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 Yamaha 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. The procedures below are described in the order that the procedures are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.
CONCERNING CRATE DAMAGE:

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! WARNING 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. A NOTE provides key information to make procedures easier or clearer.
EAA00001

CAUTION:

NOTE:

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)

EAA00008

SYMBOLS USED IN THE ASSEMBLY MANUAL

In order to simplify descriptions in this assembly 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 upward. (6): Apply motor oil. (7): Made of rubber or plastics (8): A: Ref. No. (indicating the order of operations.) 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 Styrofoam 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)

(3)

(4)

(5)

(6)

(7)

(8)

EAA00040

PREPARATION
To assemble the vehicle correctly, supplies (e.g. oils, greases, and shop rags) and sufficient working space are required. Workshop The workshop where the vehicle is assembled should be clean, spacious, and have a level floor. Self-protection Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or shoes.

(1)

(2)

EAA00050

SYMBOLS USED ON CRATE 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 to these marks while taking care not to damage the package contents.

(3)

(4)

(5)

(6)

EAA00060

UNPACKING
1. Remove the frame cover (1). NOTE: 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.) NOTE: Remove the bolts while holding the frame.

NOTE: 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 other defects.

EAA00070

PARTS LOCATION
(1) Carton box 1. (2) Carton box 2. (3) Front tire.

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. Bands 11. Washers 12. Bolts 13. Inner panels 14. Rear view mirrors 15. Windshield 16. Front fender 17. Owners manual 18. Reflectors 19. Brackets 20. Nuts

(2) Carton box 2 1. Handlebar 2. Gnip end (right) 3. Bolts (upper handlebar holders) 4. Front brake master cylinder bracket 5. Bolts (front brake master cylinder bracket) 6. Screws (left handlebar switch) 7. Collars 8. Upper handlebar holder

(3) Front tire

EAA00100

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

EAA00014 EAA00102

1. HANDLEBAR
A: Clean the right handlebar end. Apply light coat grease. B: Install the handlebar holder with the symbol mark facing forward. CAUTION: First tighten the bolts on the front side, and then tighten the bolts on the rear side. 1 2 3 Handlebar Upper handlebar holder Bolt 1 1 4 C C C C: Align the punch mark on the handlebar with the top of the lower handlebar holders. D: Tighten the bolts to specification. Bolt: 23 Nm (2.3 mSkg, 17 ftSlb)

d = 8 (0.31),

= 30 (1.18)

EAA00016 EAA00104

2. THROTTLE GRIP
A: Align the projection on the handlebar switch with the hole in the handlebar. B: Tighten the screws to specification. Screw: 3.5 Nm (0.35 mSkg, 2.5 ftSlb) C: Check the throttle grip for smooth action. 1 2 3 Screw Screw Grip end 1 1 1
d = 5 (0.20), d = 5 (0.20), = 45 (1.77) = 20 (0.79)

WARNING Proper cable routing is essential to assure safe vehicle operation. Refer to CABLE ROUTING. D: Tighten the grip end. Grip end: 26 Nm (2.6 mSkg, 19 ftSlb)

EAA00020 EAA00108

G: Tighten the wheel axle to specification. Wheel axle: 72 Nm (7.2 mSkg, 52 ftSlb) H: Tighten the wheel axle pinch bolt to specification. Wheel axle pinch bolt: 19 Nm (1.9 mSkg, 14 ftSlb) CAUTION: 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: 40 Nm (4.0 mSkg, 29 ftSlb)

3. FRONT WHEEL
A: Clean the brake discs. B: Clean the front wheel axle. C: Clean the collar. D: WARNING 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.
d = 8 (0.31), = 40 (1.57)

1 2 3 4 5 6 7 8

Front tire Collar Axle Bolt Reflector Nut Bracket Bolt

1 2 1 1 2 2 2 4

S C

E: Make sure there is an enough gap between the brake pads. NOTE: 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 direction.

C C C

d = 5 (0.20) d = 10 (0.39), = 30 (1.18)

EAA00022 EAA00110

4. FRONT FENDER
A: Tighten the front fender bolts to specification. Front bolt: 6 Nm (0.6 mSkg, 4.3 ftSlb) Rear bolt: 7 Nm (0.7 mSkg, 5.1 ftSlb) B: CAUTION: Make sure the brake hose is routed outside of the front fender. Be careful not to scratch the front fender with the front fork outer tube.

