnt out bulb PERIODIC MAINTENANCE AND ADJUSTMENT EAU24114 EAU43002 Replacing the tail brake light Replacing a turn signal light bulb bulb 1 Remove the passenger seat See 1 Remove the turn signal light unit page 4 15 by removing the screw 2 Remove the socket together with the bulb by turning it counter clockwise aN e 1 Headlight bulb holder 3 Place a new headlight bulb into po sition and then secure it with the bulb holder 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the 1 Turn signal light unit 2 Screw 2 Remove the socket together with headlight beam if necessary 1 Tail brake light bulb socket iio Baby Jt courier 3 Remove the burnt out bulb by clockwise pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the passenger seat 7 34 PERIODIC MAINTENANCE AND ADJUSTMENT 6 Install the turn signal l
96. tween the brake pads be fore installing the wheel fied torque 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel 7 38 EAU25871 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills When checking the fuel system do not smoke and make sure there are no open flames or sparks in the ar ea including pilot lights from water EWA15141 PERIODIC MAINTENANCE AND ADJUSTMENT heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage 7 39 PERIODIC MAINTENANCE AND ADJUSTMENT EAU42501 Troubleshooting charts Starting problems or poor engine performance
97. ueling follow these instructions EWA10881 1 Before refueling turn off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 4 12 UBND 1 Fuel tank filler tube 2 Maximum fuel level 3 Wipe up any spilled fuel immedi ately NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi EWA15151 ately If gasoline spills on your skin wash with soap and water If gaso line spills on your clothing change your clothes EAU13301 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve amount 3 4 L
98. urself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Specified spark plug NGK CR9EK 7 10 Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Jt 1 Spark plug gap Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads Tightening torque Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf If torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible ECA10840 NOTICE Do not use any tools to remove or in stall the spark plug cap otherwise the ignition coil coupler may get damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 Canister for California only C FUEL TANK ATMOSPHERE dh 2 ic KG El HS BODY CANISTER This model is equipped with a
99. ust like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be e You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs 10 9 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service 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 e
100. warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective 10 8 CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding the warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you IF you are still not satisfied and require additional assistance please write to YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V l N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you shoul
101. xpires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be YAMAHA EXTENDED SERVICE happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 10 10 Air filter element replacing 7 15 B Battery a pner 7 30 Brake and clutch levers checking and lubricating cce 7 28 Brake and shift pedals checking and lubricating eene 7 27 Brake fluid changing 7 24 Brake fluid level checking 7 23 Brake lever wie Brake lever free play checking 7 22 Brake light switches 7 22 Brake 4 11 C Catalytic converters Centerstand and sidestand checking and lubricating 7 28 Clutch wi 4 10 Clutch lever free play adjusting wee 7 21 Coolant 7 14 Coolant temperature warning light 4 3 D Dimmer switch 4 9 Drive chain cleaning and lubricating 7 26 Drive chain slack 7 25 E Engine break in Engine idling speed checking Engine oil and oil filter cartridge Engine stop switch
102. ze 190 50 ZR17M C 73W Manufacturer model DUNLOP D221G Loading Maximum load FZS10Z 190 kg 419 Ib FZS10ZC 189 kg 417 Ib Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Loading condition FZS10Z 90 190 kg 198 419 Ib FZS10ZC 90 189 kg 198 417 Ib Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel 9 2 SPECIFICATIONS Rim size 17M C x MT6 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 130 0 mm 5 12 in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Wheel travel 130 0 mm 5 12 in Electrical system Ignition system TCl SPECIFICATIONS Charging system AC magneto Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Headlight Bulb type Halogen bulb Bulb vol

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