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OTOR OIL ngine Life intenance Cost haust Smoke Wear and Tear OWNER'S MANUAL 5P4-E8199-E0 Starter Motor & Disc Brake Starter Motor & Disc Brake PRINTED IN INDIA 5P41- FAZER 2Y16(OM-01)-234-10-05...
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WARNING PLEASE READ THIS MANUAL CAREFULLYAND COMPLETELY BEFORE 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 INDIA PVT. LIMITED is expressly prohibited. TAKE NECESSARY PRECAUTIONS DURING RUNNING-IN PERIOD.
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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.
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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. fazer5p41.pmd 10/1/2005, 12:57 PM...
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.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS WARNING Never turn the key to "LOCK" when the Motorcycle is moving. Push Main switch cum steering Release lock Turn LOCK: The main switch controls the ignition The steering is locked in this position and lighting systems.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS Turn signal switch To signal a right-hand turn, push the switch to " ". To signal a left- hand turn, push the switch to " ". Once the switch is released it will return to the center position. To Press cancel the signal, push the switch in after it has returned to the center...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS Shift pedal Front brake lever Clutch lever Clutch lever Shift pedal Front brake lever The clutch lever is located on the left The shift pedal is located on the left The front brake lever is located on side of the engine and is used in the right handlebar.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen 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. WARNING WARNING Be sure the cap is properly installed and locked in place Open Rear brake pedal...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS 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 : Filler tube Arrow mark Always wipe off spilled fuel Fuel level...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS 1. Arrow mark 1. Arrow mark 1. Starter lever ON: With the fuel cock in this RES: This indicates reserve. If you Starter lever position, fuel flows to the run out of fuel while riding, set Starting a cold engine requires a carburettor.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS Kick starter Seat Holder Open (Bolt - 1 No.) Kick-starter Projection Open (Bolt - 1 No.) To install Raise the right Pillion footrest, and Opening of Seat rotate the kick starter away from the Insert the projection on the rear of To remove engine.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen INSTRUMENT AND CONTROL FUNCTIONS Stan- Soft Hard dard Adjusting Position (Depends upon rider's requirement) WARNING A l w a y s a d j u s t e a c h s h o c k absorber to the same setting. 1.
• If necessry, add recommended brake fluid to specified level. 3-4, 6-18 Front brake • 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.
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PRE-OPERATION CHECKS ITEM CHECKS PAGE • Check for smooth operation. 6-22 Control and meter cable • Lubricate if necessary. • Check for smooth operation. Brake and shift pedal shafts 6-23 • Lubricate if necessary. • Check for smooth operation. Brake and clutch lever pivots 6-23 •...
2. Turn the main switch to "ON." their functions. Consult a NOTE : 3. Shift the transmission into YAMAHA dealer regarding any For better engine performance neutral. control or function that you do always warm up the engine. before not thoroughly understand.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen OPERATION AND IMPORTANT RIDING POINTS CAUTION : Starting a warm engine. • Do not ride downhill with The Starter Lever may not be required Ignition Switch in “OFF” when the engine is warm. Position & in Neutral Gear. •...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen OPERATION AND IMPORTANT RIDING POINTS 8. Avoid frequent braking. Tips for reducing fuel CAUTION : 9. Always maintain your tyre consumption Be sure to replace the engine oil as pressure as per recommendation per recommended schedule. Your Motorcycle's fuel consumption 10.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen OPERATION AND IMPORTANT RIDING POINTS Parking When parking the Motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to "OFF" whenever stopping the engine. WARNING The exhaust system is hot. Park the Motorcycle in a place where pedestrians or children are not likely to touch the Motorcycle.
If you are not familiar with in the safest and most efficient Motorcycle service, this work condition possible. Safety is an should be done by a YAMAHA obligation of the Motorcycle owner. dealer. The maintenance and lubrication schedule chart should be considered...
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CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR NOTE : If you do not have necessary tools required during a service operation, take your Motorcycle to a YAMAHA dealer for service. WARNING Modifications to this Motorcycle not approved by YAMAHA may cause loss of performance, and render it unsafe for use.
