EAA00002

FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha vehicle
prior to delivery to the customer. Since some external parts of the vehicle have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be
noted that the assembled vehicle should be thoroughly cleaned, inspected, and adjusted prior to delivery
to the customer.
EAA00005

NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will
appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.
CONCERNING CRATE DAMAGE:

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

Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander, or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EAA00001

FZS6W
FZS6WC
ASSEMBLY MANUAL
E2006 by Yamaha Motor Corporation,
U.S.A. First Edition, November 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11666-20-60

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

EAA00008

SYMBOLS USED IN THE

ASSEMBLY MANUAL
In order to simplify descriptions in this assembly manual, the following symbols are
used:
(1): Coat with lithium-soap-based grease.
(2): Tighten to 10 Nm.
(10 Nm = 1.0 mSkg, 7.2 ftSlb)
(3): Towards the front of the vehicle
(4): Clearance required
(5): Install so that the arrow mark faces upward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of operations.)
B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame
and / or contained in the Styrofoam tray (upper or lower)
*: Temporarily installed or secured
E: Size or material of parts
d / D: Diameter of part
: Length of part
e.g., 5 = 5 mm (0.2 in)

EAA00040

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

(1)

(2)

(3)

(4)

(5)

(6)

EAA00050

SYMBOLS USED ON
CRATE CARTON
(1) Contents of the transport package are
fragile, therefore the package must be
handled with care.
(2) Indicates correct upright position of the
transport package.
(3) Transport package must be kept away
from rain.
(4) Do not step anywhere on this carton box.
(5) Up to 6 of the transport packages can be
piled up.
(6) Insertion of the forklift arms from this
side can cause damage.
(7) Lift arm inserting position.
If the forklift arms cannot be inserted under
the transport package in alignment with the
two yellow labels, adjust the arms so that
they are positioned evenly in relation to
these marks while taking care not to damage the package contents.

EAA00060

UNPACKING
1. Remove the frame cover (1).
NOTE:
To remove the frame cover, cut the vinyl
bands around the cover using a cutter or
scissors.

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

Remove the front wheel (4).

3. Remove the packing frame bolts (5) and

upper handlebar holders (6).

4. Remove the bolts (7).

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

and then move to the side.)
NOTE:
Remove the bolts while holding the frame.

NOTE:
Before starting the assembly, check for
damaged or missing parts. Check both the
parts contained in the carton boxes and on
the vehicle for damage, scratches, and other defects.

EAA00070

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

EAA00080

(1) Carton box 1

1. Screws and special nuts (windshield)
2. Plates
3. Collars
4. Bolts
5. Nuts
6. Bracket
7. Nuts
8. Screws
9. Bolts
10. Bands
11. Washers
12. Bolts
13. Inner panels
14. Rear view mirrors
15. Windshield
16. Front fender
17. Owners manual
18. Reflectors
19. Brackets
20. Nuts

(2) Carton box 2

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

(3) Front tire

EAA00100

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

EAA00014
EAA00102

1. HANDLEBAR
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holder
with the symbol mark facing
forward.
CAUTION:
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
1
2
3

Handlebar
Upper handlebar holder
Bolt

1
1
4

C
C
C

d = 8 (0.31), = 30 (1.18)

C: Align the punch mark on the

handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specification.
Bolt:
23 Nm (2.3 mSkg, 17 ftSlb)

EAA00016
EAA00104

2. THROTTLE GRIP
A: Align the projection on the handlebar switch with the hole in
the handlebar.
B: Tighten the screws to specification.
Screw:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)
C: Check the throttle grip for
smooth action.
1
2
3

Screw
Screw
Grip end

1
1
1

d = 5 (0.20), = 45 (1.77)
d = 5 (0.20), = 20 (0.79)

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

EAA00020
EAA00108

3. FRONT WHEEL
A: Clean the brake discs.
B: Clean the front wheel axle.
C: Clean the collar.
D:

1
2
3
4
5
6
7
8

Front tire
Collar
Axle
Bolt
Reflector
Nut
Bracket
Bolt

1
2
1
1
2
2
2
4

S
C
d = 8 (0.31), = 40 (1.57)

C
C
C

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

E: Make sure there is an enough

gap between the brake pads.

