Yamaha Fazer User Manual
(Starter Motor & Disc Brake)
5P41
OWNER'S MANUAL
5P4-E8199-E0
PRINTED IN INDIA
5P41- FAZER
2Y16(OM-01)-234-10-05
Starter Motor & Disc BrakeStarter Motor & Disc Brake
WARNING
PLEASE READ THISMANUAL CAREFULLYAND COMPLETELYBEFORE OPERATING THIS MOTORCYCLE.
OWNER'S MANUAL
YAMAHA MOTOR INDIA PVT. LIMITED
All rights reserved. Any reprinting or
unauthorised use without the written
permission of
YAMAHA MOTOR LIMITED is
expressly prohibited.
INDIA PVT.
TAKE NECESSARY PRECAUTIONS DURING RUNNING-IN PERIOD.
INTRODUCTION
Congratulations on your purchase of the FAZER. This motorcycle has been produced using the latest technology
in our modern plant, to provide you a happy, enjoyable and safe riding for many thousand kilometers and years. It
represents the high degree of craftsmanship and reliability that have made YAMAHA a leader in these fields.
This Owner's Manual will give you an understanding of the operation, inspection and basic maintenance of this
Motorcycle. To ensure a long trouble free performance, please take due care and ensure proper maintenance of
your Motorcycle as recommended in this Owner's Manual. Always demand only YAMAHA Genuine Spare Parts
and Yamalube oil. If you have any queries regarding the operation or maintenance of your Motorcycle, please
consult your YAMAHA DEALER who will be too happy to help you.
This Owner's Manual also includes the GREEN BOOK containing Guidelines, DO's and DON'Ts to be followed by
the Owner/ User of the Motorcycle for keeping Environment Clean and Green. You are requested to please read
the GREEN BOOK carefully.
We Provide
At Your Caring Service,
YAMAHA MOTOR INDIA PVT. LTD.
19/6, Mathura Road,
Faridabad-121006 (India)
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION ! BECOME ALERT ! YOUR SAFETY
IS INVOLVED !
Failure to follow WARNING instructions could result in severe injury to the
Motorcycle operator, a bystander or a person inspecting or repairing the Motorcycle.
CAUTION :
NOTE :
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A CAUTION indicates special precautions that must be taken to avoid damage to
the Motorcycle.
A NOTE provides key information to make procedures easier or clearer.
NOTE :
• This manual should be considered a permanent part of this Motorcycle and
should remain with it even if the Motorcycle is subsequently sold.
• 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 manual. If there is any question concerning this
manual, please consult your YAMAHA dealer.
1
ROAD SAFETY TIPS ....................................... 1-1
2
DESCRIPTION ................................................ 2-1
Left view ........................................................ 2-1
Right view ...................................................... 2-2
Controls/Instruments ................................... 2-3
3
INSTRUMENT AND CONTROL
FUNCTIONS .................................................... 3-1
Main switch cum steering lock ..................... 3-1
Speedometer ................................................ 3-2
Tachometer ................................................... 3-2
Indicator lights .............................................. 3-2
Handlebar switches/Kill Switch/ .................. 3-3
Starter Switch
Clutch lever ................................................... 3-4
Shift pedal ..................................................... 3-4
Front brake lever ........................................... 3-4
Rear brake pedal .......................................... 3-5
Fuel tank cap ................................................ 3-5
Fuel ............................................................... 3-6
Fuel cock ....................................................... 3-6
Starter Lever .................................................. 3-7
Kick starter .................................................... 3-8
TABLE OF CONTENTS
Seat ............................................................... 3-8
Storage compartment................................... 3-9
Rear shock absorber adjustment ............... 3-9
Handle Seat, Stay Lock................................. 3-10
4
PRE-OPERATION CHECKS ........................... 4-1
Pre-operation check list ............................... 4-1
5
OPERATION AND IMPORTANT RIDING
POINTS ............................................................ 5-1
Starting and warming up a
cold engine ................................................... 5-1
Starting a warm engine ................................ 5-2
Shifting .......................................................... 5-2
Tips for reducing fuel consumption ............. 5-3
Running-in .................................................... 5-3
Parking .......................................................... 5-4
6
PERIODIC MAINTENANCE AND MINOR
