yamaha fazer fz6 s2 instrukcja

8/3/2019 Yamaha Fazer Fz6 s2 Instrukcja

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CONCERNING CRATE DAMAGE:

WARNING

CAUTION:

EAA00002

FOREWORD

This Assembly Manual contains the information required for the correct assembly of this Yamaha vehicle

prior to delivery to the customer. Since some external parts of the vehicle have been removed at the Ya-

maha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be

noted that the assembled vehicle should be thoroughly cleaned, inspected, and adjusted prior to delivery

to the customer.

EAA00005

NOTICE

The service specifications given in this assembly manual are based on the model as manufactured.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and signifi-

cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will

appear in future editions of this manual where applicable.

The procedures below are described in the order that the procedures are carried out correctly and com-

pletely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the

vehicle operator, a bystander, or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage to

the vehicle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EAA00001

FZS6W

FZS6WC

ASSEMBLY MANUAL

E2006 by Yamaha Motor Corporation,

U.S.A. First Edition, November 2006

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11666-20-60



(1) (2)

(3) (4)

(5) (6)

(7)

(8)

EAA00008

SYMBOLS USED IN THEASSEMBLY MANUAL

In order to simplify descriptions in this as-

sembly manual, the following symbols are

used:

(1): Coat with lithium-soap-based grease.

(2): Tighten to 10 Nm.

(10 Nm = 1.0 mSkg, 7.2 ftSlb)

(3): Towards the front of the vehicle

(4): Clearance required(5): Install so that the arrow mark faces up-

ward.

(6): Apply motor oil.

(7): Made of rubber or plastics

(8):

A: Ref. No. (indicating the order of op-

erations.)

B: Part name

C: Quantity of parts per vehicle

D: Place where parts are held

V: Stored in plastic bag

C: Stored in carton box

S: Fixed inside the steel frame

and/or contained in the Styro-

foam tray (upper or lower)*: Temporarily installed or secured

E: Size or material of parts

d/D: Diameter of part

: Length of part

e.g., 5 = 5 mm (0.2 in)



(1) (2)

(3) (4)

(5) (6)

EAA00040

PREPARATIONTo assemble the vehicle correctly, supplies

(e.g. oils, greases, and shop rags) and suffi-

cient working space are required.

Workshop

The workshop where the vehicle is as-

sembled should be clean, spacious, and

have a level floor.

Self-protectionProtect your eyes with suitable safety

glasses or goggles when using compressed

air, when grinding or when doing any opera-

tion which may cause particles to fly off.

Protect hands and feet by wearing safety

gloves or shoes.

EAA00050

SYMBOLS USED ONCRATE CARTON

(1) Contents of the transport package are

fragile, therefore the package must be

handled with care.(2) Indicates correct upright position of the

transport package.

(3) Transport package must be kept away

from rain.

(4) Do not step anywhere on this carton box.

(5) Up to 6 of the transport packages can be

piled up.

(6) Insertion of the forklift arms from this

side can cause damage.

(7) Lift arm inserting position.

If the forklift arms cannot be inserted under

the transport package in alignment with the

two yellow labels, adjust the arms so that

they are positioned evenly in relation tothese marks while taking care not to dam-

age the package contents.



–1–

NOTE:

NOTE:

NOTE:

EAA00060

UNPACKING

1. Remove the frame cover (1).

To remove the frame cover, cut the vinyl

bands around the cover using a cutter or

scissors.

2. Remove the carton boxes (2) and (3).

Remove the front wheel (4).

3. Remove the packing frame bolts (5) and

upper handlebar holders (6).

4. Remove the bolts (7).

5. Remove the packing frames (8). (Lift up

and then move to the side.)

Remove the bolts while holding the frame.

Before starting the assembly, check for

damaged or missing parts. Check both the

parts contained in the carton boxes and on

the vehicle for damage, scratches, and oth-

er defects.



–2–

EAA00070

PARTS LOCATION

(1) Carton box 1.

(2) Carton box 2.

(3) Front tire.



–3–

7 EAA00080

(1) Carton box 1

1. Screws and special nuts (windshield)

2. Plates

3. Collars

4. Bolts

5. Nuts

6. Bracket

7. Nuts

8. Screws

9. Bolts

10.Bands11.Washers

12.Bolts

13.Inner panels

14.Rear view mirrors

15.Windshield

16.Front fender

17.Owner’s manual

18.Reflectors

19.Brackets

20.Nuts

(2) Carton box 2

1. Handlebar2. Gnip end (right)

3. Bolts (upper handlebar holders)

4. Front brake master cylinder bracket

5. Bolts (front brake master cylinder brack-

et)

6. Screws (left handlebar switch)

7. Collars

8. Upper handlebar holder

(3) Front tire



–4–

EAA00100

SETUP PROCEDURES

Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.