I: Tighten the reflector nuts to

specification.

NOTE:
Do not depress the brake lever
when the calipers are off the brake
discs.

EAA00110

4. FRONT FENDER
A: Tighten the front fender bolts to
specification.
Front bolt:
6 Nm (0.6 mSkg, 4.3 ftSlb)
Rear bolt:
7 Nm (0.7 mSkg, 5.1 ftSlb)
B:

1
2
2
2
1

S
C
C
C
C

d = 6 (0.24), = 22 (0.87)
d = 6 (0.24), = 30 (1.18)
d = 6 (0.24)

H: Tighten the wheel axle pinch

bolt to specification.

CAUTION:
Before tightening the wheel axle
pinch bolt, stroke the front forks
several times to make sure of
proper fork operation.

EAA00022

Front fender
Bolt
Bolt
Collar
Bracket

Wheel axle:
72 Nm (7.2 mSkg, 52 ftSlb)

WARNING
Take care not to get grease on
the brake discs or inner surface
of the brake pads. If you do so,
clean using a rag dampened
with a solvent. Foreign material
on the braking surface may
cause impaired braking action.

F: Lift the front wheel and install

the front wheel axle.
Be sure to arrow on the tire is
pointed in the rotating direction.

1
2
3
4
5

G: Tighten the wheel axle to specification.

CAUTION:
Make sure the brake hose is
routed outside of the front fender.
Be careful not to scratch the
front fender with the front fork
outer tube.

Wheel axle pinch bolt:

19 Nm (1.9 mSkg, 14 ftSlb)

Nut:
1.5 Nm (0.15 mSkg, 1.1 ftSlb)
J: Tighten the brake caliper bolts
to specification.
Brake caliper bolts:
40 Nm (4.0 mSkg, 29 ftSlb)

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

EAA00032
EAA00120

5. FRONT BRAKE MASTER

CYLINDER
A: Lubricate the pivoting parts of
the brake lever.
Recommended lubricants:
Yamaha cable lube or motor
oil

1
2
3
4

Master cylinder
Master cylinder bracket
Bolt
Brake light switch connector

1
1
2
2

C
C

d = 6 (0.24), = 20 (0.79)

B: Make sure that the UP mark

with the bracket is pointed upward.
C: Align the punch mark on the
handlebar with the gap of the
master cylinder bracket.

D: Tighten the bolts in stages and

maintain an equal gap on each
side of the bracket to specification.
Bolt:
10 Nm (1.0 mSkg, 7.2 ftSlb)
E: Connect the front brake light
switch connector.
F: Check the brake lever for
smooth action.
WARNING
Proper cable and hose routing
is essential to assure safe vehicle operation.
Refer to CABLE ROUTING.

EAA00035
EAA00123

6. HANDLEBAR SWITCH
A: Align the projection on the left
handlebar switch with the hole
in the handlebar.
WARNING
Proper cable routing is essential to assure safe vehicle operation.
Refer to CABLE ROUTING.

1
2
3

Left handlebar switch

Screw
Screw

1
1
1

B: Tighten the screws to specification.

C
C

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

Screw:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)

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

EAA00049
EAA00137

7. CLUTCH CABLE
A: Lubricate the pivoting part of
the clutch lever.
Recommended lubricants:
Yamaha cable lube or motor
oil

1
2

Clutch cable
Clutch switch lead coupler

1
1

B: To install the clutch cable, be

sure to proceed as follows:
a. Turn in the adjuster on the lever
holder until tight. Next, align the
slit in the adjuster and cable
socket with the slit in the lever
holder.
b. Insert the cable end into the lever hole. Next, while pulling the
outer cable in the direction opposite to the lever, seat the outer cable into the cable socket.