REPAIR ............................................................ 6-1
Tool kit ........................................................... 6-1
Preventive maintenance schedule .............. 6-3
Panel removal and installation .................... 6-5
Spark plug inspection .................................. 6-7
Engine Oil ..................................................... 6-8
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TABLE OF CONTENTS
Air filter ........................................................... 6-10
Carburetor adjustment ................................. 6-11
Idle speed adjustment ................................. 6-12
Throttle cable free play adjustment ............. 6-12
Valve clearance adjustment ......................... 6-13
Tyres .............................................................. 6-13
Wheels .......................................................... 6-15
Clutch lever free play adjustment ................ 6-16
Rear brake adjustment ................................ 6-17
Brake light switch adjustment ..................... 6-17
Checking front & rear brake shoes .............. 6-18
Checking brake fluid level ............................ 6-18
Drive chain slack check ................................ 6-19
Drive chain slack adjustment ...................... 6-20
Drive chain lubrication .................................. 6-22
Cable inspection and lubrication ................. 6-22
Throttle cable and grip lubrication ............... 6-22
Brake and shift pedal lubrication ................. 6-23
Brake and clutch lever lubrication ................ 6-23
Center and sidestand lubrication ................ 6-23
Front fork inspection ..................................... 6-24
Steering inspection....................................... 6-24
Wheel bearings ............................................ 6-25
Battery ........................................................... 6-25
Fuse replacement ........................................ 6-27
Headlight bulb replacement ........................ 6-28
Turn signal and taillight bulb
replacement .................................................. 6-29
Front wheel removal ..................................... 6-29
Front wheel installation ................................ 6-30
Rear wheel removal ..................................... 6-31
Rear wheel installation ................................ 6-33
Troubleshooting ........................................... 6-33
Troubleshooting chart .................................. 6-34
7
CLEANING & STORAGE ................................. 7-1
A. Cleaning ................................................... 7-1
B. Storage ...................................................... 7-2
8
SPECIFICATIONS ........................................... 8-1
9
CUSTOMER INFORMATION ........................... 9-1
Key identification number ............................. 9-1
Frame serial number ................................... 9-1
Engine serial number .................................. 9-1
10
DETACHMENTS
Pre-delivery inspection .............................. 10-1
Installation ................................................. 10-5
GREEN BOOK
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ROAD SAFETY TIPS
SAFE RIDING
1. Before riding, you should learn to ride your motorcycle properly and all the control functions should be known
to you.
2. Remember that there are no legal “rights” when it comes to survival as far as Motorcyclists are
concerned. The fact that you may be well within your rights is no guarantee that you will avoid a collision with
a bigger vehicle whose driver fails to see you. Always ride defensively and take nothing on road for granted.
3. Develop the ability to react swiftly to any unexpected road hazards or emergencies giving yourself time to
spare for appropriate response.
4. Develop the ability to get the most out of your Motorcycle, But at the same time get to know its
capabilities and limitations.
5. Right thoughtfully, planning your route well in advance.
6. Give proper Signals and use Horn and Headlights judiciously.
7. Don’t ride in another motorist’s blind spot.
8. Always make pre-ride safety checks before you start the Engine.
SAFE BRAKING
Use the basic methods of braking effectively.
1. Engine Brake : When the Throttle is released, compression backs up and acts as the Engine Brake.
If the riding condition allows, reduce speed by shifting the Gear down.
2. Front and Rear Brakes : It is important to apply equal force to the Front and Rear Brakes simultaneously.
CAUTION :
• Use Front and Rear Brakes simultaneously.
• Be sure not to disengage the clutch while braking.
• While riding downhill always use Engine as a Brake and never ride in Neutral Gear.
• While riding down hill do not switch off ignition while Engine is in gear.