–5–

1 Handlebar 1 C

2 Upper handlebar holder 1 C

3 Bolt 4 C d = 8 (0.31), = 30 (1.18)

1 Screw 1 d = 5 (0.20), = 45 (1.77)

2 Screw 1 d = 5 (0.20), = 20 (0.79)

3 Grip end 1 C

CAUTION:

WARNING

EAA00014

EAA00102

1. HANDLEBARA: Clean the right handlebar end.

Apply light coat grease.

B: Install the handlebar holder

with the symbol mark facing

forward.

First tighten the bolts on the

front side, and then tighten the

bolts on the rear side.

C: Align the punch mark on the

handlebar with the top of the

lower handlebar holders.

D: Tighten the bolts to specifica-

tion.

Bolt:

23 Nm (2.3 mSkg, 17 ftSlb)

EAA00016

EAA00104

2. THROTTLE GRIPA: Align the projection on the han-

dlebar switch with the hole in

the handlebar.

B: Tighten the screws to specifi-

cation.

Screw:

3.5 Nm (0.35 mSkg, 2.5 ftSlb)

C: Check the throttle grip for

smooth action.

Proper cable routing is essen-

tial to assure safe vehicle opera-

tion.

Refer to “CABLE ROUTING”.

D: Tighten the grip end.

Grip end:




–6–

1 Front tire 1 S

2 Collar 2 C

3 Axle 1

4 Bolt 1 d = 8 (0.31), = 40 (1.57)

5 Reflector 2 C

6 Nut 2 C d = 5 (0.20)

7 Bracket 2 C

8 Bolt 4 d = 10 (0.39), = 30 (1.18)

1 Front fender 1 S

2 Bolt 2 C d = 6 (0.24), = 22 (0.87)

3 Bolt 2 C d = 6 (0.24), = 30 (1.18)

4 Collar 2 C d = 6 (0.24)

5 Bracket 1 C

WARNING

NOTE:

CAUTION:

CAUTION:

WARNING

EAA00020

EAA00108

3. FRONT WHEELA: Clean the brake discs.

B: Clean the front wheel axle.

C: Clean the collar.

D:

Take care not to get grease on

the brake discs or inner surface

of the brake pads. If you do so,

clean using a rag dampened

with a solvent. Foreign material

on the braking surface may

cause impaired braking action.

E: Make sure there is an enough

gap between the brake pads.

Do not depress the brake lever

when the calipers are off the brake

discs.

F: Lift the front wheel and install

the front wheel axle.

Be sure to arrow on the tire is

pointed in the rotating direc-

tion.

G: Tighten the wheel axle to speci-

fication.

Wheel axle:


H: Tighten the wheel axle pinch

bolt to specification.

Wheel axle pinch bolt:


Before tightening the wheel axle

pinch bolt, stroke the front forks

several times to make sure of

proper fork operation.

I: Tighten the reflector nuts to

specification.

Nut:

1.5 Nm (0.15 mSkg, 1.1 ftSlb)

J: Tighten the brake caliper bolts

to specification.

Brake caliper bolts:


EAA00022

EAA00110

4. FRONT FENDERA: Tighten the front fender bolts to

specification.

Front bolt:

6 Nm (0.6 mSkg, 4.3 ftSlb)

Rear bolt:


B:

Make sure the brake hose is

routed outside of the front fend-

er.

Be careful not to scratch the

front fender with the front fork

outer tube.



tion.


C: Clamp the front brake hose.



–7–

1 Master cylinder 1

2 Master cylinder bracket 1 C

3 Bolt 2 C d = 6 (0.24), = 20 (0.79)

4 Brake light switch connector 2

1 Clutch cable 1

2 Clutch switch lead coupler 1

1 Left handlebar switch 1

2 Screw 1 C d = 5 (0.20), = 45 (1.77)

3 Screw 1 C d = 5 (0.20), = 30 (1.18)

WARNING

WARNING

NOTE:

WARNING

EAA00032

EAA00120

5. FRONT BRAKE MASTER

CYLINDERA: Lubricate the pivoting parts of

the brake lever.

Recommended lubricants:

Yamaha cable lube or motor

oil

B: Make sure that the “UP” mark

with the bracket is pointed up-

ward.

C: Align the punch mark on the

handlebar with the gap of the

master cylinder bracket.

D: Tighten the bolts in stages and

maintain an equal gap on each

side of the bracket to specifica-

tion.