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

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

Band

EAA00053
EAA00141

9. WINDSHIELD
CAUTION:
The windshield is made of an
acrylate resin. Take care so that
it is not scratched.
A: Tighten the screws to specification.
Screw:
0.4 Nm (0.04 mSkg, 0.3 ftSlb)
1
2
3

Special nut
Windshield
Screw

6
1
6

C
C
C

d = 5 (0.20)
d = 5 (0.20), = 18 (0.71)

10. REAR VIEW MIRRORS

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

1
2

Rear view mirror

Nut

2
4

C
C

d = 6 (0.24)

EAA00189

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

Battery
Battery cover
Bolt
Bolt

1
1
2
2

d = 6 (0.24), = 25 (0.98)
d = 6 (0.24), = 10 (0.39)

C: First, connect the positive lead

(red lead) to the positive terminal.

12. INNER PANEL

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

1
2
3
4
5
6

Inner panel
Inner panel
Bolt
Bolt
Bolt
Washer

1
2
6
2
2
2

C
C
C
C

d = 5 (0.20), = 12 (0.47)
d = 6 (0.24), = 16 (0.63)
d = 6 (0.24), = 16 (0.63)
d = 6 (0.24)

D: Second, connect the negative

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

EAA00900

CABLE ROUTING
WARNING
Proper cable and lead routing are essential to insure safe vehicle
operation.

D
E
F

(1) Left handlebar switch lead

(2) Main switch lead
(3) Clutch cable
(4) Throttle cables
(5) Right handlebar switch lead
(6) Battery negative lead coupler
(7) Battery negative lead
(8) Starter relay lead
(9) Battery positive lead
(10) Battery cover
A Clamp the right and left handlebar switch leads and handlebar.
Point the tip of the clamp downward in front of the handlebar.
B Pass the throttle cables through the wire guide.
Route the right handlebar switch lead by the outside of the wire
guide.

10

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

EAA01100

ADJUSTMENTS AND PREDELIVERY

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

11

EAA01000

A. CHECKING AND CHARGING

THE BATTERY
NOTE:
The battery used in this vehicle is a maintenance free (MF) Valve Regulated Lead
Acid Battery, it has been pre-filled with
electrolyte at the factory so there is no need
to add fluid at any time.
1. Check:
Using a digital volt meter, the state of a discharged MF battery can be checked by
measuring open-circuit voltage (the voltage
measured with the positive and negative
terminals being disconnected).
Open-circuit voltage
12.8 V or higher
Charging time
Charging is not necessary

Eyes: Flush with water for 15 minutes

and get prompt medical attention. Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., away.
Ventilate when charging or using in enclosed space. Always shield eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
D If the voltage is lower than 12.8 V the
battery must be charged. If this is not
done, the life of the battery will be
shortened drastically. Refer to the
service manual for battery charging
instructions.
D Never remove the strip of caps, nor
add any water or electrolyte.

WARNING
D Do not attempt boost charging under
any circumstances.
D Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidote: External-Flush with water. Internal-Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician
immediately.

EAA01009

B. CHECKING THE TIRE

PRESSURE
1. Check:
D tire pressure
Out of specification ! Adjust.
WARNING
D The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
D The tire pressure and the suspension
must be adjusted according to the total weight (including cargo, rider,
passenger, and accessories) and the
anticipated riding speed.
D Operation of an overloaded vehicle
could cause tire damage, an accident, or an injury.
NEVER OVERLOAD THE VEHICLE.

Basic weight:
With oil and full fuel tank
207 kg (456 lb) (except for CAL)
208 kg (459 lb) (for CAL)
Maximum load*
190 kg (419 lb) (except for CAL)
189 kg (417 lb) (for CAL)
Cold tire pressure
Up to 90 kg load*
Front
225 kPa (2.25 kgf / cm2, 33 psi)
Rear
250 kPa (2.5 kgf / cm2, 35.6 psi)
90kg X Maximum load*
Front
250 kPa (2.5 kgf / cm2, 35.6 psi)
Rear
290 kPa (2.9 kgf / cm2, 41.3 psi)
High speed riding
Front
225 kPa (2.25 kgf / cm2, 33 psi)
Rear
250 kPa (2.5 kgf / cm2, 35.6 psi)
* Load is the total weight of cargo, rider, passenger, and accessories.