WARNING Proper cable routing is essential to assure safe vehicle operation. Refer to CABLE ROUTING. C: Clamp the front brake hose.

1 2 3 4 5

Front fender Bolt Bolt Collar Bracket

1 2 2 2 1

S C C C C

d = 6 (0.24), d = 6 (0.24), d = 6 (0.24)

= 22 (0.87) = 30 (1.18)

EAA00032 EAA00120

5. FRONT BRAKE MASTER CYLINDER

A: 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 upward. 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 specification. Bolt: 10 Nm (1.0 mSkg, 7.2 ftSlb) E: Connect the front brake light switch connector. F: Check the brake lever for smooth action. WARNING Proper cable and hose routing is essential to assure safe vehicle operation. Refer to CABLE ROUTING.

1 2 3 4

Master cylinder Master cylinder bracket Bolt

Brake light switch connector

1 1 2 2

C C

d = 6 (0.24),

= 20 (0.79)

EAA00035 EAA00123

6. HANDLEBAR SWITCH
A: Align the projection on the left handlebar switch with the hole in the handlebar. WARNING Proper cable routing is essential to assure safe vehicle operation. Refer to CABLE ROUTING. B: Tighten the screws to specification. C C
d = 5 (0.20), d = 5 (0.20), = 45 (1.77) = 30 (1.18)

1 2 3

Left handlebar switch Screw Screw

1 1 1

Screw: 3.5 Nm (0.35 mSkg, 2.5 ftSlb)

EAA00049 EAA00137

7. CLUTCH CABLE
A: 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 lever hole. Next, while pulling the outer cable in the direction opposite to the lever, seat the outer cable into the cable socket.

NOTE: Check the clutch lever for smooth action. Refer to ADJUSTMENTS AND PREDELIVERY SERVICE. C: Install the clutch switch lead coupler. WARNING Proper cable routing is essential to assure safe vehicle operation. Refer to CABLE ROUTING.

1 2

Clutch cable
Clutch switch lead coupler

1 1

8. BAND
A: Clamp the left handlebar switch lead. B: Clamp the right handlebar switch lead. WARNING Proper cable routing is essential to assure safe vehicle operation. Refer to CABLE ROUTING.

Band

EAA00053 EAA00141

9. WINDSHIELD
CAUTION: The windshield is made of an acrylate resin. Take care so that it is not scratched. A: Tighten the screws to specification. Screw: 0.4 Nm (0.04 mSkg, 0.3 ftSlb) 1 2 3 Special nut Windshield Screw 6 1 6 C C C
d = 5 (0.20) d = 5 (0.20), = 18 (0.71)

10. REAR VIEW MIRRORS

A: Tighten the rear view mirrors nuts. Nut: 7 Nm (0.7 mSkg, 5.1 ftSlb)

1 2

Rear view mirror Nut

2 4

C C

d = 6 (0.24)

EAA00189

11. BATTERY
NOTE: Remove the seat and fuel tank. A: Install the battery. NOTE: Refer to ADJUSTMENTS AND PREDELIVERY SERVICE. B: Install the battery cover. Bolt: 7 Nm (0.7 mSkg, 5.1 ftSlb) 1 2 3 4 Battery Battery cover Bolt Bolt 1 1 2 2 C: First, connect the positive lead (red lead) to the positive terminal.

D: Second, connect the negative lead (black lead) to the negative terminal. NOTE: Refer to CABLE ROUTING. NOTE: Install the fuel tank and seat.

d = 6 (0.24), d = 6 (0.24),

= 25 (0.98) = 10 (0.39)

12. INNER PANEL

A: Tighten the bolts to specification. Bolt: 3.3 Nm (0.33 mSkg, 2.4 ftSlb)

1 2 3 4 5 6

Inner panel Inner panel Bolt Bolt Bolt Washer

1 2 6 2 2 2

C C C C

d = 5 (0.20), d = 6 (0.24), d = 6 (0.24), d = 6 (0.24)

= 12 (0.47) = 16 (0.63) = 16 (0.63)

EAA00900

CABLE ROUTING
WARNING 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. D E F G

Line up the left handlebar switch lead coupler and radiator fan motor lead coupler behind the head pipe. Route the clutch cable over the wire harness. Route the throttle cables above the stay assy 1. Hook the starter motor lead to the alternate pawls on the battery cover. Route the starter relay lead outside of the main switch lead and pass forward the fuse holder.