Bolt:


E: Connect the front brake light

switch connector.

F: Check the brake lever for

smooth action.

Proper cable and hose routing

is essential to assure safe ve-

hicle operation.


EAA00035

EAA00123

6. HANDLEBAR SWITCHA: Align the projection on the left

handlebar switch with the hole

in the handlebar.



tion.


B: Tighten the screws to specifi-

cation.

Screw:

3.5 Nm (0.35 mSkg, 2.5 ftSlb)

EAA00049

EAA00137

7. CLUTCH CABLEA: Lubricate the pivoting part of

the clutch lever.

Recommended lubricants:

Yamaha cable lube or motor

oil

B: To install the clutch cable, be

sure to proceed as follows:

a. Turn in the adjuster on the lever

holder until tight. Next, align the

slit in the adjuster and cable

socket with the slit in the lever

holder.

b. Insert the cable end into the le-

ver hole. Next, while pulling the

outer cable in the direction op-

posite to the lever, seat the out-

er cable into the cable socket.

Check the clutch lever for smooth

action.

Refer to “ADJUSTMENTS AND

PREDELIVERY SERVICE”.

C: Install the clutch switch lead

coupler.



tion.




–8–

1 Special nut 6 C d = 5 (0.20)

2 Windshield 1 C

3 Screw 6 C d = 5 (0.20), = 18 (0.71)

1 Band 2 C

1 Rear view mirror 2 C

2 Nut 4 C d = 6 (0.24)

WARNING

CAUTION:

8. BANDA: Clamp the left handlebar

switch lead.

B: Clamp the right handlebar

switch lead.



tion.


EAA00053

EAA00141

9. WINDSHIELD

The windshield is made of an

acrylate resin. Take care so that

it is not scratched.

A: Tighten the screws to specifi-

cation.

Screw:

0.4 Nm (0.04 mSkg, 0.3 ftSlb)

10. REAR VIEW MIRRORSA: Tighten the rear view mirrors

nuts.

Nut:




–9–

1 Battery 1

2 Battery cover 1

3 Bolt 2 d = 6 (0.24), = 25 (0.98)

4 Bolt 2 d = 6 (0.24), = 10 (0.39)

1 Inner panel 1 C

2 Inner panel 2 C

3 Bolt 6 C d = 5 (0.20), = 12 (0.47)

4 Bolt 2 C d = 6 (0.24), = 16 (0.63)

5 Bolt 2 d = 6 (0.24), = 16 (0.63)

6 Washer 2 d = 6 (0.24)

NOTE:

NOTE:

NOTE:

NOTE:

EAA00189

11. BATTERY

Remove the seat and fuel tank.

A: Install the battery.

Refer to “ADJUSTMENTS AND

PREDELIVERY SERVICE”.

B: Install the battery cover.

Bolt:


C: First, connect the positive lead

(red lead) to the positive termi-

nal.

D: Second, connect the negative

lead (black lead) to the nega-

tive terminal.


Install the fuel tank and seat.

12. INNER PANELA: Tighten the bolts to specifica-

tion.

Bolt:

3.3 Nm (0.33 mSkg, 2.4 ftSlb)



–10–

WARNING

EAA00900

CABLE ROUTING

Proper cable and lead routing are essential to insure safe vehicle

operation.

(1) Left handlebar switch lead

(2) Main switch lead

(3) Clutch cable

(4) Throttle cables

(5) Right handlebar switch lead

(6) Battery negative lead coupler

(7) Battery negative lead

(8) Starter relay lead

(9) Battery positive lead

(10) Battery cover

A Clamp the right and left handlebar switch leads and handlebar.

Point the tip of the clamp downward in front of the handlebar.

B Pass the throttle cables through the wire guide.

Route the right handlebar switch lead by the outside of the wire

guide.

C Line up the left handlebar switch lead coupler and radiator fan

motor lead coupler behind the head pipe.

D Route the clutch cable over the wire harness.

E Route the throttle cables above the stay assy 1.

F Hook the starter motor lead to the alternate pawls on the battery

cover.

G Route the starter relay lead outside of the main switch lead and

pass forward the fuse holder.



–11–

EAA01100

ADJUSTMENTS AND PREDELIVERYSERVICE

Perform the predelivery service in the order indicated by the letters.

Always follow the order as shown.



–12–

NOTE:

WARNING

CAUTION:

WARNING

EAA01000

A. CHECKING AND CHARGING

THE BATTERY

The battery used in this vehicle is a mainte-

nance free (MF) “Valve Regulated Lead

Acid Battery”, it has been pre-filled with

electrolyte at the factory so there is no need

to add fluid at any time.