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1-1
DESCRIPTION
Left view
2
STANDARD VEHICLE
10
1. Fuel cock (page 3-6)
2. Starter Lever (page 3-7)
3. Fuse (page 6-27)
4. Battery (page 6-25)
5. Storage Compartment (page 3-9)
6543 7
1
89
6. Toolkit (page 6-1)
7. Handle Seat (page 3-10)
8. Drive chain free play check window (page 6-19)
9. Side panel (L.H.) lock (page 6-5)
10. Shift pedal (page 3-4)
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2-1
Right view
STANDARD VEHICLE
DESCRIPTION
11 12 1314
15
16
11. Rear shock absorber (page 3-9)
12. Air filter (page 6-10)
13. Kick starter (page 3-8)
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14. Seat (page 3-8)
15. Engine oil filler cap (page 6-8)
16. Rear brake pedal (page 3-5,6-17)
2-2
DESCRIPTION
Controls / Instruments
19 20 21
18
17
25
STANDARD VEHICLE
17. Clutch Lever (page 3-4, 6-16)
18. Left Hand Switch (page 3-3)
19. Speedometer (page 3-2)
20. Main switch Cum Steering Lock (Page 3-1)
21. Tachometer (page 3-2)
22
23
26
24
22. Front Brake Lever (page 3-4, 6-16)
23. Throttle Grip (page6-12)
24. Fuel Tank Cap (page 3-5)
25. Turn Indicator Switch (page 3-2)
26. Starter/Kill Switch (page 3-3)
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INSTRUMENT AND CONTROL FUNCTIONS
WARNING
Never turn the key to "LOCK" when
the Motorcycle is moving.
Main switch cum steering
lock
The main switch controls the ignition
and lighting systems. Its operation is
described below.
ON:
Electrical circuits are switched on.
The engine can be started. The key
cannot be removed in this position.
OFF:
Engine will be shut off. All electrical
circuits are switched off. The key can
be removed in this position.
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1. Push
2. Release
3. Turn
LOCK:
The steering is locked in this position
and all electrical circuits are switched
off.
The key can be removed in this
position.
To lock the steering, turn the handlebars all the way to the left or right. With
the key at "OFF", push it into the main
switch and release it, turn it counterclockwise to "LOCK" and remove it.To
release the lock, turn the key to
"OFF".
3-1
1
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INSTRUMENT AND CONTROL FUNCTIONS
1
2
1. Speedometer
2. Odometer
Speedometer
The speedometer shows riding
speed.
This speedometer is equipped with
an odometer.
1
1. Tachometer
Tachometer
The Tachometer Indicates Engine
Speed (RPM) and is Pulse Operated.
1
3
2
1. Turn indicator light “ ”
2. High beam indicator light “ ”
3. Neutral indicator light “N”
Indicator lights
Turn indicator light " "
The indicator flashes when the turn
switch is moved to the left or right. .
Neutral indicator light "N"
This indicator comes on when the
transmission is in neutral.
High beam indicator light" "
This indicator comes on when the
headlight high beam is used.
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3-2
2
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INSTRUMENT AND CONTROL FUNCTIONS
1
3
2
5
1. PassSwitch " "
2. Dimmer Switch
3. Light switch
4. Turn signal cum cancellation switch“ “
5. Horn switch
4
Handlebar switches
Pass switch ""
Press the switch to operate the
Passing Light.
Dimmer switch
Turn the switch to" " for the high
beam and to " " for the low beam.
Turn signal switch
To signal a right-hand turn, push the
switch to " ". To signal a lefthand turn, push the switch to " ".
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 center
position.
Horn switch " "
Press the switch to sound the horn.
Lights switch
Turning the light switch to " ",
turns on the meter light and tail-light.
Turning the light switch to “ ",
turns the headlight on also.
2
OFF
ON
1
Press
1. Starter Switch
2. Kill Switch
Starter Switch
Press the button to start the bike.
Vehicle should be in
1) Neutral Position
2) If in Gear clutch lever to be
pressed
Kill Switch
Kill switch is an emergency switch to
cut "OFF" engine & should always
be in "ON" positon at the time of
starting the vehicle.
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INSTRUMENT AND CONTROL FUNCTIONS
1
1
1
1
1. Clutch lever
Clutch lever
The clutch lever is located on the left
handlebar. Pull the clutch lever to
the handlebar 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.
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1. Shift pedal
Shift pedal
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch when
1. Front brake lever
Front brake lever
The front brake lever is located on
the right handlebar. Pull it toward the
handlebar to apply the front brake.
shifting.
Use your toe or heel to shift up and
your toe to shift down.
USE BOTH BRAKES SIMULTANEOUSLY
3-4
4
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INSTRUMENT AND CONTROL FUNCTIONS
NOTE :
This tank cap cannot be closed
unless the key is in the lock. The key
cannot be removed if the cap is not
locked properly.
1 Rear brake pedal
Rear brake pedal
The rear brake pedal is on the right
side of the Motorcycle. Press down on
the brake pedal to apply the rear
brake.