12

EAA01011

C. CHECKING THE ENGINE OIL

LEVEL

Quantity
Without oil filter cartridge replacement
2.5 L (2.20 Imp qt, 2.64 US qt)

1. Stand the vehicle on a level surface.

NOTE:
D Place the vehicle on a suitable stand.
D Make sure that the vehicle is upright.
2. Let the engine idle for a few minutes, and
then turn it off.
3. Remove:
D dipstick
4. Check:
D engine oil level
The engine oil level should be between
the maximum level mark (a) and minimum level mark (b).
Below the minimum level mark ! Add
the recommended engine oil to the proper level.
NOTE:
D Before checking the engine oil level, wait
a few minutes until the oil has settled.
D Do not screw the dipstick in when checking the oil level.

CAUTION:
D Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. Therefore, do not add any chemical additives.
D Do not allow foreign materials to enter the crankcase.
NOTE:
API service SG type or higher JASO standard MA
5. Start the engine, warm it up for several
minutes, and then turn it off.
6. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a
few minutes until the oil has settled.
7. Install:
D dipstick

Recommended engine oil

10_C (10_F) to 20_C (70_F)
YAMALUBE 4 (10W-30) or
SAE 10W-30
10_C (50_F) to 40_C (110_F)
YAMALUBE 4 (20W-40) or
SAE 20W-40

EAA01017

1. Stand the vehicle on a level surface.

3. Start the engine, warm it up for several

minutes, and then turn it off.
4. Check:
D coolant level

NOTE:
D Place the vehicle on a suitable stand.
D Make sure that the vehicle is upright.

NOTE:
Before checking the coolant level, wait a few
minutes until it settles.

D. CHECKING THE COOLANT

LEVEL

2. Check:
D coolant level
The coolant level should be between the
maximum level mark (a) and minimum
level mark (b).
Below the minimum level mark ! Add
the recommended coolant to the proper
level.
CAUTION:
D Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze
concentration of the coolant.
D Use only distilled water. Soft water
may be used if distilled water is not
available.

13

EAA01020

E. ADJUSTING THE ENGINE

IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed,
the throttle bodies synchronization should
be adjusted properly, the air filter should be
clean, and the engine should have adequate compression.

3. Adjust:
D engine idling speed
a. Turn the throttle stop screw (1) in direction (a) or (b) until the specified engine
idling speed is obtained.
Direction (a)
Engine idling speed is increased.
Direction (b)
Engine idling speed is decreased.

1. Start the engine and let it warm up for

several minutes.
2. Measure:
D engine idling speed
Out of specification ! Adjust.
Engine idling speed
1,250 X 1,350 r / min

EAA01022

F. ADJUSTING THE THROTTLE

CABLE FREE PLAY
NOTE:
Prior to adjusting throttle cable free play, the
engine idling speed should be adjusted.
1. Measure:
D throttle cable free play (a)
Out of specification ! Adjust.
Throttle cable free play (at the flange
of the throttle grip)
3 X 5 mm (0.12 X 0.20 in)

EAA01023

G. ADJUSTING THE FRONT

BRAKE
1. Adjust:
D brake lever position
(distance (a) from the throttle grip to the
brake lever)
a. While pushing the brake lever forward,
turn the adjusting dial (1) until the brake
lever is in the desired position.
NOTE:
Be sure to align the setting on the adjusting
dial with the arrow mark (2) on the brake lever holder.
Position #1
Distance (a) is the largest.
Position #5
Distance (b) is the smallest.