1. Check:

Using a digital volt meter, the state of a dis-

charged MF battery can be checked by

measuring open-circuit voltage (the voltage

measured with the positive and negative

terminals being disconnected).

Open-circuit voltage

12.8 V or higher

Charging time

Charging is not necessary

D Do not attempt boost charging under

any circumstances.

D Battery electrolyte is poisonous and

dangerous, causing severe burns,etc. It contains sulfuric acid. Avoid

contact with skin, eyes or clothing.

Antidote: External-Flush with water. In-

ternal-Drink large quantities of water or

milk. Follow with milk of magnesia, beat-

en egg, or vegetable oil. Call physician

immediately.

Eyes: Flush with water for 15 minutes

and get prompt medical attention. Bat-

teries produce explosive gases. Keep

sparks, flame, cigarettes, etc., away.

Ventilate when charging or using in en-

closed space. Always shield eyes when

working near batteries.

KEEP OUT OF THE REACH OF CHIL-

DREN.

D If the voltage is lower than 12.8 V thebattery must be charged. If this is not

done, the life of the battery will be

shortened drastically. Refer to the

service manual for battery charging

instructions.

D Never remove the strip of caps, nor

add any water or electrolyte.

EAA01009

B. CHECKING THE TIREPRESSURE

1. Check:

D tire pressure

Out of specification! Adjust.

D The tire pressure should only be

checked and regulated when the tire

temperature equals the ambient air

temperature.

D The tire pressure and the suspension

must be adjusted according to the to-

tal weight (including cargo, rider,

passenger, and accessories) and the

anticipated riding speed.D Operation of an overloaded vehicle

could cause tire damage, an acci-

dent, or an injury.

NEVER OVERLOAD THE VEHICLE.

Basic weight:

With oil and full fuel tank

207 kg (456 lb) (except for CAL)

208 kg (459 lb) (for CAL)

Maximum load*

190 kg (419 lb) (except for CAL)

189 kg (417 lb) (for CAL)

Cold tire pressure

Up to 90 kg load*

Front

225 kPa (2.25 kgf/ cm2, 33 psi)

Rear

250 kPa (2.5 kgf/ cm2, 35.6 psi)

90kgXMaximum load*

Front

250 kPa (2.5 kgf/ cm2, 35.6 psi)

Rear

290 kPa (2.9 kgf/ cm2, 41.3 psi)

High speed riding

Front

225 kPa (2.25 kgf/ cm2, 33 psi)

Rear

250 kPa (2.5 kgf/ cm2, 35.6 psi)

* Load is the total weight of cargo, rider, pas-

senger, and accessories.



–13–

NOTE:

NOTE:

CAUTION:

NOTE:

NOTE:

NOTE:

CAUTION:

NOTE:

EAA01011

C. CHECKING THE ENGINE OIL

LEVEL1. Stand the vehicle on a level surface.

D Place the vehicle on a suitable stand.

D Make sure that the vehicle is upright.

2. Let the engine idle for a few minutes, and

then turn it off.

3. Remove:

D dipstick

4. Check:

D engine oil level

The engine oil level should be between

the maximum level mark (a) and mini-

mum level mark (b).

Below the minimum level mark ! Add

the recommended engine oil to the prop-

er level.

D Before checking the engine oil level, wait

a few minutes until the oil has settled.

D Do not screw the dipstick in when check-

ing the oil level.

Recommended engine oil

–10_C (10_F) to 20_C (70_F)

YAMALUBE 4 (10W-30) or

SAE 10W-30

10_C (50_F) to 40_C (110_F)

YAMALUBE 4 (20W-40) or

SAE 20W-40

Quantity

Without oil filter cartridge replacement

2.5 L (2.20 Imp qt, 2.64 US qt)

D Engine oil also lubricates the clutch

and the wrong oil types or additives

could cause clutch slippage. There-

fore, do not add any chemical addi-

tives.

D Do not allow foreign materials to en-

ter the crankcase.

API service SG type or higher JASO stan-

dard MA

5. Start the engine, warm it up for several

minutes, and then turn it off.

6. Check the engine oil level again.

Before checking the engine oil level, wait a

few minutes until the oil has settled.

7. Install:

D dipstick

EAA01017

D. CHECKING THE COOLANTLEVEL

1. Stand the vehicle on a level surface.



2. Check:

D coolant level

The coolant level should be between the

maximum level mark (a) and minimum

level mark (b).

Below the minimum level mark ! Add

the recommended coolant to the proper

level.

D Adding water instead of coolant low-

ers the antifreeze content of the cool-

ant. If water is used instead of cool-

ant, check and correct the antifreeze

concentration of the coolant.