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1
1
1. Open
Fuel tank cap
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:
Push the tank cap into position with
the key inserted. To remove the key,
turn it counterclockwise to the
original position.
Ensure the arrow on fuel tank is
towards the Front of the bike when
inserting Fuel Tank Cap in Fuel
Tank.
3-5
5
WARNING
WARNING
Be sure the cap is properly
installed and locked in place
before riding the Motorcycle.
1
1. Arrow
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INSTRUMENT AND CONTROL FUNCTIONS
1
1. Filler tube
2. Fuel level
2
Fuel
Make sure there is sufficient fuel in the
tank. Fill the fuel tank to the bottom of
the filler tube as shown in the
illustration.
IT IS A GOOD PRACTICE TO RETURN THE FUEL COCK LEVER TO
"Off" POSITION WHEN ENGINE IS NOT RUNNING
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 to avoid
Spillage
CAUTION :
Always wipe off spilled fuel
immediately with a dry and clean
soft cloth. Fuel may deteriorate
painted surfaces or plastic parts.
Recommended Fuel :
Regular gasoline (Petrol)
Fuel tank capacity :
Total :
13.0 L
Reserve :
1.2 L
OFF
1
1. Arrow mark
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions,
which should be set as shown in the
illustrations.
OFF: With the fuel cock in this
position, fuel will not flow.
Always set the fuel cock to this
position when the engine is not
running.
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INSTRUMENT AND CONTROL FUNCTIONS
1
ON
1. Arrow mark
ON: With the fuel cock in this
position, fuel flows to the
carburettor. Set the fuel cock to
this position when starting the
engine and while riding.
RES
1. Arrow mark
1
RES: This indicates reserve. If you
run out of fuel while riding, set
the fuel cock to this position.
Fill the tank at the first
opportunity. Be sure to set the
fuel cock back to "ON" after
refueling
NEVER MIX OIL IN PETROL
3-7
a
1. Starter lever
b
Starter lever
Starting a cold engine requires a
richer air-fuel mixture. A separate
starter circuit supplies this mixture.
Move the Starter Lever in
Direction a to Turn on theStarter
Move the Starter Lever in
Direction b to TurnOff the Starter
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INSTRUMENT AND CONTROL FUNCTIONS
2
1
1. Kick starter
Kick-starter
Raise the right Pillion footrest, and
rotate the kick starter away from the
engine. Push the starter down
lightly with your foot Kick until the
gears engage, then kick smoothly and
forcefully to start the engine. This
model has a primary-coupled kick
starter so the engine can be started in
any gear if the clutch is disengaged.
However, shifting to neutral before
starting is recommended.
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1. Seat Holder
2. Projection
To install
Insert the projection on the rear of
seat in to seat holder. Then push
down on front of the seat and tighten
the bolts on the left and right hand
side of the seat.
kick
1. Open (Bolt - 1 No.)
2. Open (Bolt - 1 No.)
Opening of Seat
To remove
Open side panels as per instructions
on page 6-5.
Remove the two bolts 1 and 2 as
shown in figure. Lift the front of the
seat and slide forward to remove.
ALWAYS USE A HELMET WHILE RIDING FOR YOUR SAFETY
3-8
8
1
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1
1. Storage compartment
Storage compartment
The storage compartment is located
inside the L.H. Side Cover
INSTRUMENT AND CONTROL FUNCTIONS
1
b
2
a
1. Spring preload adjusting ring
2. Position indicator
Rear shock absorber
adjustment
Each shock absorber is equipped
with a spring preload adjusting ring.
Adjust spring preload as follows.
Turn the adjusting ring in direction a
to increase spring preload and in
direction b to decrease spring
preload. Make sure that the
appropriate notch in the adjusting
ring is aligned with the position
indicator on the rear shock absorber.
Stan-
Soft
Adjusting
Position
(Depends upon rider's requirement)
12345
dard
Hard
WARNING
Always adjust each shock
absorber to the same setting.
Uneven adjustment can cause poor
handling and loss ofstability.
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INSTRUMENT AND CONTROL FUNCTIONS
1
1
1. HandleSeat
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1. Stay Lock on Saree Guard
Stay Lock
For mounting Helmet Lock
3-10
10
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Owners are personally responsible for their vehicle's condition. Your Motorcycle's vital functions can start to
deteriorate quickly and unexpectedly- even if it remains unused (for instance, if it is exposed to the elements). Any
damage. fluid leak or loss of tyre pressure could have serious consequence Therefore' it is very important that, in
addition to a thorough visual inspection, you check the following points before each ride.