10

EAA01100

ADJUSTMENTS AND PREDELIVERY SERVICE

Perform the predelivery service in the order indicated by the letters. Always follow the order as shown.

11

EAA01000

A. CHECKING AND CHARGING THE BATTERY

NOTE: The battery used in this vehicle is a maintenance 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 discharged 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 WARNING 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. Internal-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF THE REACH OF CHILDREN. CAUTION: D If the voltage is lower than 12.8 V the battery 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 TIRE PRESSURE

1. Check: D tire pressure Out of specification ! Adjust. WARNING 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 total weight (including cargo, rider, passenger, and accessories) and the anticipated riding speed. D Operation of an overloaded vehicle could cause tire damage, an accident, 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) 90kg X Maximum 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, passenger, and accessories.

12

EAA01011

C. CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface. NOTE: 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 minimum level mark (b). Below the minimum level mark ! Add the recommended engine oil to the proper level. NOTE: D Before checking the engine oil level, wait a few minutes until the oil has settled. D Do not screw the dipstick in when checking 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) CAUTION: D Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. D Do not allow foreign materials to enter the crankcase. NOTE: API service SG type or higher JASO standard MA 5. Start the engine, warm it up for several minutes, and then turn it off. 6. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 7. Install: D dipstick

EAA01017

D. CHECKING THE COOLANT LEVEL

1. Stand the vehicle on a level surface. NOTE: D Place the vehicle on a suitable stand. D Make sure that the vehicle is upright. 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. CAUTION: D Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, 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 NOTE: Before checking the coolant level, wait a few minutes until it settles.

13

EAA01020

E. ADJUSTING THE ENGINE IDLING SPEED

NOTE: 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 adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Measure: D engine idling speed Out of specification ! Adjust. Engine idling speed 1,250 X 1,350 r / min

3. Adjust: D engine idling speed a. Turn the throttle stop screw (1) in direction (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

NOTE: Prior to adjusting throttle cable free play, the engine idling speed should be adjusted. 1. Measure: D throttle cable free play (a) Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 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. WARNING 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 BRAKE

1. 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. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark (2) on the brake lever holder. Position #1 Distance (a) is the largest. Position #5 Distance (b) is the smallest.

WARNING 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. CAUTION: After adjusting the brake lever position, make sure that there is no brake drag. WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding 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.

14

EAA01027

c. Tighten the locknut (1) to specification. Locknut 18 Nm (1.8 mSkg, 13 ftSlb) WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding 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. CAUTION: After adjusting the brake pedal position, make sure that there is no brake drag.

H. ADJUSTING THE REAR BRAKE

1. Measure: D brake pedal position (a) (below the bottom of the footrest bracket) Out of specification ! Adjust. Brake pedal position (top of the footrest) 25.8 mm (1.02 in) 2. D a. b. Adjust: brake pedal position Loosen the locknut (1). 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. WARNING After adjusting the brake pedal position, make sure that the end of the adjusting bolt (c) is visible through the hole (d).

EAA01032

I. CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface. NOTE: D Place the vehicle on a suitable stand. D Make sure that the vehicle is upright. 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 B

WARNING D Use only designated brake fluid. Other brake fluids may cause the ruber seals to deteriorate, causing leakage 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 water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure that the top of the reservoir is level.

Front brake Rear brake

15

EAA01035

J. BLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING Bleed the hydraulic brake system whenever: D the system was disassembled, D a brake hose was loosened or removed, D the brake fluid level is very low, D brake operation is faulty. NOTE: D Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow. D When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. D If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when 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 diaphragm. 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 depress the brake pedal and hold it in position. 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 release 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 6 Nm (0.6 mSkg, 4.3 ftSlb) k. Fill the reservoir to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL. WARNING After bleeding the hydraulic brake system, check the brake operation.