Colorprofile:Disabled CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR PREVENTIVE MAINTENANCE SCHEDULE DURING SERVICE DAYS OR KMS AFTER WHICHEVE OCCURS FIRST ITEM OPERATION 180 DAYS OR 30 DAYS OR 90 DAYS OR 2000 KMS 2500~2700 KMS 4500~5000 KMS 500~700 KMS Check valve clearances, adjust if necessary. VALVES Check condition, gap;...
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Check operation, free play, cable damage -THROTTLE Readjust or replace as required. -CLUTCH -FRONT BRAKE IT IS RECOMMENDED THAT THE ABOVE BE SERVICED BY AUTHORIZED YAMAHA DEALER. SERVICE MORE FREQUENTLY WHEN THE VEHICLE IS DRIVEN IN DUSTY AREAS. CHAPT4_5_6.cdr Wednesday,October19,200510:32:42AM...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Lug 2. Panel B 2. Panel A Panel removal and installa- 3. Lug tion Removal of Panel A The panels illustrated need to be Unlock the panel. removed to perform some of the maintenance described in this Pull the lug 1 towards you to remove manual.
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR 1. Lug 1. Lug 1. Lug. 2. Lug 2. Lug 2. Lug 3. Lug 3. Lug Removal of Panel B Installation of Panel A Installation of Panel B Loosen screw completely and follow Slide the panel towards the Rear of Follow the same procedure as given t h e s a m e p r o c e d u r e a s f o r...
Do not attempt to diagnose any problems yourself. Instead, take A.- Spark plug gap: 0.6-0.7 mm the Motorcycle to a YAMAHA dealer. When installing the plug, always You should periodically remove and clean the gasket surface and use a inspect the spark plug because heat new gasket.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler cap 1. Dipstick Maximum level Minimum level 2. Engine oil replacement Engine oil a. Warm up the engine for a few 1. Oil level measurement NOTE : minutes. a. Place the Motorcycle on the Wait a few minutes until the oil level b.
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR Start the engine and warm up Tightening torque: for a few minutes. While Drain plug: warming up, check for oil leak- 14.5 It-lb (2.0 m-kg) age. If oil leakage is found, stop the engine immediately and e.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter element Air filter case cover Air filter element 2. Frame Screw(4 Nos) Lockable SpringWire Air filter The air filter should be cleaned at 5. Remove the air filter elements 3. Remove the air filter from the the specified intervals.
1. Do not Tamper/Adjust with TPS NOTE : (Throttle Position Sensor) If the specified idle speed cannot be 2. Do not Open BS (Butterfly Slide) obtained by performing the above Valve Screws. adjustment, consult a YAMAHA Please refer Page 6.3 dealer. 6-12 CHAPT6_A.cdr Saturday,October01,20051:03:43PM...
If proper adjustment cannot be obtained or the clutch does not work correctly, ask a YAMAHA dealer to i n s p e c t t h e i n t e r n a l c l u t c h mechanism.
20 ~ 30 mm the proper adjustment, ask a (Instruction 2, a ) at the brake pedal vated by the brake pedal and is YAMAHA dealer. end. Turn the adjusting nut in properly adjusted when the brake •...
Have a YAMAHA dealer check the l e a k a g e a n d p o o r b r a k i n g brake fluid at the intervals specified in performance the periodic maintenance.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR 1. Chain joint 1. Locknut Adjusting nut 2. Adjusting Nut Cotter pin If the chain is disassembled, be sure Axle nut 4. Loosen the chain adjusting the chain lock is placed in the Drive chain slack adjust- locknuts on each chain puller.
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR Adjust the free play in the CAUTION : brake pedal. • Maintain chain slackness within specified limits as per specifications. WARNING Check the operation of the brake • To maintain correct axle light after adjusting the rear alignment, Ensure the notch brake.
Lubricate the pivoting and mating Lubricate the pivoting parts. joints. Recommended Grease : Check to see that the center and MULTIPURPOSE sidestand move up and down smoothly. WARNING If the center and/or sidestand does not move smoothly, consult a YAMAHA dealer. 6-23 Chapt6_b.cdr Saturday,October01,20051:04:48PM...
Check for scratches or damage forward and backward. If any free on the inner tube and excessive play can be felt, ask a YAMAHA oil leakage from the front fork. dealer to inspect and adjust the steering. Inspection is easier if the front wheel is removed.