D Use only distilled water. Soft water

may be used if distilled water is not

available.

3. Start the engine, warm it up for several

minutes, and then turn it off.4. Check:

D coolant level

Before checking the coolant level, wait a few

minutes until it settles.



–14–

NOTE:

NOTE:

WARNING

NOTE:

WARNING

CAUTION:

WARNING

EAA01020

E. ADJUSTING THE ENGINE

IDLING SPEED

Prior to adjusting the engine idling speed,

the throttle bodies synchronization should

be adjusted properly, the air filter should be

clean, and the engine should have ade-

quate compression.

1. Start the engine and let it warm up for

several minutes.

2. Measure:

D engine idling speed


Engine idling speed

1,250X 1,350 r/min

3. Adjust:

D engine idling speed

a. Turn the throttle stop screw (1) in direc-

tion (a) or (b) until the specified engine

idling speed is obtained.

Direction (a)

Engine idling speed is increased.

Direction (b)

Engine idling speed is decreased.

EAA01022

F. ADJUSTING THE THROTTLE

CABLE FREE PLAY

Prior to adjusting throttle cable free play, the

engine idling speed should be adjusted.1. Measure:

D throttle cable free play (a)


Throttle cable free play (at the flange

of the throttle grip)

3X 5 mm (0.12X 0.20 in)

2. Adjust:

a. Loosen the locknut (1).

b. Turn the adjusting nut (2) in direction (a)

or (b) until the specified throttle cable

free play is obtained.

Direction (a)Throttle cable free play is increased.

Direction (b)

Throttle cable free play is decreased.

c. Tighten the locknut.

After adjusting the throttle cable free

play, turn the handlebar to the right and

to the left to ensure that this does not

cause the engine idling speed to change.

EAA01023

G. ADJUSTING THE FRONT

BRAKE1. Adjust:

D brake lever position

(distance (a) from the throttle grip to the

brake lever)

a. While pushing the brake lever forward,

turn the adjusting dial (1) until the brake

lever is in the desired position.

Be sure to align the setting on the adjusting

dial with the arrow mark (2) on the brake le-

ver holder.

Position #1

Distance (a) is the largest.

Position #5

Distance (b) is the smallest.

After adjusting the brake lever position,

make sure that the pin on the brake lever

holder is firmly inserted in the hole in the

adjusting dial.

After adjusting the brake lever position,

make sure that there is no brake drag.

A soft or spongy feeling in the brake le-

ver can indicate the presence of air in the

brake system. Before the vehicle is oper-

ated, the air must be removed by bleed-

ing the brake system.

Air in the brake system will considerably

reduce braking performance and could

result in loss of control and possibly an

accident. Therefore, check the brake

system and bleed if necessary.



–15–

A

B

WARNING

WARNING

CAUTION:

NOTE:

WARNING

CAUTION:

NOTE:

EAA01027

H. ADJUSTING THE REAR BRAKE1. Measure:

D brake pedal position (a)

(below the bottom of the footrest brack-

et)


Brake pedal position (top of the footrest)

25.8 mm (1.02 in)

2. Adjust:

D brake pedal position

a. Loosen the locknut (1).

b. Turn the adjusting bolt (2) in direction (a)

or (b) until the specified brake pedal

position is obtained.

Direction (a)

Brake pedal is raised.

Direction (b)

Brake pedal is lowered.

After adjusting the brake pedal position,

make sure that the end of the adjusting

bolt (c) is visible through the hole (d).

c. Tighten the locknut (1) to specification.

Locknut


A soft or spongy feeling in the brake ped-

al can indicate the presence of air in the

brake system. Before the vehicle is oper-

ated, the air must be removed by bleed-

ing the brake system. Air in the brake

system will considerably reduce brakingperformance and could result in loss of

control and possibly an accident. There-

fore, check the brake system and bleed if

necessary.

After adjusting the brake pedal position,

make sure that there is no brake drag.

EAA01032

I. CHECKING THE BRAKE FLUID

LEVEL1. Stand the vehicle on a level surface.



2. Check:

D brake fluid level

Below the minimum level mark (a) !

Add the recommended brake fluid to the

proper level.

Recommended brake fluid

DOT 4

A Front brake

B Rear brake

D Use only designated brake fluid.

Other brake fluids may cause the rub-

er seals to deteriorate, causing leak-

age and poor brake performance.

D Refill with the same type of brake

fluid that is already in the system.

Mixing brake fluids may result in a

harmful chemical reaction, leading to

poor brake performance.