EAA01036

K. ADJUSTING THE CLUTCH CABLE FREE PLAY

1. Measure: D clutch cable free play (a) Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 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.

16

EAA01050

L. ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

WARNING Securely support the vehicle so that there is no danger of it falling over.

Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: D spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owners tool kit. a. Turn the adjusting ring (1) in direction (a) or (b). b. Align the desired position on the adjusting 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

NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Both wheels should be on the ground without a rider on the vehicle. 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Measure: D drive chain slack (a) Out of specification ! Adjust. Drive chain slack 45 X 55 mm (1.77 X 2.17 in)

4. D 5. D a. b.

Loosen: wheel axle nut (1) Adjust: drive chain slack Loosen both locknuts (2). 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.

NOTE: 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 specification. Wheel axle nut 125 Nm (12.5 mSkg, 90 ftSlb) d. Tighten the locknuts to specification. Locknut 16 Nm (1.6 mSkg, 12 ftSlb)

17

EAA01062

N. ADJUSTING THE REAR BRAKE LIGHT SWITCH

NOTE: The rear brake light switch is operated by the movement of the brake pedal. The rear brake light switch is properly adjusted 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 BEAMS

The 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 DIGITAL CLOCK

Turn the key to ON. 1. Adjust: D digital clock (1) a. Push the SELECT button (3) and RESET button (2) together for at least 2 seconds. 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.

18

EAA10000

APPENDICES SERVICE DATA

Engine idling speed: Spark plug: Type: Gap: Fuel: Recommended fuel: Fuel tank capacity: Total: Valve clearance (cold): IN: EX: Tire pressure: Up to 90 kg load* 90 kg load X Maximum load* High-speed riding Unleaded gasoline only 19.4 L (4.27 Imp gal, 5.13 US gal) 0.13 X 0.20 mm (0.0051 X 0.0079 in) 0.23 X 0.30 mm (0.0091 X 0.0118 in) Front: 225 kPa (2.25 kgf / cm2, 33 psi) Rear: 250 kPa (2.5 kgf / cm2, 35.6 psi) Front: 250 kPa (2.5 kgf / cm2, 35.6 psi) Rear: 290 kPa (2.9 kgf / cm2, 41.3 psi) Front: 225 kPa (2.25 kgf / cm2, 33 psi) Rear: 250 kPa (2.5 kgf / cm2, 35.6 psi) 1,250 X 1,350 r / min CR9EK (NGK) 0.6 X 0.7 mm (0.0236 X 0.0276 in)

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 EQUIPMENT
1. Owners manual1 pc. 2. Owners tool kit 1 pc.

EAA10200

OWNERS TOOL KIT

1. Owners tool bag 2. Wrench (10-12) 3. Wrench (12-14) 4. Special wrench 5. Extension bar 6. Spark plug wrench 7. Screwdriver grip 8. Screwdriver bit (Phillips-slotted) 9. Hexagon wrench (4) 10. Hexagon wrench (5) 11. Wrench (32) 12. Wrench (36) 1 pc. 2 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc.

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TIGHTENING TORQUES
Item Engine: Spark plug Engine oil drain bolt Chassis: Upper bracket pinch bolt Steering stem nut Upper bracket and upper handlebar holder Under bracket pinch bolt Lower ring nut Front fork cap bolt Damper rod assembly bolt Front brake master cylinder and master cylinder bracket Front brake master cylinder cap screw Front brake hose union bolt Front brake hose holder and front fork Front cowling stay and frame Front cowling bracket and frame Front fender (front bolt) and front fork Front fender (rear bolt) and front fork Left handlebar switch screw Grip end bolt Right handlebar switch screw Rear view mirror nut Wind shield screw Inner panel bolt (front side) Inner panel bolt (left and right side) Battery cover bolt Clutch lever holder pinch bolt Engine mount bolts (left of front side) Engine mount bolts (left of rear side) Engine mount bolts (right of front side) Engine mount self locking nut (upper) Engine mount self locking nut (lower) Pivot shaft and frame Rear shock absorber and frame Rear shock absorber and rear arm Seal guard and rear arm Rear fender and rear arm Rear brake hose holder and rear arm Fuel tank bracket and frame Fuel tank bracket and fuel tank Fuel tank and rear frame Fuel tank and fuel tank cap Fuel pump and fuel tank Ignition coil and battery box Seat lock and frame Thread size M10 M14 M8 M22 M8 M25 M35 M10 M6 M4 M10 M6 M8 M6 M6 M6 M5 M16 M5 M5 M5 M6 M6 M6 M10 M10 M10 M10 M10 M18 M10 M10 M6 M6 M6 M6 M6 M6 M5 M5 M6 M6 Tightening Nm 18 43 mSkg 1.8 4.3 ftSlb 13 31