14

2. Adjust:
a. Loosen the locknut (1).
b. Turn the adjusting nut (2) in direction (a)
or (b) until the specified throttle cable
free play is obtained.
Direction (a)
Throttle cable free play is increased.
Direction (b)
Throttle cable free play is decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free
play, turn the handlebar to the right and
to the left to ensure that this does not
cause the engine idling speed to change.

WARNING
After adjusting the brake lever position,
make sure that the pin on the brake lever
holder is firmly inserted in the hole in the
adjusting dial.
CAUTION:
After adjusting the brake lever position,
make sure that there is no brake drag.
WARNING
A soft or spongy feeling in the brake lever can indicate the presence of air in the
brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.
Air in the brake system will considerably
reduce braking performance and could
result in loss of control and possibly an
accident. Therefore, check the brake
system and bleed if necessary.

EAA01027

c. Tighten the locknut (1) to specification.

H. ADJUSTING THE REAR BRAKE

1. Measure:
D brake pedal position (a)
(below the bottom of the footrest bracket)
Out of specification ! Adjust.
Brake pedal position (top of the footrest)
25.8 mm (1.02 in)
2.
D
a.
b.

Adjust:
brake pedal position
Loosen the locknut (1).
Turn the adjusting bolt (2) in direction (a)
or (b) until the specified brake pedal
position is obtained.
Direction (a)
Brake pedal is raised.
Direction (b)
Brake pedal is lowered.

Locknut
18 Nm (1.8 mSkg, 13 ftSlb)
WARNING
A soft or spongy feeling in the brake pedal can indicate the presence of air in the
brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake
system will considerably reduce braking
performance and could result in loss of
control and possibly an accident. Therefore, check the brake system and bleed if
necessary.
CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.

WARNING
After adjusting the brake pedal position,
make sure that the end of the adjusting
bolt (c) is visible through the hole (d).

EAA01032

I. CHECKING THE BRAKE FLUID

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

2. Check:
D brake fluid level
Below the minimum level mark (a) !
Add the recommended brake fluid to the
proper level.
Recommended brake fluid
DOT 4
A
B

WARNING
D Use only designated brake fluid.
Other brake fluids may cause the ruber seals to deteriorate, causing leakage and poor brake performance.
D Refill with the same type of brake
fluid that is already in the system.
Mixing brake fluids may result in a
harmful chemical reaction, leading to
poor brake performance.
D When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately.

Front brake
Rear brake

NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the reservoir is level.

15

EAA01035

J. BLEEDING THE HYDRAULIC

BRAKE SYSTEM
WARNING
Bleed the hydraulic brake system whenever:
D the system was disassembled,
D a brake hose was loosened or removed,
D the brake fluid level is very low,
D brake operation is faulty.

NOTE:
D Be careful not to spill any brake fluid or
allow the brake fluid reservoir to overflow.
D When bleeding the hydraulic brake system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the
bleeding procedure.
D If bleeding is difficult, it may be necessary to let the brake fluid settle for a few
hours. Repeat the bleeding procedure
when the tiny bubbles in the hose have
disappeared.

d. Place the other end of the hose into a

container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position.
g. Loosen the bleed screw.
This will release the tension and cause
the brake lever to contact the throttle grip
or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the
brake fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 mSkg, 4.3 ftSlb)
k. Fill the reservoir to the proper level.
Refer to CHECKING THE BRAKE
FLUID LEVEL.
WARNING
After bleeding the hydraulic brake system, check the brake operation.

1. Bleed:
D hydraulic brake system
a. Add the recommended brake fluid to the
proper level.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose (1) tightly to
the bleed screw (2).
A Front
B Rear

EAA01036

K. ADJUSTING THE CLUTCH

CABLE FREE PLAY
1. Measure:
D clutch cable free play (a)
Out of specification ! Adjust.
Clutch cable free play (at the end of
the clutch lever)
10 X 15 mm (0.39 X 0.59 in)

16

2. Adjust:
D clutch cable free play
Handlebar side
a. Turn the adjusting dial (1) in direction (b)
or (c) until the specified clutch cable free
play is obtained.
Direction (b)
Clutch cable free play is increased.
Direction (c)
Clutch cable free play is decreased.

