AA20201 INTRODUCTION Congratulations on your purchase of the Yamaha FZR600/FZR600C. This model is the re- sult of Yamaha’s vast experience in the production of fine sporting, touring, and paceset- ting racing machines. It represents the high degree of craftsmanship and reliability that have mace Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic main- tenance of this motorcycle. If you have any questions about 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 stan- dards without reducing the motorcycle’s performance or economy of operation. To main- tain these high standards, it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.EAAIOT00 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following nota- tions: a The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FROUGIIIEY Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspect- ing or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: ANOTE provides key information to make procedures easier or clear- er.Uy00001 NOTE: This manual should be considered a permanent part of this motorcycle and should re- main with it even if the motorcycle is subsequently sold. e Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this man- ual. If there is any question concerning this manual, please consult your Yamaha deal- er. Euu60001 PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATIS- FACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR IN- SPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.AFFIX DEALER LABEL HERE eAAQ0000 FZR600K/FZR600KC OWNER’S MANUAL ©1997 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 1997 All rights 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-11626-11-06Aas0001 CONTENTS SAFETY AND GENERAL INFORMATION a CONTROL FUNCTIONS B PRE-OPERATION CHECKS OPERATION AND IMPORTANT RIDING POINTS PERIODIC MAINTENANCE AND MINOR REPAIR CLEANING AND STORAGE a SPECIFICATIONS a CONSUMER INFORMATIONSAFETY AND GENERAL INFORMATION SAFETY INFORMATION... LOCATION OF THE IMPORTANT LABELS... DESCRIPTION MOTORCYCLE IDENTIFICATION Identification numbers record... Key identification number.. Vehicle identification number .. Model label.....A SAFETY INFORMATION TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL AS- PECTS OF MOTORCYCLE OPERATION. 2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL. 3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. 4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. YA ied 1. Always make pre-operation checks. Careful checks may help prevent an accident. 2. This motorcycle is designed to carry the operator and a passenger.3. S The failure of motorists to detect and recognize motorcycles in traffic is the predom- inating 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 acci- dent. Therefore: a. Wear a brightly colored jacket. b. Use extra caution when you approach and pass through intersections, since inter- sections are the most likely places for motorcycle accidents. c. Ride where other motorists can see you. Avoid riding in another motorist's “blind spot”. . Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure you are qualified. Also, only lend your motorcycle to experienced op- erators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c. We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with your motorcycle and all of its controls. . Many motorcycle accidents have been caused by motorcycle operator errors. A typ- ical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). 12a. Always obey the speed limits and never travel faster than warranted by road and traffic conditions. b. Always signal before turning or changing lanes. Make sure other motorists see you. 6. The operator's and passenger's posture are important for proper control. a. The operator should keep both hands on the handlebars and both feet on the op- erator footrests during operation to maintain control of the motorcycle. b. The passenger should always hold on to the operator, or the seat strap or grab bar if the motorcycle is so equipped, with both hands and keep both feet on the passenger footrests. c. Never carry a passenger unless he or she can firmly place both feet on the passen- ger footrests. 7. Never ride under the influence of alcohol or drugs. 8. This motorcycle is designed for on-road use only. It is not suitable for off-road use. die ea ENP ealal te The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet.2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or re- ducing abrasions or lacerations. ing clothing. It could catch on the control levers, footrests, or wheels and cause injury or accident. . Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. 6. A passenger should also observe the above precautions. MODIFICATION Modifications made to the motorcycle not approved by Yamaha, or the removal of orig- inal equipment, may render your motorcycle unsafe for use and may cause severe per- sonal injury. Modifications may also make your motorcycle illegal to use. gLOADING AND ACCESSORIES Adding accessories or cargo to your motorcycle can adversely affect stability and han- dling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your motor- cycle. Use extra care if riding a motorcycle which has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your mo- torcycle: The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 346 Ibs. (157 kg): FZR600/335 Ibs. (152 kg): FZR600C. When loading within these weight limits, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability. 2. Shifting weights can create a sudden imbalance. Make sure that accessories and car- go are securely attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently.3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, including such cargo as sleeping bags, duffle bags, or tents, can create unstable handling or slow steering response. Nee sie) S53 Genuine Yamaha accessories have been specifically designed for use on this motorcy- cle. Since Yamaha cannot test all other accessories which may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. You should use extreme caution when selecting and installing any acces- sories. Keep in mind these guidelines for mounting accessories in addition to those provided under “LOADING”. 1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. a. Accessories fitted to the handlebar or the front fork area can create instability due toimproper weight distribution or aerodynamic 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.b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcy- cle may become unstable in cross winds. These accessories may also cause insta- i bility when being passed by or passing large vehicle. c. Certain accessories can displace the operator from his or her normal riding posi- tion. This improper position limits the freedom of movement of the operator and may limit control ability. Therefore such accessories are not recommended. 2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. GASOLINE AND EXHAUST GAS 1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn off the engine when refueling. b. Take care not to spill any gasoline on the engine or exhaust system when refuel- ing. c. Never refuel while smoking or in the vicinity of an open flame. 2. Never start the engine or let it run for any length of time in a closed area. The ex- haust fumes are poisonous and may cause loss of consciousness and death wit! short time. Always operate your motorcycle in an area that has adequate ventila3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key. When parking the motorcycle, note the following: a. The engine and exhaust system may be hot. Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over. ¢. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an open flame. The motorcycle could catch fire. 4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the fuel cock is turned to “ON” or “RES” (for vacuum type)/“OFF” (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank. 5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get in your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it off with soap and water and change your clothes.EAAAOO00 LOCATION OF THE IMPORTANT LABELS i Please read the following labels carefully before operating this motorcycle.CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. YAMAHA WARNING ‘© BEFORE YOU OPERATE THIS VEHICLE, READ ‘THE OVINER'S MANUAL AND ALL LABELS. ‘¢ ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye proton, and protective clothing, YAMAHA ‘7896-00 CAUTION ‘© Road owners manual before servicing battery © Electrolyte will damage metal parts or paint Helectroyte spills, wash area with fresh water immediately. 1 Be sure to connect breather hose after instaling battery. Rom CANISTER 10 TwoseHene YAMANAMOTORCO,L1D. @ AWARNING This unit contains high pressure nitrogen gas. Mishandling can cause explosion. © Read owner's manual for instructions. * Donot incinerate, puncture or open. YAMAHA Tan aR TIRE INFORMATION Ut 901g 108d FRONT» :2254P, 225 ote, 33 pi REAR 220.0 kgm, 28 pt (920 ig (108 bs = masimur oo FRONT: 250%, 250\gHom?, 36 pst REAR £2004, 200\gHem?, 2 ptDESCRIPTION j Left view 1. Tailfbrake light 2. Rear turn signal light 3. Top cover (See page 5-18) 4. Upper cowl 5. Front turn signal/position light 6. Lower cowl (See page 5-13) 7. Brake pedal (See page 2-8) wnRight view 10. nn, 13, 14, 18, Headlight Starter "CHOKE" Fuel cock Rider seat Passenger seat Helmet Folder Shift pecal Radiator (See page 5-48) (See page 2-11) (See page 2-10) (See page 2-13) (See page 2-13) (See page 2-14) (See page 2-7) (See page 5-24)Controls/Instruments 16, "7, 18. 19. 20. 21. 22. 23, Clutch lever Handlebar switches Speedometer Tachometer Engine temperature gauge Brake lever Throttle grip Main switch (See page 2-7) (See page 2-5) (See page 2-4) (See page 2-4) (See page 2-5) (See page 2-8) (See page 3-5) (See page 2-1)AA60000 EAAs1400 MOTORCYCLE IDENTIFICATION Key identification number cAnsis00 Identification numbers record Record the key identification number, ve- hicle identification number and model la- bel information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 1. Key identification number The key identification number is stamped on the key. Record this number in the space provided and use it for reference 2. VEHICLE IDENTIFICATION NUMBER: when obtaining a new key. 3. MODEL LABEL INFORMATION: ° eAA80000 Vehicle identification number Ans2200 Model label pr —— 1. Vehicle identitcation number The vehicle identification number is stamped into the steering head pipe. euuoowo NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. 