30 3.0 22 110 11 80 23 2.3 17 30 3.0 22 See NOTE1 24 2.4 17 23 2.3 17 10 1.0 7.2 2 0.2 1.4 30 3.0 22 10 1.0 7.2 33 3.3 24 7 0.7 5.1 6 0.6 4.3 7 0.7 5.1 3.5 0.35 2.5 26 2.6 19 3.5 0.35 2.5 7 0.7 5.1 0.4 0.04 0.3 3.3 0.33 2.4 4.5 0.45 3.3 7 0.7 5.1 11 1.1 8.0 55 5.5 40 55 5.5 40 55 5.5 40 55 5.5 40 55 5.5 40 125 12.5 90 40 4.0 29 40 4.0 29 7 0.7 5.1 7 0.7 5.1 7 0.7 5.1 7 0.7 5.1 7 0.7 5.1 7 0.7 5.1 6 0.6 4.3 4 0.4 2.9 7 0.7 5.1 7 0.7 5.1

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Item Rotor and mud guard Licence plate light and flap Rear reflector and flap Flap and bracket 6 Blacket 6 and rear frame Seat handle and tail/brake right unit Rear fender cover and seat handle Seat handle bolt Muffler and rear fender Side cover and rear frame Rear mud guard and rear frame Engine stop switch and frame Coolant reserver tank bracket and crankcase Coolant reserver tank bracket and radiator Coolant reserver tank bracket and coolant reserver tank Front wheel axle Front wheel axle pinch bolt Front brake caliper and front fork Front brake disc and front wheel Brake caliper bleed screw Rear wheel axle nut Rear brake disc and rear wheel Rear brake caliper bolt front and rear brake caliper bracket Rear brake caliper bolt rear and rear brake caliper bracket Rear wheel sprocket and rear wheel drive hub Chain adjusting bolt lock nut Rear brake hose union bolt Sidestand bolt lock nut Sidestand bracket and frame Sidestand switch nut Footrest bracket and frame Rear brake reserver tank and sub-complete bracket 1 Rear master cylinder and footrest bracket Mainstand and nut Footrest and footrest bolt Brake pedal and brake shaft Footrest bracket and footrest cover plate
NOTE 1:

Thread size M6 M5 M5 M6 M6 M6 M5 M8 M6 M6 M6 M4 M10 M6 M6 M18 M8 M10 M6 M7 M24 M8 M8 M8 M10 M8 M10 M10 M10 M5 M8 M6 M8 M10 M8 M6 M5

Tightening Nm 3 4 4 7 19 3 4 23 7 10 7 2 13 7 4 72 19 40 18 6 125 30 27 22 100 16 30 46 63 4 30 7 23 73 10 8 7 mSkg 0.3 0.4 0.4 0.7 1.9 0.3 0.4 2.3 0.7 1.0 0.7 0.2 1.3 0.7 0.4 7.2 1.9 4.0 1.8 0.6 12.5 3.0 2.7 2.2 10 1.6 3.0 4.6 6.3 0.4 3.0 0.7 2.3 7.3 1.0 0.8 0.7 ftSlb 2.2 2.9 2.9 5.1 14 2.2 2.9 17 5.1 7.2 5.1 1.4 9.4 5.1 2.9 52 14 29 13 4.3 90 22 20 16 72 12 22 33 46 2.9 22 5.1 17 53 7.2 5.8 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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PRINTED IN USA