PRE-OPERATION CHECKS
PRE - OPERATION CHECK LIST
ITEM CHECKS
Front brake
Rear brake
Clutch
Throttle grip and housing
Engine oil
Drive chain
Wheels and tyres
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• Check operation, condition and free play.
• Adjust if necessary.
• If necessry, add recommended brake fluid to specified level.
• If soft or spongy, have YAMAHA dealer bleed hydraulic system.
• Check fluid level in reservoir.
• Check hydraulic system for leakage.
• Check operation, condition and free play.
• Adjust if necessary.
• Check operation, condition and free play.
• Adjust if necessary.
• Check for smooth operation.
• Lubricate if necessary.
• Check oil level.
• Fill with oil if necessary.
• Check chain slack and condition.
• Lubricate if necessary.
• Adjust if necessary.
• Check tyre pressure, wear, damage and spoke tightness.
• Tighten spokes if necessary.
4-1
1
PAGE
3-4, 6-18
3-5, 6-17
3-4, 6-16
6-12, 6-22
6-8 ~ 6-9
6-19 ~ 6-20
6-13 ~ 6-15
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PRE-OPERATION CHECKS
ITEM CHECKS
Control and meter cable
Brake and shift pedal shafts
Brake and clutch lever pivots
Center and sidestand pivot
Chassis fasteners
Fuel Tank
Lights, signals and switches
Battery
• Check for smooth operation.
• Lubricate if necessary.
• Check for smooth operation.
• Lubricate if necessary.
• Check for smooth operation.
• Lubricate if necessary.
• Check for smooth operation.
• Lubricate if necessary.
• Make sure that all nuts, bolts, and screws are properly tightened.
• Tighten if necessary.
• Check fuel level.
• Fill with fuel if necessary.
• Check for proper operation.
• Check fluid level.
• Fill with distilled water if necessary.
PAGE
6-22
6-23
6-23
6-23
-
3-5 ~ 3-6
3-3, 6-28 ~ 6-29
6-25 ~ 6-26
WARNING
If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the Motorcycle.
IF WAITING AT TRAFFIC SIGNAL IS FOR LONG, SWITCH OFF THE ENGINE
TO PROTECT THE ENVIRONMENT AND TO LOWER FUEL CONSUMPTION
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OPERATION AND IMPORTANT RIDING POINTS
WARNING
1. 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 thoroughly understand.
2. 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.
Always operate your
Motorcycle in an area with
adequate ventilation.
3. Before starting out, always be
sure the side stand is up.
Failure to retract the side stand
completely can result in a
serious accident when you try
to turn a corner.
Starting and warming up a
cold engine
1. Turnthe fuel cock to "ON"
2. Turnthe main switch to "ON."
3. Shift the transmission into
neutral.
NOTE :
When the transmission is in neutral,
the neutral indicator light should be on.
If the light does not comeon, aska YMI
dealer to inspect it.
4 Fully open the Starter Lever and
completely close the throttle grip.
5. Kick the kick starter to start the
engine.
6. After starting the Engine, turn back
the Starter Lever to the Warmingup Position (About Half way)
7. After Warming-up the Engine,
turn off the Starter Lever
completely.
NOTE :
For better engine performance
always warm up the engine. before
take off. Never open throttle fully
when engine is cold, otherwise
engine tends to stop.
NOTE :
The engine is warm when it
responds normally to the throttle
with the Starter Lever in “OFF”
direction.
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OPERATION AND IMPORTANT RIDING POINTS
Starting a warm engine.
The Starter Lever may not be required
when the engine is warm.
CAUTION :
See the "Running-in" section prior
to operating the Motorcycle for the
first time.
NEVER RIDE MOTORCYCLE WITH CLUTCH PARTIALLY ENGAGED.
4
3
2
N
1
a
a. Shift pedal
N. Neutral, 1,2,3,4 Gear Shift Patterns
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 pedal is shown in the
illustration.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
CAUTION :
• Do not ride downhill with
Ignition Switch in “OFF”
Position & in NeutralGear.
• Always ride motor cycle with
Ignition Switch in “ON”
Position & in NeutralGear.
• Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.
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