EAA01050

L. ADJUSTING THE REAR SHOCK

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

Spring preload

Direction (a)
Spring preload is increased
(suspension is harder).
Direction (b)
Spring preload is decreased
(suspension is softer).

CAUTION:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust:
D spring preload

Adjusting positions
Standard: 3
Minimum: 1
Maximum: 7

NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the
owners tool kit.
a. Turn the adjusting ring (1) in direction (a)
or (b).
b. Align the desired position on the adjusting ring with the stopper (2).

EAA01059

M. ADJUSTING THE DRIVE CHAIN

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

17

4.
D
5.
D
a.
b.

Loosen:
wheel axle nut (1)
Adjust:
drive chain slack
Loosen both locknuts (2).
Turn both adjusting nuts (3) in direction
(a) or (b) until the specified drive chain
slack is obtained.
Direction (a)
Drive chain is tightened.
Direction (b)
Drive chain is loosened.

NOTE:
D To maintain the proper wheel alignment,
adjust both sides evenly.
D Push the rear wheel forward to make
sure that there is no clearance between
the swingarm end plates and the ends of
the swingarm.
c. Tighten the wheel axle nut to specification.
Wheel axle nut
125 Nm (12.5 mSkg, 90 ftSlb)
d. Tighten the locknuts to specification.
Locknut
16 Nm (1.6 mSkg, 12 ftSlb)

EAA01062

N. ADJUSTING THE REAR BRAKE

LIGHT SWITCH
NOTE:
The rear brake light switch is operated by
the movement of the brake pedal.
The rear brake light switch is properly adjusted when the brake light comes on just
before the braking effect starts.
1. Check:
D rear brake light operation timing
Incorrect ! Adjust.

EAA01065

O. ADJUSTING THE HEADLIGHT

BEAMS
The following procedure applies to both of
the headlights.
1. Remove:
D front cowlling inner panels
2. Adjust:
D headlight beam (vertically)
a. Turn the adjusting screw (1) in direction
(a) or (b).
Direction (a)
Headlight beam is raised.
Direction (b)
Headlight beam is lowered.

EAA00185

P. ADJUSTING THE DIGITAL

CLOCK
Turn the key to ON.
1. Adjust:
D digital clock (1)
a. Push the SELECT button (3) and RESET button (2) together for at least 2 seconds.
b. When the hour digits start flashing, push
the RESET button (2) to set the hours.
c. Push the SELECT button (3), and the
minute digits will start flashing.
d. Push the RESET button (2) to set the
minutes.
e. Push the SELECT button (3) and then
release it to start the clock.

18

2. Adjust:
D rear brake light operation timing
a. Hold the main body (1) of the rear brake
light switch so that it does not rotate and
turn the adjusting nut (2) in direction (a)
or (b) until the rear brake light comes on
at the proper time.
Direction (a)
Brake light comes on sooner.
Direction (b)
Brake light comes on later.

3. Adjust:
D headlight beam (horizontally)
a. Turn the adjusting screw (2) in direction
(a) or (b).
Direction (a)
Headlight beam moves to the left.
Direction (b)
Headlight beam moves to the right.
4. Install:
D front cowling inner panels.