D

When refilling, be careful that waterdoes not enter the reservoir. Water

will significantly lower the boiling

point of the brake fluid and could

cause vapor lock.

Brake fluid may damage painted sur-

faces and plastic parts. Therefore, al-

ways clean up any split brake fluid im-

mediately.

In order to ensure a correct reading of the

brake fluid level, make sure that the top of

the reservoir is level.



–16–

A

B

WARNING

NOTE:

WARNING

EAA01035

J. BLEEDING THE HYDRAULIC

BRAKE SYSTEM

Bleed the hydraulic brake system when-

ever:

D the system was disassembled,

D a brake hose was loosened or re-

moved,

D the brake fluid level is very low,

D

brake operation is faulty.

D Be careful not to spill any brake fluid or

allow the brake fluid reservoir to over-

flow.

D When bleeding the hydraulic brake sys-

tem, make sure that there is always

enough brake fluid before applying the

brake. Ignoring this precaution could al-

low air to enter the hydraulic brake sys-

tem, considerably lengthening the

bleeding procedure.

D If bleeding is difficult, it may be neces-

sary to let the brake fluid settle for a few

hours. Repeat the bleeding procedurewhen the tiny bubbles in the hose have

disappeared.

1. Bleed:

D hydraulic brake system

a. Add the recommended brake fluid to the

proper level.

b. Install the brake fluid reservoir dia-

phragm.

c. Connect a clear plastic hose (1) tightly to

the bleed screw (2).

A Front

B Rear

d. Place the other end of the hose into a

container.

e. Slowly apply the brake several times.

f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in posi-

tion.

g. Loosen the bleed screw.

This will release the tension and cause

the brake lever to contact the throttle grip

or the brake pedal to fully extend.

h. Tighten the bleed screw and then re-

lease the brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the

brake fluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw


k. Fill the reservoir to the proper level.

Refer to “CHECKING THE BRAKE

FLUID LEVEL”.

After bleeding the hydraulic brake sys-

tem, check the brake operation.

EAA01036

K. ADJUSTING THE CLUTCH

CABLE FREE PLAY1. Measure:

D clutch cable free play (a)


Clutch cable free play (at the end of

the clutch lever)

10X 15 mm (0.39X 0.59 in)

2. Adjust:

D clutch cable free play

Handlebar side

a. Turn the adjusting dial (1) in direction (b)

or (c) until the specified clutch cable free

play is obtained.

Direction (b)

Clutch cable free play is increased.

Direction (c)

Clutch cable free play is decreased.



–17–

WARNING

CAUTION:

NOTE:

NOTE:

CAUTION:

WARNING

NOTE:

NOTE:

EAA01050

L. ADJUSTING THE REAR SHOCK

ABSORBER ASSEMBLY

Securely support the vehicle so that

there is no danger of it falling over.

Spring preload

Never go beyond the maximum or mini-

mum adjustment positions.

1. Adjust:

D spring preload

Adjust the spring preload with the special

wrench and extension bar included in the

owner’s tool kit.

a. Turn the adjusting ring (1) in direction (a)

or (b).

b. Align the desired position on the adjust-

ing ring with the stopper (2).

Direction (a)

Spring preload is increased

(suspension is harder).

Direction (b)

Spring preload is decreased

(suspension is softer).

Adjusting positions

Standard: 3

Minimum: 1

Maximum: 7

EAA01059

M. ADJUSTING THE DRIVE CHAIN

SLACK

The drive chain slack must be checked at

the tightest point on the chain.

A drive chain that is too tight will over-

load the engine and other vital parts, and

one that is too loose can skip and dam-age the swingarm or cause an accident.

Therefore, keep the drive chain slack

within the specified limits.

1. Stand the vehicle on a level surface.

Securely support the vehicle so that

there is no danger of it falling over.

Both wheels should be on the ground with-

out a rider on the vehicle.

2. Rotate the rear wheel several times and

check the drive chain to locate its tight-

est point.

3. Measure:

D drive chain slack (a)


Drive chain slack

45X 55 mm (1.77X 2.17 in)

4. Loosen:

D wheel axle nut (1)

5. Adjust:

D drive chain slack

a. Loosen both locknuts (2).

b. Turn both adjusting nuts (3) in direction

(a) or (b) until the specified drive chain

slack is obtained.

Direction (a)

Drive chain is tightened.

Direction (b)Drive chain is loosened.

D To maintain the proper wheel alignment,

adjust both sides evenly.

D Push the rear wheel forward to make

sure that there is no clearance between

the swingarm end plates and the ends of

the swingarm.

c. Tighten the wheel axle nut to specifica-

tion.