1. Mode! label The model label is affixed to the frame un- der the seat. (See page 2-16 for seat re- moval procedures.) Record the information on this label in the space pro- vided. This information will be needed to order spare parts from your Yamaha deal- er.£AB00000 CONTROL FUNCTIONS Main switch Indicator lights Oil level indicator circuit check.. 2-3 Speedometer. 2-4 Tachometer 2-4 Engine temperature gauge. Handlebar switches Clutch lever. Shift pedal .. Front brake lever. Rear brake pedal. Fuel tank cap Fuel cock, Starter “CHOKE” Rear shock absorber Rear shock absorber adjustment. EXUP (Exhaust ultimate powervalve). Sidestand . Sidestand/clutch switch operation check.A800100 Main switch The main switch controls the ignition and lighting systems. Its operation is described below. exsoww00 ON: All electrical circuits are switched on, and the headlight, meter light, taillight, and front position lights come on. The engine can be started. The key cannot be removed in this position. 24 exsoost0 OFF: All electrical circuits are switched off. The key can be removed in this position. xsoor01 LOCK: The steering is locked in this position, and all electrical circuits are switched off. The key can be removed in this position. Refer to “Steering lock” [page 2-11) for opera- tion instructions. exsorro2 P (Parking): The steering is locked in this position. The taillight and front position light come on but all other circuits are off. The key can be removed in this position. vua0700 NOTE: Always turn the mein switch to “OFF” or “LOCK” and remove the key when the mo- torcycle is unattended.EAB10000 Indicator lights il level indicator light “OIL” Neutral incicator light "NEUTRAL" Turn indicator light “TURN” High beam indicator light "HIGH BEAM* easiaus Turn indicator light “TURN” This indicator flashes when the turn switch is moved to the left or right. ag10201 Neutral indicator light “NEUTRAL” This indicator comes on when the trans- mission is in neutral. 22 ner0201 High beam indicator light “HIGH BEAM” This indicator comes on when the head- light high beam is used. exsro002 Oil level indicator light “OIL” This indicator comes on when the oil level is low. This light circuit can be checked by the following procedure. euuo0 Do not run the motorcycle until you know it has sufficient engine oi tuo NOTE: Even if the oil is filled to the specified level, the indicator light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not abnormal.n20108, Oil level indicator circuit check Turn the main switch to “ON” and the engine stop switch to “RUN”. Oil level indicator light Oil level indicator light does not come on. comes on. Put the transmission in neutral Check engine oil level. or apply the clutch lever, then push the start switch. +7 Oil level indicator light Oil level indicator light Oil level Oil level comes on. does not come on. is OK. is low. Engine oil level and ‘Ask a Yamaha dealer to Supply electrical circuit are OK. inspect electrical circuit. engine oil. Go ahead with riding. 23xnec0s Speedometer anso200 Tachometer 2. Odometer 4 eset knob 1. Speedomerer 3. Trip odometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to “0” with the re- set knob. Use the trip odometer to esti- mate how far you can ride on a tank of fuel. This information will enable you to plan fuel stops in the future. 1. Techometer 2. Red zone This model is equipped with an electric ta- chometer so the rider can monitor the en- gine speed and keep it within the ideal power range. euvootce Do not operate in the red zone. Red zone: 11,500 r/min and abovecxssoro2 Engine temperature gauge AB60000 Handlebar switches 1. Engine temperature gauge This gauge indicates the coolant temperature when the main switch is on. The engine oper- ating temperature will vary with changes in weather and engine load. If the needle points to the red zone or higher, stop your motorcy- cle and let the engine cool. (See page 5-20 for details.) When the engine is overheated, do not con- tinue ri uus0500 1. Dimmer switch “LIGHTS 2. Turn signal switch "TURN" 3. Horn ewitch “HORN” 4. Engine stop switch “ENGINE STOP" 5. Start switch “START” Dimmer switch “LIGHTS” Turn the switch to “HI” for the high beam and to “LO” for the low beam.A860201 Turn signal switch “TURN” This model is equipped with self-cancelling turn signals. To signal a right-hand turn, push the switch to the right. To signal a left- hand turn, push the switch to the left. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the cen- ter position. If the switch is not cancelled by hand, it will self-cancel after the motorcycle has travelled for about 10 seconds or ap- proximately 150 m (490 ft) whichever is greater. The self-cancelling mechanism only operates when the motorcycle is mov- ing. Therefore the signal will not self-cancel while you are stopped at an intersection. eanso201 Horn switch “HORN” Press the switch to sound the horn. 26 £A860002 Engine stop switch “ENGINE STOP” The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to “RUN” to start the engine. In case of emer- gency, turn the switch to “OFF” to stop the engine. eascores Start switch “START” The starter motor cranks the engine when pushing the start switch. Evusore0 STION: See starting instructions prior to starting the engine.eAsr0008 Clutch lever The clutch lever is located on the left han- dlebar, and the ignition circuit cut-off sys- tem is incorporated in the clutch lever holder. Pull the clutch lever to the handle- bar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to the engine starting procedures for a de- scription of the ignition circuit cut-off sys- tem.) 27 AB80001 Shift pedal 1, Shift pedal N. Neutral This motorcycle is equipped with a con- stant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting.AB90001 A990101 Front brake lever Rear brake pedal 1. Front brake lever 1. Rear brake pedal The front brake lever is located on the right The rear brake pedal is on the right side of handleber. Pull it toward the handlebar to __the motorcycle. Press down on the brake apply the front brake. pedal to apply the rear brake. 28eacoosor Fuel tank cap 1. Open TO OPEN: Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened. TO CLOSE: Position the “4” mark so it is facing for- ward and push downwards. euuorze0 NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be re- moved if the cap is not locked properly. EUu6r100 AWARNING Be sure the cap is properly installed and locked in place before riding the motorcy- cle.eAcio10s Fuel cock OFF 1. Arrow mark 1. Arrow mark The fuel cock supplies fuel from the tank to ON: With the fuel cock in this position, the carburetors while filtering it also. fuel flows to the carburetors. Set the The fuel cock has three positions: fuel cock to this position when start- OFF: With the fuel cock in this position, ing the engine and while riding. fuel will not flow. Always set the fuel cock to this position when the en- gine is not running. 240EAC20502 Starter “CHOKE” RES 1. Arrow mark RES: This indicates reserve. If you run out of fuel while riding, move the fuel cock to this position. Fill the tank at the first opportunity. Be sure to set the fuel cock back to “ON” after refu- eling! 1. Starter “CHOKE” Starting a cold engine requires a richer air- fuel mixture. A separate starter circuit sup- plies this mixture. Move in direction @ to turn on the starter. Move in direction @ to turn off the starter.Eaca0401 Steering lock OFF (Push) Lock (Push) @ coy The steering is locked when the main switch is turned to “LOCK”. To lock the steering, turn the handlebars all the way to the left. With the key at “OFF”, push it into the main switch and release it, turn it coun- terclockwise to “LOCK”, and remove it. To release the lock, turn the key to “OFF”. 1. Push 2. Release 3. Turn euust400 PGI Never turn the key to “LOCK” when the motorcycle is moving.excosioa Parking With the main switch in the “LOCK” posi- tion, push the key into the main switch, re- lease it, and then turn to the “P” position. The battery can discharge from extended 2| use of the “P” position. 213 1. Open 1. Passenger seat To remove the seat, insert the key in the lock and turn it clockwise. When reinstalling the seat, insert the lobe on the rear of the seat into the receptacle on the end cover, then push down the seat. 2. Rider seat a. Remove the passenger seat and then pull upward on the rear of the rider seat.b. When reinstalling the rider seat, insert the lobes on the seat front into the re- ceptacle on the frame and fit the hitch over the stopper. c. Reinstall the passenger seat. euuor700 NOTE; Make sure that the seat is securely fitted.Helmet holder 1. Hotmet holder 2. Open To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder in its original position. euur2000 AWARNING Never ride with a helmet in the helmet holder. The helmet may hit objects, caus- ing loss of control and possibly an acci- dent. Rear shock absorber A WARNING This shock absorber contains surized nitrogen gas. Read and under- stand the following information before handling the shock absorber. The manu- facturer cannot be held responsible for property damage or personal injury that may result from improper handling. 1. Do not tamper with or attempt to open the cylinder assembly. Do not subject the shock absorber 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 c in any way. Cylinder damage will re- sult in poor damping performance. . Take your shock absorber to a Yamaha dealer for any service. 2.ensreot Rear shock absorber adjustment ‘2. Increase spring preload _b. Decrease spring preload This shock absorber is equipped with a spring preload adjuster. Adjust spring pre- load as follows. Turn the adjusting ring in direction @ to increase spring preload and in direction © to decrease spring preload. easozeot EXUP (Exhaust ultimate powervalve) This model is equipped with an EXUP sys- tem within the exhaust pipe. This valve is always actuated by a computer-controlled servomotor in accordance with engine rpm. evutzeor GAUTION, © The EXUP was set at the Yamaha fac- tory after many tests. If the settings are changed by someone without suf- ficient technical knowledge, poor en- gine performance and damage may result. if the EXUP does not operate, ask a Yamaha dealer to inspect. Star. dard — Hard Soft ‘Adjusting Position 3 The EXUP servomotor can be heard in the following instances: @ When the main switch is turned on and the engine is started. @ When the engine stalls while the main switch is on.Eaoso101 Sidestand 1. Sidestand switch This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 4-2 for an explanation of this system.) 