EAA10000

APPENDICES
SERVICE DATA
Engine idling speed:

1,250 X 1,350 r / min

Spark plug:
Type:
Gap:

CR9EK (NGK)
0.6 X 0.7 mm (0.0236 X 0.0276 in)

Fuel:
Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

Total:

19.4 L (4.27 Imp gal, 5.13 US gal)

Valve clearance (cold):

IN:
EX:

0.13 X 0.20 mm (0.0051 X 0.0079 in)

0.23 X 0.30 mm (0.0091 X 0.0118 in)

Tire pressure:
Up to 90 kg load*
90 kg load X Maximum load*
High-speed riding

Front: 225 kPa (2.25 kgf / cm2, 33 psi)

Rear: 250 kPa (2.5 kgf / cm2, 35.6 psi)
Front: 250 kPa (2.5 kgf / cm2, 35.6 psi)
Rear: 290 kPa (2.9 kgf / cm2, 41.3 psi)
Front: 225 kPa (2.25 kgf / cm2, 33 psi)
Rear: 250 kPa (2.5 kgf / cm2, 35.6 psi)

Maximum load*

189 kg (417 lb) (for CAL)

190 kg (419 lb) (except for CAL)
* Load is the total weight of cargo, rider, passenger, and accessories.

EAA10100

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

EAA10200

OWNERS TOOL KIT

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

19

1 pc.
2 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.

TIGHTENING TORQUES
Tightening

Thread
size

Nm

mSkg

ftSlb

Engine:
Spark plug
Engine oil drain bolt

M10
M14

18
43

1.8
4.3

13
31

Chassis:
Upper bracket pinch bolt
Steering stem nut
Upper bracket and upper handlebar holder
Under bracket pinch bolt
Lower ring nut
Front fork cap bolt
Damper rod assembly bolt
Front brake master cylinder and master cylinder bracket
Front brake master cylinder cap screw
Front brake hose union bolt
Front brake hose holder and front fork
Front cowling stay and frame
Front cowling bracket and frame
Front fender (front bolt) and front fork
Front fender (rear bolt) and front fork
Left handlebar switch screw
Grip end bolt
Right handlebar switch screw
Rear view mirror nut
Wind shield screw
Inner panel bolt (front side)
Inner panel bolt (left and right side)
Battery cover bolt
Clutch lever holder pinch bolt
Engine mount bolts (left of front side)
Engine mount bolts (left of rear side)
Engine mount bolts (right of front side)
Engine mount self locking nut (upper)
Engine mount self locking nut (lower)
Pivot shaft and frame
Rear shock absorber and frame
Rear shock absorber and rear arm
Seal guard and rear arm
Rear fender and rear arm
Rear brake hose holder and rear arm
Fuel tank bracket and frame
Fuel tank bracket and fuel tank
Fuel tank and rear frame
Fuel tank and fuel tank cap
Fuel pump and fuel tank
Ignition coil and battery box
Seat lock and frame

M8
M22
M8

M25
M35
M10
M6
M4
M10
M6
M8
M6
M6
M6
M5
M16
M5

M5
M5
M6
M6
M6
M10
M10
M10
M10
M10
M18
M10
M10
M6
M6
M6
M6
M6
M6
M5
M5
M6
M6

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

Item

20

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

Tightening

Thread
size

Nm

mSkg

ftSlb

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

3
4
4
7
19
3
4
23
7
10
7
2
13
7
4
72
19
40
18
6
125
30
27
22
100
16
30
46
63
4
30
7
23
73
10
8
7

0.3
0.4
0.4
0.7
1.9
0.3
0.4
2.3
0.7
1.0
0.7
0.2
1.3
0.7
0.4
7.2
1.9
4.0
1.8
0.6
12.5
3.0
2.7
2.2
10
1.6
3.0
4.6
6.3
0.4
3.0
0.7
2.3
7.3
1.0
0.8
0.7

2.2
2.9
2.9
5.1
14
2.2
2.9
17
5.1
7.2
5.1
1.4
9.4
5.1
2.9
52
14
29
13
4.3
90
22
20
16
72
12
22
33
46
2.9
22
5.1
17
53
7.2
5.8
5.1

NOTE 1:

1. First, tighten the ring nut to approximately 52 Nm (5.2 mSkg, 38 ftSlb) with a torque wrench, then loosen
the ring nut completely.
2. Retighten the lower ring nut 18 Nm (1.8 mSkg, 13 ftSlb).

21

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