Wheel axle nut

125 Nm (12.5 mSkg, 90 ftSlb)

d. Tighten the locknuts to specification.

Locknut




–18–

NOTE:

EAA01062

N. ADJUSTING THE REAR BRAKE

LIGHT SWITCH

The rear brake light switch is operated by

the movement of the brake pedal.

The rear brake light switch is properly ad-

justed when the brake light comes on just

before the braking effect starts.

1. Check:

D rear brake light operation timing

Incorrect! Adjust.

2. Adjust:

D rear brake light operation timing

a. Hold the main body (1) of the rear brake

light switch so that it does not rotate and

turn the adjusting nut (2) in direction (a)

or (b) until the rear brake light comes on

at the proper time.

Direction (a)

Brake light comes on sooner.

Direction (b)

Brake light comes on later.

EAA01065

O. ADJUSTING THE HEADLIGHT

BEAMSThe following procedure applies to both of

the headlights.

1. Remove:

D front cowlling inner panels

2. Adjust:

D headlight beam (vertically)

a. Turn the adjusting screw (1) in direction

(a) or (b).

Direction (a)

Headlight beam is raised.

Direction (b)

Headlight beam is lowered.

3. Adjust:

D headlight beam (horizontally)

a. Turn the adjusting screw (2) in direction

(a) or (b).

Direction (a)

Headlight beam moves to the left.Direction (b)

Headlight beam moves to the right.

4. Install:

D front cowling inner panels.

EAA00185

P. ADJUSTING THE DIGITALCLOCK

Turn the key to “ON”.

1. Adjust:

D digital clock (1)

a. Push the “SELECT” button (3) and “RE-

SET” button (2) together for at least 2 se-

conds.

b. When the hour digits start flashing, push

the “RESET” button (2) to set the hours.

c. Push the “SELECT” button (3), and the

minute digits will start flashing.

d. Push the “RESET” button (2) to set the

minutes.e. Push the “SELECT” button (3) and then

release it to start the clock.



–19–

EAA10000

APPENDICESSERVICE DATA

Engine idling speed: 1,250X 1,350 r/min

Spark plug:

Type: CR9EK (NGK)

Gap: 0.6X 0.7 mm (0.0236X 0.0276 in)

Fuel:

Recommended fuel: Unleaded gasoline onlyFuel tank capacity:

Total: 19.4 L (4.27 Imp gal, 5.13 US gal)

Valve clearance (cold):

IN: 0.13X 0.20 mm (0.0051X 0.0079 in)

EX: 0.23X 0.30 mm (0.0091X 0.0118 in)

Tire pressure:

Up to 90 kg load* Front: 225 kPa (2.25 kgf /cm2, 33 psi)

Rear: 250 kPa (2.5 kgf/ cm2, 35.6 psi)

90 kg loadXMaximum load* Front: 250 kPa (2.5 kgf /cm2, 35.6 psi)


High-speed riding Front: 225 kPa (2.25 kgf / cm2, 33 psi)


Maximum load* 189 kg (417 lb) (for CAL)190 kg (419 lb) (except for CAL)

* Load is the total weight of cargo, rider, passenger, and accessories.

EAA10100

STANDARD EQUIPMENT1. Owner’s manual1 pc.

2. Owner’s tool kit 1 pc.

EAA10200

OWNER’S TOOL KIT1. Owner’s tool bag 1 pc.

2. Wrench (10-12) 2 pc.3. Wrench (12-14) 1 pc.

4. Special wrench 1 pc.

5. Extension bar 1 pc.

6. Spark plug wrench 1 pc.

7. Screwdriver grip 1 pc.

8. Screwdriver bit (Phillips-slotted) 1 pc.

9. Hexagon wrench (4) 1 pc.

10.Hexagon wrench (5) 1 pc.

11. Wrench (32) 1 pc.

12.Wrench (36) 1 pc.



–20–

TIGHTENING TORQUES

Thread Tightening

size Nm mSkg ftSlb

Engine:

Spark plug M10 18 1.8 13

Engine oil drain bolt M14 43 4.3 31

Chassis:

Upper bracket pinch bolt M8 30 3.0 22

Steering stem nut M22 110 11 80

Upper bracket and upper handlebar holder M8 23 2.3 17

Under bracket pinch bolt – 30 3.0 22

Lower ring nut M25 See NOTE1

Front fork cap bolt M35 24 2.4 17

Damper rod assembly bolt M10 23 2.3 17

Front brake master cylinder and master cylinder bracket M6 10 1.0 7.2

Front brake master cylinder cap screw M4 2 0.2 1.4

Front brake hose union bolt M10 30 3.0 22

Front brake hose holder and front fork M6 10 1.0 7.2

Front cowling stay and frame M8 33 3.3 24Front cowling bracket and frame M6 7 0.7 5.1