247 euuse801 AWARNING This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the opera- tor, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a malfunction, re- turn the motorcycle to a Yamaha dealer immediately for repair.EADs0e2 Sidestand/clutch switch operation check Check the operation of the sidestand switch and clutch switch against the infor- mation below. TURN THE MAIN SWITCH TO “ON” AND. THE ENGINE STOP SWITCH TO “RUN”. i SIDESTAND IS DOWN. i ENGINE WILL STALL. 1 SIDESTAND SWITCH IS OK. TRANSMISSION IS IN GEAR AND SIDESTAND IS UP. PULL IN CLUTCH LEVER AND. PUSH THE START SWITCH. | ENGINE WILL START. | CLUTCH SWITCH IS OK. ' Evuse100 A WARNING If improper operation is noted, consult a Yamaha dealer immediately.PRE-OPERATION CHECKS PRE-OPERATION CHECKS 3-1 Cast wheels and tires Accessories or replacement parts... 3-13 Chassis fasteners... Lights, signals and switches Battery. Fuel...Before using this motorcycle, check the following points: No, TEM ROUTINE PAGE * Check operation, free play, fluid level and fluid leakage. 1 | Front brake + Fill with DOT 4 brake fluid if necessary. 33-34, = Check operation, fluid level and fluid leakage. 5:27 ~ 5-33 i] eae + Fill with DOT 4 brake fluid if necessary. = Check operation, condition and free play. 3 | Clutch + Adjust if nesessary. cau — * Check engine oil level. 35-36, 4 [Engine oil + Fill with oil if necessary. 5-15 ~ 5-19 ; = Check chain slack and condition. 5 | Drive chain liloe it nocessare 3-8, 5-35 ~ 5-37 ; + Check for coolant level and leakage. 6 |Engine coolant | . Fill with coolant if necessary. ascend 7 | Throttle + Check for smooth operation. 35, 5-38 * Check fluid level. 8 | Battery + Fill with distilled water if necessary. Sale caeedait Lights, signals and | _ ; 44, 588.6! 9 | Ushes, st Check operation. 3-14, 5-48 ~ 5-50 70 | Wheels/tires + Check tire pressure, wear and damage. 38-313 11 Chassis fasteners |_| * check of tightness of all chassis nuts, bolts and screws. ana + Tighten if necessary.NOTE:. Pre-operation checks should be made each time the motoroycle is used. Such an inspec- tion can be thoroughly accomplished in a very short time, and the added safety it assures is more than worth the time involved. PGT 1. The engine, exhaust system will be very hot after the engine has been run. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair. 2. If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating the motorcycle. 32EAEraR08 Brakes 1. Brake lever and brake pedal Check for correct free play in the front brake lever and correct rear brake ped- al height. Adjust if necessary. Make sure the brakes are working properly by checking at low speed shortly after starting out. (See page 5-27 for de- tails.) euuste00 POG A soft, spongy feeling in the brake lever (and/or brake pedal) tes a failure in the brake system. Do not operate the mo- torcycle until the failure in the brake sys- tem is corrected, Ask a Yamaha dealer for immediate repairs. A soft, spongy feeling could indicate a hazardous condition in the brake system. 2. Brake fluid Check the brake fluid level. Fill the master cylinder with brake fluid if nec- essary. (See page 5-32 for details.) Recommended brake fluid: DOT 4 3. Check the disc pads. (See page 5-31 for details.) evuoz201 NOTE; ———_________ When this brake service is necessary, con- sult a Yamaha dealer. 33exero72 Brake fluid leakage Apply each brake for a few minutes. Check to see if any brake fluid leaks out from the pipe joints or the master cylinders. euus7a0 Brake flu faces or plastic parts. Never spill any fluid. If spilled, clean it up immediately. uus2500 AWARNING If brake fluid leakage is found, ask a Yamaha dealer for immediate repairs. Such leakage could indicate a hazardous easzoon2 Clutch Check the free play in the clutch lever and make sure the clutch operates properly. If the free play is incorrect, adjust it. (See page 5-34 for details.)eaesor08 Actos Throttle grip Engine oil Make sure the engine oil is at the specified level. Fill with oil as necessary. (See page 5-15 for details.) 2. Free play Turn the throttle grip to see if it operates properly. Make sure the grip returns by spring force when released. There should be a free play of 3 ~ 5 mm (0.12 ~ 0.2 in) at the throttle grip. If the free play is incorrect, ask a Yamaha dealer to make this adjust- ment. 35Recommended oil: Se a ie YAMALUBE 4 (20W40) or SAE 20W40 type SE motor oil YAMALUBE 4 (10W30) or Tee SAE 10W30 type SE motor oil orc BC 1 Recommended engine oil classification: API Service “SE”, “SF” type or equivalent (e.g. “SF-SE”, “SF-SE-CC”, “SF-SE-SD” etc.) Oil quantity: Total amount: 3.0 L (2.6 Imp at, 3.2 US qt) Periodic oil change: 2.2L (1.9 Imp qt, 2.3 US qt) With oil filter replacement: 2.5L (2.2 Imp qt, 2.6 US qt)E6000 Coolant 1. Maximum level mark 2. Minimum level mark Check the coolant level in the reservoir tank when the engine is cold. The coolant level will vary with engine temperature. The coolant level is satisfactory if it is be- tween the minimum and maximum marks on the tank. If the coolant level is at or be- low the minimum mark, fill with tap water (soft water) to bring the level up to the maximum mark. Change the coolant every two years. (See page 5-20 for details.) 37 euue2600 A WARNING Do not remove the radiator cap when the engine is hot. CAUTION: Hard water or salt water is harmful to the engine. You may use distilled water if you can’t get soft water. e Reservoir tank capacity: 0.28 L (0.25 Imp qt, 0.30 US qt)excsoo01 Chain Check the general condition of the chain and the chain slack before every ride. Lu- bricate and adjust the chain as necessary. (See page 5-35 for details.) 38 eAzsz008 Tires To ensure maximum performance, long service and safe operation, note the fol- lowing: 1, Tire air pressure Always check and adjust the tire pres- sure before operating the motorcycle. evus7s00 AWARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, sad- dlebags, etc. if approved for this model), and vehicle speed.Sts iy arm enced 152 kg (335 Ib) (FZR600C) Cold tire pressure: Front Rear Up to 90 kg (198 Ib) load* |(2.25 kaf/em2,| (2.5 kgticm?, gota rset) ioat~ | Sagem? | as tater, jaximum loa¢ 36 psi) 42 psi) High speed riding (2.5 kgf/em’, | (2.9 kgf/cm? seeat | aun * Load is the total weight of cargo, rider, passenger and accessories. 39 uu67701 A WARNING Proper loading of your motorcycle is im- portant for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Se- curely pack your heaviest items close to the center of the motorcycle, and distrib- ute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pres- sure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if ap- proved for this model) does not exceed the maximum load of the motorcycle. Op- eration of an overloaded motorcycle could cause tire damage, an accident, or even in- jury.1. Tread depth 2, Side wall 3, Wear indicator 2. Tire inspection Always check the tires before operat- ing the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire re- placed. ‘Minimum tire tread depth {front and rear) Soy euuse001 GIT It is dangerous to ride with a worn-out tire. When a tire tread begins to show lines, have a Yamaha dealer replace the tire immediately. Brakes, tires and related wheel parts replacement should also be left to a Yamaha dealer. 3. Tire information This motorcycle is equipped with tubeless tires, tire valves and cast wheels.UU76700 ® ® @® AWARNING i a @ After extensive tests, the tires men- tioned below have been approved by Yamaha Motor Co., Ltd. for this mod- el. No guarantee for handling charac- can be given if tis proved are used on this motorcycle, 1. Tievalve 2. Valvosore 3. Valve capwith sea! The front and rear tires should be of the same manufacture and design. FRONT: © The use of tire valves and valve cores eens a Type. other than listed below could cause patel ee = tire deflation during extreme high etre une ZR MP7 speed riding, Always use genuine | 2u"! T0779 vRI7-v240_| SPORT MAX parts or their equivalent for replace- Bridgestone 140/79 VR17-V240_|_CYROX-17 ment. REAR: © Be sure to install the valve caps se- Manufacturer Size Type curely, as these are important to pre- Michelin 149/60 ZR18- M59 vent air pressure leakage during | Pirelli 140/60 ZR18: MP7 extreme high speed riding. Dunlop 740/60 VR18-V240_| SPORT MAX SS Bridgestone 140/60 VR18-V240_ CYROX-16Type Tire valve TRAIZ Valve core 4#9000A (Genuine) 312 evurren2 AWARNING This motorcycle fitted with super high- speed running tires. The following points must be observed in order for you to make fully effective use of these tires. 1. Never fail to use the specified tires in tire replacement. Other tires may have a danger of bursting at super high-speeds. . New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approxi- mately 100 km (60 mi) should be trav- eled at normal speed before any high- speed riding is done. . Before any high-speed runs, the tires should be warmed-up sufficiently. }. Always inflate to the correct tire pres- sure according to the operating con: tions.eaeosr01 Cast wheels and tires To ensure maximum performance, long service, and safe operation, note the fol- lowing: 1. Always inspect the wheels before a ride. Check for cracks, bends, or warpage of the wheels. If any abnor- mal condition exists in a wheel, con- sult a Yamaha dealer. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced. . Tires and wheels should be balanced whenever either one is changed or re- placed. Failure to have a wheel bal- anced can result in poor performance, adverse handling characteristics, and shortened tire life. . Ride at moderate speeds after chang- ing a tire since the tire surface must first be broken in for it to develop its optimal characteristics. 3413 EAES2800 Accessories or replacement parts euve9700 POZE This motorcycle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your motorcycle should be de- signed specifically for it, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are de- signed and tested to be compatible with your motorcycle. Please consider Genuine Yamaha Parts and Accessories before making an accessory purchase. Use of non- Yamaha-approved parts or accessories may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of parts or accessories manu- factured by other companies, Yamaha can- not be held liable for any consequences caused by the use of items which have not been approved by Yamaha.eacesi01 Chassis fasteners Always check the tightness of all chassis nuts, bolts and screws before a ride. Take the motorcycle to a Yamaha dealer or refer to the Service Manual for correct tighten- ing torque. Eaeriso0 Lights, signals and switches Check all the lights, meter lights and indi- cator lights to make sure they are in work- ing condition. Check the operation of the handlebar switches and main switch.encrosoe Battery Check the fluid level and fill if necessary. Use only distilled water if refilling is neces- sary. (See page 5-43 for details.) 