Professional Documents
Culture Documents
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:
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
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.
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
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)
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)
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)
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.
1
2
3
4
5
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.
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
1
2
3
4
Master cylinder
Master cylinder bracket
Bolt
Brake light switch connector
1
1
2
2
C
C
d = 6 (0.24), = 20 (0.79)
EAA00035
EAA00123
6. HANDLEBAR SWITCH
A: Align the projection on the left
handlebar switch with the hole
in the handlebar.
WARNING
Proper cable routing is essential to assure safe vehicle operation.
Refer to CABLE ROUTING.
1
2
3
1
1
1
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
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)
1
2
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)
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)
EAA00900
CABLE ROUTING
WARNING
Proper cable and lead routing are essential to insure safe vehicle
operation.
D
E
F
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
11
EAA01000
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
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
Quantity
Without oil filter cartridge replacement
2.5 L (2.20 Imp qt, 2.64 US qt)
CAUTION:
D Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. Therefore, do not add any chemical additives.
D Do not allow foreign materials to enter the crankcase.
NOTE:
API service SG type or higher JASO standard MA
5. Start the engine, warm it up for several
minutes, and then turn it off.
6. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a
few minutes until the oil has settled.
7. Install:
D dipstick
EAA01017
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.
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
3. Adjust:
D engine idling speed
a. Turn the throttle stop screw (1) in direction (a) or (b) until the specified engine
idling speed is obtained.
Direction (a)
Engine idling speed is increased.
Direction (b)
Engine idling speed is decreased.
EAA01022
EAA01023
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
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
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
NOTE:
D Be careful not to spill any brake fluid or
allow the brake fluid reservoir to overflow.
D When bleeding the hydraulic brake system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the
bleeding procedure.
D If bleeding is difficult, it may be necessary to let the brake fluid settle for a few
hours. Repeat the bleeding procedure
when the tiny bubbles in the hose have
disappeared.
1. Bleed:
D hydraulic brake system
a. Add the recommended brake fluid to the
proper level.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose (1) tightly to
the bleed screw (2).
A Front
B Rear
EAA01036
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
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
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
EAA01065
EAA00185
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:
Spark plug:
Type:
Gap:
CR9EK (NGK)
0.6 X 0.7 mm (0.0236 X 0.0276 in)
Fuel:
Recommended fuel:
Tire pressure:
Up to 90 kg load*
90 kg load X Maximum load*
High-speed riding
Maximum load*
EAA10100
STANDARD EQUIPMENT
1. Owners manual1 pc.
2. Owners tool kit 1 pc.
EAA10200
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
PRINTED IN USA