Front fender (front bolt) and front fork M6 6 0.6 4.3

Front fender (rear bolt) and front fork M6 7 0.7 5.1

Left handlebar switch screw M5 3.5 0.35 2.5

Grip end bolt M16 26 2.6 19

Right handlebar switch screw M5 3.5 0.35 2.5

Rear view mirror nut – 7 0.7 5.1

Wind shield screw M5 0.4 0.04 0.3

Inner panel bolt (front side) M5 3.3 0.33 2.4

Inner panel bolt (left and right side) M6 4.5 0.45 3.3

Battery cover bolt M6 7 0.7 5.1Clutch lever holder pinch bolt M6 11 1.1 8.0

Engine mount bolts (left of front side) M10 55 5.5 40

Engine mount bolts (left of rear side) M10 55 5.5 40

Engine mount bolts (right of front side) M10 55 5.5 40

Engine mount self locking nut (upper) M10 55 5.5 40

Engine mount self locking nut (lower) M10 55 5.5 40

Pivot shaft and frame M18 125 12.5 90

Rear shock absorber and frame M10 40 4.0 29

Rear shock absorber and rear arm M10 40 4.0 29

Seal guard and rear arm M6 7 0.7 5.1

Rear fender and rear arm M6 7 0.7 5.1

Rear brake hose holder and rear arm M6 7 0.7 5.1Fuel tank bracket and frame M6 7 0.7 5.1

Fuel tank bracket and fuel tank M6 7 0.7 5.1

Fuel tank and rear frame M6 7 0.7 5.1

Fuel tank and fuel tank cap M5 6 0.6 4.3

Fuel pump and fuel tank M5 4 0.4 2.9

Ignition coil and battery box M6 7 0.7 5.1

Seat lock and frame M6 7 0.7 5.1



–21–

NOTE 1:

Thread Tightening

size Nm mSkg ftSlb

Rotor and mud guard M6 3 0.3 2.2

Licence plate light and flap M5 4 0.4 2.9

Rear reflector and flap M5 4 0.4 2.9

Flap and bracket 6 M6 7 0.7 5.1

Blacket 6 and rear frame M6 19 1.9 14

Seat handle and tail /brake right unit M6 3 0.3 2.2Rear fender cover and seat handle M5 4 0.4 2.9

Seat handle bolt M8 23 2.3 17

Muffler and rear fender M6 7 0.7 5.1

Side cover and rear frame M6 10 1.0 7.2

Rear mud guard and rear frame M6 7 0.7 5.1

Engine stop switch and frame M4 2 0.2 1.4

Coolant reserver tank bracket and crankcase M10 13 1.3 9.4

Coolant reserver tank bracket and radiator M6 7 0.7 5.1

Coolant reserver tank bracket and coolant reserver tank M6 4 0.4 2.9

Front wheel axle M18 72 7.2 52

Front wheel axle pinch bolt M8 19 1.9 14

Front brake caliper and front fork M10 40 4.0 29Front brake disc and front wheel M6 18 1.8 13

Brake caliper bleed screw M7 6 0.6 4.3

Rear wheel axle nut M24 125 12.5 90

Rear brake disc and rear wheel M8 30 3.0 22

Rear brake caliper bolt front and rear brake caliper bracket M8 27 2.7 20

Rear brake caliper bolt rear and rear brake caliper bracket M8 22 2.2 16

Rear wheel sprocket and rear wheel drive hub M10 100 10 72

Chain adjusting bolt lock nut M8 16 1.6 12

Rear brake hose union bolt M10 30 3.0 22

Sidestand bolt lock nut M10 46 4.6 33

Sidestand bracket and frame M10 63 6.3 46Sidestand switch nut M5 4 0.4 2.9

Footrest bracket and frame M8 30 3.0 22

Rear brake reserver tank and sub-complete bracket 1 M6 7 0.7 5.1

Rear master cylinder and footrest bracket M8 23 2.3 17

Mainstand and nut M10 73 7.3 53

Footrest and footrest bolt M8 10 1.0 7.2

Brake pedal and brake shaft M6 8 0.8 5.8

Footrest bracket and footrest cover plate M5 7 0.7 5.1

1. First, tighten the ring nut to approximately 52 Nm (5.2 mSkg, 38 ftSlb) with a torque wrench, then loosen

the ring nut completely.2. Retighten the lower ring nut 18 Nm (1.8 mSkg, 13 ftSlb).

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