315 Fuel 1. Filler tube 2. Fuel level Make sure there is sufficient fuel in the tank. Euust000 WARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may over- flow when the fuel heats up later and ex- pands.Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may rate painted surfaces or plastic 3:16 EAEST7ON Recommended fuel: UNLEADED FUEL Fuel tank capacity: Total: 18.0 L (4.0 Imp gal, 4.8 US gal) Reserve: 3.4L (0.7 Imp gal, 0.9 US gal) Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+MV/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium un- leaded fuel. Unleaded fuel will give you longer spark plug life and reduced mainte- nance cost. If unleaded gasoline is not available, then leaded regular gasoline can be used.Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle per- formance problems. 347AF00000 OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine.. Starting a warm engine. +5 Shifting, -6 To start out and accelerate .. 4-6 To decelerate. Recommended shift poin Engine break-in... Parking...euus7201 AWARNING 1. a° Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thorough- ly understand. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always op- erate your motorcycle in an area with adequate ventilation. . Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner. 41 1. Be careful where you store personal items on the motorcycle. Avoid block- ing the air cleaner intake or perfor- mance will suffer. . Be careful not to put anything near the battery and its terminals. Electri- cal failure and acid corrosion may re- sult.exer Starting and warming up a cold engine uum NOTE: This motorcycle is equipped with an igni- tion circuit cut-off system. 1. The engine can be started only under the following conditions: a. The transmission is in neutral. b. The sidestand is up, the transmission is in gear and the clutch is disengaged. 2. The motorcycle must not be ridden when the sidestand is down.euuse200 AWARNING Before going through the following steps, check the function of the sidestand switch and clutch switch. (Refer to page 2-18.) TURN MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “RUN”, ee IF THE TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF THE TRANSMISSION IS IN GEAR AND i SIDESTAND IS UP, PUSH THE START SWITCH. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START. y RETRACT THE SIDESTAND AND PUT TRANSMISSION IN GEAR. y MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN. 431. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “RUN”. 3. Shift transmission into neutral. euuo0001 NOTE; When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 4, Turn on the starter “CHOKE” completely close the throttle grip. 5. Start the engine by pushing the start switch. evunesor NOTE; If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possi- ble to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. and euuassor The oil level indicator light should come on when the start switch is pushed and should go off when the start switch is re- leased. If the indicator light flickers or re- mains on, immediately stop the engine and check the engine oil level and for oil leakage. If necessary, fill the engine with oil and check to see that the oil level indi- cator light goes off. If the light does not go off even with sufficient oil in the crankcase or the light does not come on when push- ing the start switch, consult a Yamaha dealer. 6. After starting the engine, turn off the starter. The starter operation periods differ with the ambient temperature. Refer to the following notes.earv0802 Starting a warm engine EUUO310" The starter “CHOKE” is not required when NOTE: the engine is warm. @ The engine is warm when it responds —«vus1401 normally to the throttle with the start- i er turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter circuit on longer than necessary. The length of time the starter is needed depends upon the ambient temperature. Warm ambient temperatures (above 10°C/50°F) re- quire about 7 seconds of starter use. Cold ambient temperatures (below 10°C/50°F) require about 35 seconds with the starter turned on, then about 2.5 minutes with the starter in the half- way position. For maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine. See the “Engine break-in” section p operating the motorcycle for the first time.£20009 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift ped- al is shown in the illustration. (Page 2-7) To shift into neutral, depress the shift ped- al repeatedly until it reaches the end of its travel, then raise the pedal slightly. Euusts01 1. Do not coast for long periods with the engine off, and do not tow the motor- cycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. 2. Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to with- stand the shock of forced shifting and can be damaged by shifting without using the clutch. EAF20101 To start out and accelerate: 1. 2. 3. Pull the clutch lever to disengage the clutch. Shift into first gear. The neutral indica- tor light should go out. Open the throttle gradually, and at the same time, release the clutch lever slowly. . At the recommended shift point in the table below, close the throttle, and at the same time, quickly pull in the clutch lever. . Shift into second gear. (Be careful not to shift into neutral.) . Open the throttle part way and gradu- ally release the clutch lever. . Follow the same procedure when shifting to the next higher gear. Al- ways shift gears at the recommended shift points.EAF20002 To decelerate: 1. Apply both the front and the rear brakes at the same time to slow the motorcycle. When the motorcycle reaches 25 km/h (15.5 mish), shift into first gear. Any time the engine is about to stall or runs very roughly, pull in the clutch and use the brakes to stop. When the motorcycle is almost com- pletely stopped, shift into neutral. The neutral indicator light should come on. Recommended shift point — ‘Acceleration 7 shift point shift point km/h (mish) km/h (mifh) ist > 2nd 1619.9) = and > 3rd 24(14.9) - 3rd > 4th 32(19.9) 25 (15.5) ath > Sth 40 (24.9) 25 (15.5) Sth — 6th 48.(29.9) 25 (15.5),earsooco Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km (600 mi). For this reason we ask that you carefully read the following material, Because the engine is brand new, you must not put an exces- sive load on it for the first 1,000 km (600 mi). The various parts in the engine wear and polish themselves to the correct oper- ating clearances. During this period, pro- longed full throttle operation, or any condition which might result in excessive heating of the engine, must be avoided. 48 earsove2 1. 0 ~ 150 km (0 ~ 90 mi): Avoid operation above 5,000 r/min. Stop the engine and let it cool for 5 to 10 minutes after every hour of opera- tion. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position. 2. 150 ~ 500 km (90 ~ 300 mi): Avoid prolonged operation above 6,500 r/min. Rev the motorcycle freely through the gears, but do not use full throttle at any time. 3. 500 ~ 1,000 km (300 ~ 600 mi): Avoid prolonged full throttle opera- tion. Avoid cruising speeds in excess of 5,000 r/min. evus2001 After 1,000 km (600 mi) of operation, be sure to replace the engine oil and4. 1,000 km (600 mi) and beyond: Full throttle can be used. euu2e701 Never let engine speeds enter the red zone. © If any engine trouble should occur during the break-in period, consult a ‘ Yamaha dealer immediately. 49 exewor1 Parking When parking the motorcycle, stop the en- gine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine. euvesoo1 PGI The exhaust system is hot. Park the mo- torcycle in a place where pedestrians or children are not likely to touch the motor- cycle, Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn.PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance Tool kit Periodic maintenance e1 contrcl system.. General maintenance/lubricatior Spark plug inspection Canister (for California only) Cowling/panel removal and installation .. Top cover removal 515 Engine oil 515 Cooling system Radiator fan Air filter, Carburetor adjustment Valve clearance adjustment... Front brake lever free play adjustment .. 5-27 Rear brake pedal height adjustment. Brake light switch adjustment. Checking the front and rear brake pads. Inspecting the brake fluid level.. 5-32 Brake fluid replacement. 5-33 Clutch lever free play adjustmentt....0..5-34 Drive chain slack check. 5-35 Drive chain slack adjustment. 5-35 Drive chain lubricatio 5-37 Cable inspection and lubrication 5-37 5-38 5-38 5-39 5-39 5-40 541 542 5-43, 5-43, 5-47 5-48, 5-50 5-51 5-52 Throttle cable and grip lubrication Brake and shift pedal lubricatior Brake and clutch lever lubrication Sidestand lubrication Rear suspension lubrication Front fork inspection. Steering inspection Wheel bearings. Battery Fuse replacement. Replacing the headlight bulb... Taillight bulb replacement Troubleshootin Troubleshooting chaextoor Periodic inspection, adjustment, and lubri- cation will keep your motorcycle in the saf- est and most efficient condition possible. Safety is an obligation of the motorcycle owner. The most important points of mo- torcycle inspection, adjustment, and lubri- cation are explained in the following pages. “Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establish- ment or individual using any part which is certified (if applicable)”. uuss200 If you are not familiar with motorcycle ser- vice, this work should be done by a Yamaha dealer. EAH00900 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL. THESE CON- TROLS NOT ONLY FUNCTION TO EN- SURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOL- LOWING TABLES OF PERIODIC MAINTE- NANCE, THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES.Eaw0200 Tool kit 1. Tool kit The service information included in this manual is intended to provide you, the owner, with the necessary information for completing some of your own preventive maintenance and minor repairs. The tools provided in the owner's tool kit are to as- sist you in the performance of periodic maintenance. However, some other tools such as a torque wrench are also neces- sary to perform the maintenance correctly. 52 evut8800 NOTE; If you do not have necessary tools re- quired during a service operation, take your motorcycle to a Yamaha dealer for service. PZ GITIT Modifications to this motorcycle not ap- proved by Yamaha may cause loss of per- formance, excessive emissions, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM TNITIAL ‘ODOMETER READINGS 7 a, = aa 7 1 1,000 km | 7,000 km | 13,000 km | 19,000 km | 25,000 km | 31,000 km me = ROUTINE {600 mit | (4,400 mi) | (8-200 mi | (123000 mi | (18,800 mi | (19,600 mi month | 7 months | 13 months | 19 months | 25 months | 31 months ~ Cheek and adjust valve clearance 1] [Valve clearance |” nen engine is cold ° = Check condition + Adjust gap and clean. 2| |spark plugs | + Replace at 13,000 km (or 13 © | Reptace | © | Replace | 0 months) end thereafter every 12,000 km (or 12 months) Ne ~ Check breather hose for eracks or } ° }° a]. |Crankease damage ° ° breather system | . Replace it necessary. ~ Check fuel hose for eracks oF 4] +|Fuettine samat ° ° ° ° ° + Replace i necessary. ~ Replace initial 31,000 kr (19,600 5| + | Fue ter mil and thereafter every 30,000 Replace km (19,000 mi ~ Check for leakage, 6| + | Exhaust system | Retighten if necessary. ° ° ° ° ° + Replace gaskets) if necessary. | [Carburetor |= Adjust synchronization of 7|*| Synchronization | carburetors ° 2 2 2 2 2 Check and edjust engine ile 8| + 1dte speed speed ° ° ° ° ° + Rajust throttle cable free play. 53INITIAL ODOMETER READINGS wT 72 73 4 No. iTem ROUTINE 1,000 km | 7,000 km | 13,000 km | 19,000 km | 25,000 km | 31,000 km (600 mi) | (4,400 mi) | (8,200 mi | (12,000 mi) | (15,800 mi | (19,600 mil month | 7months | 13 months | 19 months | 25 months | 31 months Evaporative |» Chock control system for 9+ emission contro! | damage. ° ° Feel + Replace if necessary Items marked with an asterisk *) require special tools, data and technical skills for servicing. Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing these ites. ++ For California type only NOTE: For farther odometer reading, repeat the above maintenance at the period established; **1: Every 6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi), **3: Every 24,000 km (15,200 mi) and **4: Every 30,000 km (19,000 mi) intervals. 64GENERAL MAINTENANCE/LUBRICATION TNTIAL ‘ODOMETER READINGS Gal aa 75 7 REMARKS we 14000 km | 7,000 km | 13,000 km | 19,000 km | 26,000 km | 31,000 km od ee {600 mi) | (4,400 mi) | (8,200 mi} | (123000 mi (16,800 mi | (19/600 mi) month | 7 months |13 months | 19 months | 25 months | 31 months TTYAMALUBE @ (2040) or ae SAE 20040 type "SE" motor 1) | enaineot |" engine Betore| sa vaiAr uses ° ° ° ° ° ° (1030) or SAE 10WV20 type "SE" motor 0 2 [= [oirfiker [> Replace o 3 o Clean with compressed a} ef ainmer | air ° ° ° ° ° + Replace i necessary Cheek hose for cracks or damage. : ° ° ° ° ° . + Replace i 4] +1 Sfetene necessary Replace Ethylene glycol coolant every Replace goolant every | antifreeze coolant Agius free 5 play. . 5 + Replace pads ) ) i) iS ic iS itnecessary. 55TRTAL “ODOMETER READINGS 7 wa, ees _ REMARKS Tye 1,000 km | 7,000 km | 13,000 km | 19,000 km | 25,000 km | 31,000 km a iM {600 mi) | (4,400 mi) | (8,200 mi) | (12,000 mi) | (15,800 mi) | (19,600 mi) or or or or oF or ‘imonth_| 7 months | 13 months | 19 months | 25 months | 31 months 6| | cuter cane ° ° ° ° ° ° + Check chain condition. «| privechain |*Adiust and | SAE sow-sow svery 600 km 7| +] Drivechain |" Adiustand | SAE sovy Every 600 km (300 mi) chain thoroughly. Apply chain | Vamaha chain and 8| + | Conti ard | tube cable lube or SAE ° ° ° ° ° ° meter cal thoroughly. 10W30 motor oil Rear arm pivorshatt | 9, Le + Apply grease | Molybdenum 9] fa sion | URIS | Gsufi groase ° link pivots Brake/clutch Yamaha chain and }10] | teverpivor |" ApPIVchaIN | cable lube or SAE ° ° ° ° ° shafts lonely. 10W30 motor oi Brake podal | Lubric Yamaha chein and 11) * | and shift + Apply chain | cable lube or SAE ° ° ° ° oO edalshatts |"iube lightly. | 1030 motor oi Check ‘operation and | Yamaha chain and 112] «| Sidestand | lubricate cable lube or SAE ° ° ° ° ° + Apply chain | 10W30 motor oil lube light 56NIAC ‘ODOMETER READINGS a a no. | mem | REMARKS ae 1,000 | 7,000 rm | 13,000 km | 19,200 km | 25,000 km | 31,000 km {600 mi) | (4400 mi) | (8-200 mn | 12.000 mi | (15,800 mi] (1,600 mi month | 7 months |13 months | 19 months | 25 months | 31 months 7 Check 13| * | Front fork operation and fe} oO oO fe} fe) feokage ~ Check bearing assombly for | steering | iooseness. | Lithium soap base ie bearings + Moderately grease. ° i) i) So iS repack every 24,000 km {18,200 mi. 7 Check . bearing for a smooth ° ° ° ° ° rotation. ~ Check specific gravity and 16| | Battery ° ° ° ° ° operation ~ Check and | sidestand |" clean or 7) * | switet replace if ° ° c ° ° ° necessary. +1) If ambient temperature does not go below 5°C/40"F *2) if ambient temperature does not go below 15°C/60°F. Items marked with an asterisk (*} require special tools, data and technical skills for servicing. Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing the items. 57NOTE:. For farther odometer reading, repeat the above maintenance at the period established; **1: Every 6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi) and **3: Every 24,000 km (15,200 mi) intervals. ewuzisoo NOTE: © The air filter needs more frequent service if you are riding in unusually wet or dusty ar- eas. © Brake fluid replacement 1. When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. 2. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder ev- ery two years. 3. Replace the brake hoses every four years or if cracked or damaged. 58eanzore2 Spark plug inspection MM 1. Spark plug gap The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. Normally, all spark plugs from the same engine should have the same color on the white insulator around the center elec- trode. The ideal color at this point is a me- dium-to-light tan color for a motorcycle that is being ridden normally. If one spark plug shows a distinctly different color, there could be something wrong with the engine. 59 Do not attempt to diagnose such problems yourself. Instead, take the motorcycle to a Yamaha dealer. You should periodically remove and inspect the spark plugs be- cause heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion becomes exces- sive, or if carbon and other deposits are ex- cessive, you should replace the spark plug with the specified plug. Specified spark plug: CR9E (NGK) U27ESR-N (DENSO) Before installing any spark plug, measure the electrode gap with a wire thickness gauge. Adjust the gap to specification. Spark plug gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten the spark plug to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m-kg, 9.0 ft-lb) evuaae0 NOTE; If a torque wrench is not available when you are installing a spark plug, a good esti- mate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tight- ened to the specified torque as soon as possible.exieoos Canister (for California only) This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before using this motor- cycle be sure to: 1. Check each hose connection. 2. Check each hose and canister for cracks or damage. Replace if dam- aged. 3. Make sure the vent hose is not blocked. Clean it if necessary. Roll over valve assembly Carburetor Fuel tank Canistereavorioa Cowling/panel removal and installation 1. Cowling A 2, Panel B 3. Top cover The cowlings/panels indicated in the illus- tration need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a cowling/panel has to be removed or rein- stalled. 512eapst602 Cowling A To remove: To install: Remove the bolts shown and disconnect Place in the originel position, install the the turn signal leads. bolts and connect the turn signal leads. 513avo2s00 Panel B Removal: Installation: 1. Remove the seats. 1. Fit the tabs on the side cover into the 2. Remove the bolts and pull outward on slots in the end cover. the areas shown. 2. Insert the projections on panel B into 3. Pull the rear portion of panel B slightly the grommets in the frame. downward to remove. 3, Tighten the bolts and reinstall the seats.EAcT2401 Top cover removal enuteror Engine oil . Remove the seats. . Remove the top cover bolts. 5. Remove the fuel tank cap, then re- move the top cover. euur6800 NOTE; Temporarily install the fuel tank cap on the fuel tank when the top cover is removed. wNs 515 1. Level window 3. Minimum level mark 1. Oil level inspection a. Place the motorcycle on a level place and hold it in an upright position. Warm up the engine for several min- utes. euuesso1 NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. 2. Maximum level markb. With the engine stopped, check the oil level through the level window locat- ed at the lower part of the right side crankcase cover. euvo4o00 NOTE: Wait a few minutes until the oil level set- tles before checking. c. The oil level should be between maxi- mum and minimum marks. If the level is low, fill the engine with sufficient oil to reach the specified level. 1. Oilfiller cap 2. a. Remove the lower cowling. b. Engine oil and oil filter cartridge re- placement Warm up the engine for several min utes. . Stop the engine. Place an oil pan un- der the engine and remove the oil filler cap.Stay 2. Engine oll drain plug d, Remove the lower cowling stay. e. Remove the drain plug and drain the oil. 1. Oil fiter 2, Oil filter wrench f. Remove the oil filter by using an oil fil- ter wrench. evursoot NOTE: An oil filter wrench is available at a nearby Yamaha dealer. g. Reinstall the drain plug and tighten it to the specified torque. Tightening torque Drain plug: 43 Nm (4.3 m-kg, 31 ft-lb)1, Oring h. Apply a light coat of engine oil to the O-ring of the new oil filter. ewvosnor NOTE: ——______ Make sure the O-ring is seated properly. 1. Torque wrench i. Install the oil filter and tighten it to the specified torque with an oil filter wrench. Tightening torque: Oil filter: 17 Nm (1.7 m-kg, 12 ft-lb) j. Fill the engine with sufficient oil to reach the specified level. Install the oil filler cap and tighten. Recommended oil: See page 3-6.evus2001 euussi01 If the indicator light flickers or remains on, Engine oil also lubricates the clutch immediately stop the engine and consult and additives could cause clutch slip-__ with a Yamaha dealer. page. ee @ Be sure no foreign material enters the: Install the lower cowling stay and low- crankcase. er cowling. k. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. I. After the engine is started, the oil level indicator light should go off if the oil is at the specified level.enero Cooling system 1. If your motorcycle overheats euvro%01 PNUZUNN 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 inju- ry. Open the radiator cap as follows. Wait until the engine has cooled. Place a thick rag like a towel over the radiator cap and slowly rotate the cap counterclock- wise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. If overheating is detected, perform the fol- lowing checks. Engine overheating 1 Check the cooling system for leakage. Wait until the engine has cooled. Refer to preced- ing WARNING No teakage | [__Leakage ‘heck the coolont level eanomeat| | Ges oaea sndor radiate. ee a ‘CORRECT { Restart the engine. ifthe ‘engine overheats again, ‘aska Yamaha dealer to ingpect and repair it. euvoisoo Note; If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the rec- ommended coolant as soon as possible.1. Radiator cap 1. Coolant drain bolt («21 2. Changing the coolant e. Remove the drain bolts. a. Remove the seats, top cover, panel B and cowling A. (See page 2-13 ~ 2-14, 5-13 ~ 5-15.) b. Temporarily install the fuel tank cap. c. Place a container under the engine. d. Remove the radiator cap.1. Coolant drain bott 1, Reservoir tank hose f. Disconnect the reservoir tank hose on the reservoir tank side, and drain the reservoir tank of its coolant. Ly 522g. Drain the coolant completely, and thoroughly flush the cooling system with clean tap water. h, Retighten the drain bolts. If the gasket is damaged, replace it. Tightening torque: Drain bolt : 7.Nm (0.7 m-kg, 5.1 ft-lb) i. Reconnect the reservoir tank hose. j. Pour the recommended coolant into i the radiator until it’s full. Recommended coolant: High quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixed ratio: 50/50% Total amount: 2.2L (1.9 Imp qt, 2.3 US at) Reservoir tank capacity: 0.28 L (0.25 Imp qt, 0.30 US at) From minimum to maximum level: 0.18 L (0.16 Imp qt, 0.19 US at) euuses00 Hard water or salt water is harmful to the engine. You may use distilled water if you can't get soft water.k. Reinstall the radiator cap. |. Run the engine several minutes to re- check the coolant level in the radiator. If itis low, fill with more coolant until it reaches the top of the radiator. m. Fill the reservoir tank with coolant up to maximum level. n. Reinstall the reservoir tank cap and check for coolant leakage. evuotaoo a If you find any leaks, ask a Yamaha dealer to inspect. o. Reinstall cowling A, panel B, the top cover and seats. (See page 2-13 ~ 2-14, 5-13 ~ 5-15.) 5-24 eanroon Radiator fan Operation The radiator fan operation is completely automatic. It is switched on or off accord- ing to the coolant temperature in the radia- tor.Eanss403 Air filter The air filter should be cleaned at the spec- ified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas. 1. Remove the top cover. 2. Temporarily install the fuel tank cap. 5-25 op . Remove the air filter case cover by re- moving the screws. . Pull out the air filter. . Tap the air filter lightly to remove most of the dust and dirt and blow out the remaining dirt with compressed air as shown. If the air filter is dam- aged, replace it.6. Reassemble by reversing the removal procedure. 03 CAUTION, @ Make sure the air filter is properly seated in the air filter case. © The engine should never be run with- out the air filter installed. Excessive piston and/or cylinder wear may re- sul anoa002 Carburetor adjustment The carburetors are important parts of the engine and emission control system. Ad- justing should be left to a Yamaha dealer with the professional knowledge, special- ized data and equipment to do so properly.envioosor Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. eanooioa Front brake lever free play adjustment 1. Locknut 3. 1-3 mm (0.04 0.12) The free play at the front brake lever should be 1 ~ 3mm (0.04 ~ 0.12 in). . Loosen the locknut. 3 Turn the adjusting bolt in direction @ to increase free play or in direction © to decrease free play. 3. After adjusting, tighten the locknut. 2. Adjusting bolt 5:27eEuueTs00 AWARNING @ Check the brake lever free play. Be sure the brake is working properly. © A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. This air must be removed by bleeding the brake sys- tem before the motorcycle is operat- ed. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer in- spect and bleed the system if neces- ‘Sary.anooeo2 Rear brake pedal height adjustment a. 44mm (17 in} The top of the brake pedal should be posi- tioned 44 mm (1.7 in) below the top of the footrest. If not, ask a Yamaha dealer to ad- just it. 5-29 EUUT9300 POZGIMTS A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system cause greatly dit it pability and can result in loss of control and an accident. Have a Yamaha dealer in- spect and bleed the system if necessary.EAHe3202 Brake light switch adjustment 1. Cover 1. Main body 2. Adjusting nut The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect. To adjust the rear brake light switch, hold the switch body so it does not rotate while turning the adjust- ing nut. Turn the adjusting nut in direction @ to make the brake light come on earlier. Turn the adjusting nut in direction ® to make the brake light come on later. 5-30Checking the front and rear brake pads Rear o fo VA L_~< 1. Wear indicator 1, Wear indicator A wear indicator is provided on each brake. This indicator allows checking of i brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator. If the indicator is ALMOST in contact with the disc plate, ask a Yamaha dealer to replace the pads.Inspecting the brake fluid level Front 1. Minimum level mark Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and replenish when necessary. Observe these precau- tions: 1. When checking the fluid level, make sure the top of the master cylinder is level by turning the handlebars. 5-32 1, Minimum level mark 2. Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. Recommended brake fluid: DOT 4 3. Refill with the same type of brake flu- id. Mixing fluids may result in a harm- ful chemical reaction and lead to poor brake performance.4. Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boil- ing point of the fluid and may result in vapor lock. . Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. . Have a Yamaha dealer check the cause if the brake fluid level goes down. 5-33 canes Brake fluid replacement 1 Complete fluid replacement should be done only by trained Yamaha service personnel. . Have a Yamaha dealer replace the fol- lowing components during periodic maintenance or when they are dam- aged or leaking. . Replace all rubber seals every two years. . Replace all hoses every four years.eaoans Clutch lever free play adjustment or a oh xOv 1. Free play 2. Locknut 3, Adjusting bolt The clutch lever free play should be adjust- ed to 8 ~ 12 mm (0.31 ~ 0.47 in). If the free play is incorrect, adjust as follows. 1. Loosen the locknut. 2. Turn the adjusting bolt at the clutch le- ver in direction @ to increase free play or indirection © to decrease free play. 3. Tighten the locknut. 534 euurre00 NoTe: If proper adjustment cannot be obtained or the clutch does not work correctly, ask a Yamaha dealer to inspect the internal clutch mechanism.eauoeor Drive chain slack check eauzaoe Drive chain slack adjustment a, 20~ 30 mm (0.8 ~ 1.2in} uu04801 NOTE:. Spin the wheel several times and find the tightest position of the chain. Check and/or adjust the chain slack while it’s in this tightest position. To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider. Check the slack at the position shown in the illustra- tion. Normal slack is approximately 20 ~ 30 mm (0.8 ~ 1.2 in). If the slack exceeds 30 mm (1.2 in), adjust. a. Cotter pin 4 Adjusting nut 1. 2. 3. 2. Axlenut 5. Aligrment marks Remove the cotter pin from the axle nut. Loosen the axle nut. Loosen the locknuts on each side. To tighten the chain, turn the chain ad- justing nuts in direction @. To loosen the chain, turn the adjusting nuts in di- rection © and push the wheel for- ward. Turn each adjusting nut exactly the same amount to maintain correct axle alignment. There are marks on each side of the swingarm. Use these marks to align the rear wheel.Tightening torque: Axle nut: 107 Nm (10.7 m-kg, 77 ft-lb) 5. Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown in the illustration. If the notch in the nut and the cotter pin hole 1. Cotter pin do not match, tighten the nut slightly to align them. euuee700 PROZGNTe) Always use a new cotter pin on the axle nut. evu2e201 Too little chain slack will overload the en- e and other vital parts. Keep the slack 4. After adjusting, tighten the locknuts. Then tighten the axle nut to the speci- fied torque.eAuore2 Drive chain lubrication The chain consists of many parts which work with each other. If the chain is not maintained properly, it will wear out quick- ly. Therefore, the chain must be serviced regularly. This service is especially neces- sary when riding in dusty areas. This mo- torcycle is equipped with a sealed type chain. Steam cleaning, high-pressure washes, and solvents can damage chain so do not use these for cleaning it. Use only kerosene to clean the drive chain. Wipe it dry, and thoroughly lubricate it with SAE 30 ~ 50W motor oil. Do not use any other lubricants on the drive chain. They may contain solvents that could damage the sealed chain. EUUEe200 Be sure to oil the chai motorcycle or after washing the g in the rain. 537 EAno101 Cable inspection and lubrication euusie01 AWARNING Damage to the outer housing of cables may allow internal rusting and cause in- terference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. Lubricate the inner cable and the cable end. If it does not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha Chain and Cable Lube or SAE 10W30 motor oilanaes Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubri- cated, since the grip must be removed to get at the end of the throttle cable. After re- moving the screws, hold the end of the ca- ble up in the air and put in several drops of lubricant. With the throttle grip disassem- bled, coat the metal surface of the grip as- sembly with a suitable all-purpose grease. easoave Brake and shift pedal lubrication Lubricate the pivoting parts. Recommended lubricant: Yamaha Chain and Cable Lube or SAE 10W30 motor oil 5-38asst eaataoe Brake and clutch lever lubrication Sidestand lubrication Lubricate the pivoting parts. Lubricate the sidestand pivoting and mat- ing parts. Check to see that the sidestand moves up and down smoothly. Recommended lubricant: Yamaha Chain and Cable Lube or SAE 10W30 motor oil Recommended lubricant: Yamaha Chain and Cable Lube or SAE 10W30 motor oil EuU70401 AWARNING If the sidestand does not move smoothly, consult a Yamaha dealer. 5:39easa1901 Rear suspension lubrication Lubricate the pivoting parts. Recommended lubricant: Molybdenum disulfide greaseeaosoe Front fork inspection Euu6s700 AWARNING Securely support the motorcycle so there no danger of it falling over. 1. Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. . Operation check Place the motorcycle on a level place. a. Hold the motorcycle in an upright po- sition and apply the front brake. b. Push down hard on the handlebars several times and check if the fork re- bounds smoothly. TION: If any damage or unsmooth movement is found with the front fork, consult a Yamaha dealer. EUUL2600isoz01 Steering inspection Periodically inspect the condition of the steering. Worn out or loose steering bear- ings may be dangerous. Place a stand un- der the engine to raise the front wheel off the ground. Hold the lower end of the front forks and try to move them forward and backward. If any free play can be felt, ask a Yamaha dealer to inspect and adjust the steering. inspection is easier if the front wheel is removed. 542 Euves700 Securely support the motorcycle so there is no danger of it falling over.eatsot0a Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smooth- ly, have a Yamaha dealer inspect the wheel bearings. The wheel bearings should be inspected according to the Gen- eral Maintenance Schedule. earo0ot Battery Check the level of the battery electrolyte and make sure that the terminals are tight. Fill with distilled water if the electrolyte level is low. evussen2 CAUTION: When inspecting the battery, be sure the breather hose is routed correctly. If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cos- metic damage to the motorcycle can oc- cul_- Battery 544 EUUEsE00 Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. It con- tains sulfuric acid. Avoid contact with eyes or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quant or milk. Follow with milk of magnesi: beaten egg, or vegetable oil. Call a physi- cian 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 an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDRE!1. Maximum level mark 2. Minimum level mark Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. The level should be between the minimum level and maximum level marks. Use only distilled water if refilling is necessary. evuse800 Normal which are harmful to a battery; therefore, tap water contains minerals refill only with distilled water. Euv65601 AWARNING Take care not to spill battery fluid on the chain. Battery fluid may weaken the chain causing shorter chain life and possibly re- an accident.Storage 1. When the motorcycle will not be used for a month or longer, remove the bat- tery, fully charge it and store it in a cool, dry place. Completely recharge the battery before reinstallation. . If the battery will be stored for longer than two months, check the specific gravity of the fluid at least once a month and fully recharge the battery when it is too low. . Always make sure the connections are correct when putting the battery back in the motorcycle. Make sure the breather hose is properly connected and is not damaged or obstructed. 5-46EAtg9s03 Fuse replacement euu2e400 Do not use fuses of higher amperage rat- ing than those recommended. Substitu- tion of a fuse of improper rating can cause extensive electrical system damage and possibly a fire. 1. Main fuse 2 2 Headlight fuse a 5: Ignition fuse The fuse boxes are located under the rid- er's seat. If any fuse is blown, turn off the main switch and the switch of the circuit in question. Install a new fuse of specified amperage. Turn on the switches and see if the electrical device operates. If the fuse immediately blows again, consult a Yamaha dealer. Spare fuse (x 3) Signaling system fuse Fan fuse Specified fuses: Main fuse: 320A Headlight fuse: 20A Signaling system fuse: 10 A Radiator fan fuse: 10A Ignition fuse: 10AeAierao1 Replacing the headlight bulb 1, Air duct 1. Cover 2. Bulb holder cover If the headlight bulb burns out, replace the 2. Remove the cover on the rear of the bulb as follows: headlight. 1. Remove the air duct. 3. Remove the headlight connector and the bulb holder cover. 4. Turn the bulb holder counterclockwise and remove the defective bulb.euu66002 WARNING Keep flammable products and your hands away from a bulb whil Do not touch a bulb until it cools down. 5. Put a new bulb into position and se- cure it in place with the bulb holder. evusai01 Avoid touching the glass part of a bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on a bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.1. Don’t touch 6. 7. 8. Install the bulb holder cover and the headlight connector. Install the cover on the rear of the headlight. Install the air duct. If the headlight beam adjustment is necessary, ask a Yamaha dealer to make that adjust- ment. 5-50 EAsr0401 Taillight bulb replacement 1. Remove the seat. 2. To remove the socket, turn it counter- clockwise. 3. To remove the defective bulb, turn it counterclockwise. 4. Push a new bulb into the socket and turn it clockwise. . Install the socket and turn it clockwise. . Install the seat. eaexssone Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during opera- tion. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, experience, and know-how to properly service your motorcycle. Use only genuine Yamaha parts on your mo- torcycle. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. 55151200 Troubleshooting chart Euuse300 POEM Never check the fuel system while smoking or in the vicinity of an open flame. 1. - (Check if tare i fuel | inthe fol tank [Enough fue! | ef Asks Vamana dealer to inspect No fuel [suport | ef Rasa engine 2. Compression Fkcataiones Use electric startor yy No compression Inspect 23. Ignition Remove spark a Wipe with dy cloth and wovrect, park gap or replace spat plugs plugs! and Shock slectode yy Dry — | +L aska Yarsha desler to inspect —— Engine wna aver uieky | —-[asttery goo Use oleic startar ry [Engine wr over [Check connections, [recharge 552aK00000 CLEANING AND STORAGE A. Cleaning. B. Storage...eaxorana A. CLEANING Frequent, thorough cleaning of your mo- torcycle will not only enhance its appear- ance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the motorcycle: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plugs and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the chain, sprockets or wheel axles. . Rinse the dirt and degreaser off with a garden hose. Use only enough pres- sure to do the job. euu24802 Excessive hose pressure may cause water seepage and deterioration of wheel bear- ings, front fork, brakes, transmission seals and electrical parts. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. 4. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at plac- es. 5. Rinse the motorcycle off immediately with clean water and dry all surfaces with a chamois, clean towel or soft ab- sorbent cloth. 6. Dry the chain and lubricate it to pre- vent rust.7. Clean the windscreen. 9. Automotive-type wax may be applied evuare00 to all painted and chrome-plated sur- faces. Avoid combination cleaner- waxes. Many contain abrasives which may mar the paint or protective finish on the fuel tank and side covers. When finished, start the engine and let it idle Clean the windscreen with a cloth or for several minutes. sponge dampened with a neutral de- tergent, and after cleaning, thoroughly wash it off with water. Some cleaning compounds for plastics may leave scratches on surfaces of the wind- screen. Before using them, make a test by polishing an area which does not affect your visibility. 8. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. Avoid using any alkaline or strong a cleaner, gasoline, brake fluid, or any other solvent. 62eaKoatoe B. STORAGE Long term storage (60 days or more) of your motorcycle will require some preven- tive procedures to guard against deteriora- tion. After thoroughly cleaning the motorcycle, prepare for storage as follows: 1. Fill the fuel tank with fuel and add fuel stabilizer (if available). 2. Remove each spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in each spark plug hole and reinstall the spark plugs. Turn the engine over several times (ground spark plug leads) to coat the cylinder walls with oil. uuse400 AWARNING When using the starter motor to crank the engine, remove the spark plug wires, and ground them to prevent sparking. 3. Clean the chain and lubricate it (refer to “Drive chain lubrication”). 4. Lubricate all control cables. 63 5. Block up the frame to raise both wheels off the ground. 6. Tie a plastic bag over the exhaust pipe outlets to prevent moisture from en- tering. 7. If storing in a humid or salt-air atmo- sphere, coat all exposed metal surfac- es with a light film of oil, Do not apply oil to any rubber parts or the seat cov- er. 8. Remove the battery and fully charge it. Store it in a cool, dry place and re- charge it once a month. Do not store the battery in an excessively warm or cold place (less than 0'C (30°F) or more than 30°C (90°F). See page 5-46 for battery storage precautions. uvossoo NOTE: Make any necessary repairs before storing the motorcycle.SPECIFICATIONS SPECIFICATIONS. .....ssssssssesseessnsnnneeessenssne 71SPECIFICATIONS Model FZR600/FZR600C Dimension: Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance 2,095 mm (82.5 in) 700 mm (27.6 in) 1,155 mm (45.5 in) 785 mm (30.9 in) 1,425 mm (56.1 in) 135 mm ( 5.3 in) Basic weight (with oil and full fuel tank): 201 kg (443 Ib): FZR600 206 kg (454 Ib): FZR600C Mi imum turning radius: 3,500 mm (138 in) Engine: Type Cylinder arrangement Displacement Bore x Stroke Compression ratio Starting system Lubrication system Liquid cooled, 4-stroke, gasoline, DOHC Parallel 4-cylinder, Forward inclined 599 cm? 59.0 x 54.8 mm (2.32 x 2.16 in) 2:1 Electric starter Wet sumpModel FZR600/FZR600C Engine oil (4-cycle) See page 3-6. Radiator capacity: (Including all routes) 2.2L (1.9 Imp at, 2.3 US at) Air filter: Dry type element Fuel: Type UNLEADED FUEL Tank capacity 18.0 L (4.0 Imp gal, 4.8 US gal) Reserve amount 3.4L (0.7 Imp gal, 0.9 US gal) Carbure:or: Typeimanufacturer BDST32/MIKUNI Spark plug: Typeimanufacturer CR9E/NGK U27ESR-N/DENSO Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Clutch type: Wet, multi-dise 72Model FZR600/FZR600C Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Spur gear 82/48 (1.708) Chain drive 45/15 (3.000) Constant mesh 6-speed Operation Left foot operation Gear ratio: Ist 37/13 (2.846) 2nd - 37/19 (1.947) 3rd 31/20 (1.550) ath 28/21 (1.333) Sth 31/26 (1.192) 6th 30/27 (1.111) Chassis: Frame type Double cradle Caster angle 25° Trail 94 mm (3.7 in) Tire: Type Tubeless Size: front 110/70 ZR17 (MICHELIN, PIRELLI) rear 110/70 VR17-V240 (BRIDGESTONE, DUNLOP) 140/60 ZR18 (MICHELIN, PIRELLI) 140/60 VR18-V240 (BRIDGESTONE, DUNLOP)Model FZR600/FZR600C Brake: Front type Dual, Disc brake operation | Right hand operation Rear type Single, Disc brake operation | Right foot operation ‘Suspension: front Telescopic fork rear Swingarm (Link suspension) ‘Shock aosorber: front Coil spring, Oil damper rear Gas, Coil spring, Oil damper Wheel travel: front 130 mm (5.1 in) rear 115 mm (4.5 in) Electricel: Ignition system T.C.l. (digital) Generator system Battery type/voltage, capacity AC. generator GM12AZ/12V, 12AH Headlight type: Quartz bulb 14Model FZR600/FZR600C Bulb voltage, wattage/quantity: Headlight 12V, 35W/35W x 2 Tail/brake light 12V, BW/27W x 2 Front turn signal/position light 12V, 27WiBW x2 Rear turn signal light 12V, 27W x 2 Meter light 12V, 1.7Wx4 Neutral indicator light 12V, 3.4W x1 High beam indicator light 12V, 3.4W x1 Oil level indicator light 12V, 3.4W x1 Turn indicator light 12V, 3.4W x1 75AL10100 CONSUMER INFORMATION Reporting safety defects Motorcycle noise regulation. Maintenance record. Street and enduro motorcycle limited warranty ... Yamaha extended service..eatoneoo REPORTING SAFETY DEFECTS Ifyou 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 Administra- tion (NHTSA) in addition to notifying YAMAHA MOTOR CORP. U.S.A.. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in 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 CORP. U.S.A.. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. Department of Transpor- tation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline. ataL0300 MOTORCYCLE NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal lew prohibits the following acts or the causing thereof: (1) The removal or render- ing inoperative by any person other than for purposes of maintenance, repair, or replace- ment of any device or element of design incorporated into any new vehicle 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 ren- dered inoperative by any person. “AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LIST- ED BELOW”. These acts include tampering with the following systems; i.e., modification, removal, etc. Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system, Air cleaner element Intake duct 82EALo0801 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document that maintenance has been completed in accordance with the emission warran- ty. The chart below is printed only as a reminder to you that the maintenance work is re- quired. It is not acceptable proof of maintenance work. MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE ‘SERVICING DEALER. NAME AND ADDRESS REMARKS 1,000km (600mi) or Imo. 7,000km (4,400mi)or 7 mos. 73,000km, (8,200mi)or 13 mos. 19,000km (12,000mijor 19 mos 25,000km (15,800mijor 25 mos. 83MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE ‘SERVICING DEALER, NAME AND ADDRESS REMARKS 31,000km (19,600mi)or 31 mos. 37,000km (23,400mi)or 37 mos. -43,000km (27,200mi)or 43 mos. 49,000km_ (31,000mi)or 49 mos. 55,0C0km, (34,800mi)or 55 mos. 61,0C0km (38,600mi)or 61 mos. a4YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ‘Yemaha Motor Corporation, US.A. hereby warrants ochnew srt or enduro model Yamshe motorcyae purchased from on authorized Yamaha motoreyeie Gowan the continental Unted States wl be efor fetece n mater and workmanship forthe period of tie stated her, subject to cram ead tatiana ‘THE PERIOD OF WARRANTY or Yomans moteryeiee ‘nail equppad with headin, stopigh, and tun ‘gna shal be one Il yee rom the date of rehaee, MODELS EXCLUDED FROM WARRANTY inclu ‘hore used far nan omaha-authonzed renting Test Ing. oF ether commercial purposes, and TZ model. ‘DURING THE PERIOD OF WARRANTY ony outhorzed or replace, st Yorahe' option, ony part adjusged otective by Yamane dos to faulty workmanehip oF material tom the factory. Pars used in waranty ‘Boars willbe werranted forthe balance ofthe pro Gers waranty period. All parts replaced under war ‘anty become property of Yomahe MtorCatpration usa Inelae any faiures caused by 1 Competition or racing vse {ualtatvelyequtaient te genuine Yamaha parts = Abnormal stain, neglect, or abuse 4. Leck of proper maintenance 1. Damage due to improper traneporaton, SPECIFIC EXCLUSIONS from this sorranty shall ‘THE CUSTOMER'S RESPONSIBILITY under hi war 1" Operate and maintain the motoreyte as specified inhe sppropiate Ovne's Mens, ond 2. Gwe notice to on authorized Yamaha motorcycle ‘ear of any and el apparent defects within ten (10) days afer escovery, and make the machine Such dosle's pace of business WARRANTY TRANSFER: To transfer the warranty ftom the orginal puremaser to ary subssqvent pu Chaser, tis imperative that he machine beinapected sna egstred fr waranty by an eutharizea Yarnaha ‘otoryele dalr In order forts waranty froma Inetfect ths inspection and registration must take Place within ton (1) day ater transfer An inspec ton and regtation te abe chaged for this service. EMISSIONS CONTROL SYSTEM WARRANTY Yamane Motor Corporation, US. slo warrant to he Uutumate purchaser and each suosequent purchase of tach Yamaha motoreyle covered by tha waranty ‘with adiaplacement of S0ce or greater, that the veh leis designed but. and equipped so as to cantorm Ste time of sle with al US. emissions standards Souza st het of manufacture and tat ti ee from defects mn materials and workmanship wich ‘would court not to meet thee standart he DoiodsIsted immediately below: Fasure otha thon ‘hore resulting trom defects n mater or workman hp which nce olay a2 result of owner abuse Sd /orlack of proper mantenance are net covered by ENGINE DISPLACEMENT e100 Soce 0 168ee 12,000 ko (7.468 mies) 85 170ce to 27862 18,000 km (11185 mies) ‘ot five year, whichever occurs st 20,000 km (18.681 mas) or five years, whichever occurs fst YAMAHA MOTOR CORPORATION. US A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OF IMPLIED. ALL” IMPLIED “WARRANTIES OF MERCHANTABILITY “AND FITNESS FOR A PARTICULAR PURPOSE "WHICH EXCEED THE COBUGATIONS AND TIME LiMTS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMANA MOTOR CORPORATION, USA. 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 LDS OF USE. SOME STATES DO NOT ALLOW "THE EXCLUSION. OF LIMITATION OF InciDENTAL 9R CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THiS WARRANTY GIVES YOU SPECIFIC LEGAL [IGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. ‘YAMAHA MOTOR CORPORATION, USA, P.O. Box 6555>e WARRANTY QUESTIONS AND ANSWERS nat costs are my responsibilty during the warranty period? ‘The curtomers responsibilty ineludes af cons of normal maintenance services, non waranty repars,seelent and clison damage and ool iter, a Tes, spark lugs. and brake shows or pads What are sone examples of “abnormal” sain, neglect, of sbuse? "These tree gonerel and ovelg each ether m arent. Specie examples include Running the machine ut of ot sustained high spm, fll throte use: operating the machine with broken of demaged part which causes another pat ta, damepe br faure dus to imoroper or careless taneporavon and oe down 90d son It Younave any spectic questions on operation or maintenance please contat yout oes the waranty cover ncental costs such #8 towing or transportation due 10 May parton any o al ofthe recommended maintenance shown in the Owner's Yes, you srs qulfed mechan and fallow the procedures specie in ha Oura's ‘nd Service Wanual We doreeommend, however that tems rearing special fools fr aauipment be done by a Yamaha motoreyele dealer ‘Wa tne waranty be void of canceled if | do not operate or maintain my new Imotorycle actly as speciiog inthe Owner's Manual? No The werranty an new motorcycle cannot be "waded or “canceled” However ia particular aur s caused by operation oF maintenance other than as shown in the Owners Manual that fre: may not be covered under warranty what respenbity does my dealer have under ths warranty? Each Yamona motoryele dealers expected to 1’ Completay set up every new machine before se 2. Eaplan th operation, maintenance and waranty raqemants to yours tn addon, exshvamaha motoryeie delet held responsible for hs apt. sevice \s the warrany Wansteable to second owners? Yea The remnder of te exiting warranty con be tanstered upon request. The Unit na obo nepectod ond eropstred ty euhorze Yermehe motocyte desler 86 customer senvice your machine requites waranty service you must take 0 any authorizes ‘Yarmahs motoreyele dealer within the continental United States. Be Sue 10 bring your waranty regiatation identeston or ether vat proot of the ‘nginl date of purchase Its question or prabiem anses garding ay, frst contact the owner of the deaarshp. Since al waranty mates a> hhanlod atthe desir lve, th person es the best postion to hep You you esti aot setaied and reqre addtional sssstonce lease te YAMAHA MOTOR CORPORATION US.A. (CUSTOMER RELATIONS DEPARTMENT PO. Box 6556 Ccyoress, Catone 90890 \When contacting Yamaha Motor Corperaton, USA. don't forget to ineude {ny important information such as names, sddresics, model, engine ser ‘CHANGE OF ADDRESS: Te federal goveinment requies each manufacturer of a motor voice to Imointasn 9 complete uptodate Ist cl ll frst purchasers aganat the Dotsiity of asaetyrelsted dotect and recall Ths lata compled fom ‘he purchseeragitations sont to Yamaha Motor Corporation, USA, by Se Ssoling dear atthe tne of you purchase t you should mave ater you have purchased your new motoreyle, pease [sve us of your new adarest by sending apoatard isting yor motorvete ‘model name. engine eral number, desir number fr deslers nal as ‘Shown am you watenty enttestion, your name and new maling adds Mai wo YAMAHA MOTOR CORPORATION, US.A PO. Box 658 Ccypeess Cafonia 90630, ‘This wal ensure that Yamaha Motor Corporation, US.A. hae an upto date registration record in sccoraence with federal am,YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). © 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. * Y.E.S. is flexible. You choose the plan thats right for you: 12 months, 24 months, or 36 months beyond your ‘warranty period. * Y.ES. 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.ES. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory- backed protection can be. * 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. ‘In addition, Travel and Recreation interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to {$150 reimbursement per cocurrence 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.ES. plan period. + Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide. * Y.E.S. coverage is transferrable to a new owner it 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 stil 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.We urge you to act now. You'll get the excellent benefits of TRIP coverage right away, and you'll rest easy knowing youll have sirong factory-backed protection even after your Yamaha Limited Warranty expires. You can also save money: Y.E.S. costs less within the first 90 days after you buy your Yamaha, See your dealer today! A special note’ It visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your engine number). We'll be happy to help you get the Y.E.S. coverage you need. ‘Yamaha Service Marketing P.O. Box 6555 Cypress, CA90630 (714) 761-7631 Y YAMAHA EXTENDED SERVICE