If there is play in the front or rear so there is no danger of it falling wheel hub or if the wheel does not over. turn smoothly, have a YAMAHA dealer inspect the wheel bearings. 1. Maximum level mark 2. Minimum level mark...
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR Replenishing the battery fluid CAUTION : Antidote: A poorly maintained battery will EXTERNAL: Flush with water. When inspecting the battery, be corrode and discharge quickly. The sure the breather hose is routed INTERNAL: Drink large quantities battery fluid should be checked at correctly.
Install a new fuse of proper connected and is not damaged or amperage. Turn on the switches and obstructed. see if the electrical device operates. If the fuse immediately blows again, consult a YAMAHA dealer. 6-27 Chapt6_c.cdr Saturday,October01,20051:05:29PM...
2. Loosen the Bolt "2" below the secure it in place with the bulb Headlight Cowling. holder. 3. Slide Headlight forward.. 6. Install the Head Light Assy. 7. If the headlight beam adjustment is necessary, ask a YAMAHA dealer to make adjustment. 6-28 Chapt6_c.cdr Saturday,October01,20051:05:29PM...
PERIODIC MAINTENANCE AND MINOR REPAIR Front wheel removal WARNING • It is advisable to have a YAMAHA dealer service the wheel. • S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over.
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cotter Pin 2. Axle Nut Speedometer Cable 3. Remove the cotter pin '1' and axle 1. Place the Motorcycle on the nut '2'. centerstand. 4. Remove the Axle. 2. Loosen the Speedometer cable 5.
Rear wheel removal Always use a new cotter pin. WARNING • It is advisable to have a YAMAHA dealer service the Axle nut torque: wheel. 33 ft-lb (4.55 m-kg) • S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over.
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2. Remove the cotter pin and nut. lever. Then remove the tension bar 4. Remove the axle nut cotter pin from the brake shoe plate. and the axle nut. ALWAYS USE YAMAHA GENUINE SPARE PARTS 6-32 Chapt6_c.cdr Saturday,October01,20051:05:33PM...
If your Motorcycle requires tightening torque. any repair, bring it to a YAMAHA 5. Take the Motorcycle off the dealer. The skilled technicians at a centerstand. YAMAHA dealership have the tools, 6.
2. Compression There is compression Go to Ignition check. Use kick starter. No compression. Ask YAMAHA dealer to inspect. 3. Ignition Wipe clean with dry cloth Open the throttle half-way and correct spark plug and start the engine.
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen CLEANING AND STORAGE A. CLEANING 1. Before cleaning the Motorcycle: CAUTION : a. Block off the end of the exhaust Direct excessive Hose Pressure Frequent, thorough cleaning of your pipe to prevent water entry; a may cause water Entry Into Wheel Motorcycle will not only enhance its plastic bag and strong rubber Bearing, Front Fork Brakes,...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen CLEANING AND STORAGE B. STORAGE 8. Clean the seat with a vinyl solvent and lubricate it. Reinstall upholstery cleaner to keep the the chain or store it in a plastic bag Long term storage (60 days or more) (tied to frame for safe-keeping).
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen SPECIFICATIONS Specifications EngineOil: Type: YAMALUBE 4-Stroke motor Model FAZER oil (20W40 type SG) Dimensions Overall length 2065 mm CAUTION : Overall width 730 mm Be sure to use motor oils that do not contain Overall height 1060 mm antifriction modifiers.
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen SPECIFICATIONS Spark plug : Tyre with Tube Type/Manufacturer CR7HSA (NGK) Size Spark plug gap 0.6-0.7 mm Front 2.75 x18” 4PR (RIBBED) Clutch type : Wet, multiple-disc Transmission : Rear 3.00 X18” 6PR (UNIVERSAL) Primary reduction system Helical gear Air pressure (cold tyre ): Primary reduction ratio 3.578 (68/19)
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Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen SPECIFICATIONS Wheels: Electrical: Type: Ignition system: DC-CDI (Digitally Timing Front Spoke wheel Advanced) Rear Spoke wheel Generator system: Size: Type Flywheel magneto Front 1.60 X 18 Standard output Rear 1.60 X 18 Battery: Brakes: Type Lead acid Front : Voltage, capacity 12V 5.0 AH Type...
Colorprofile:GenericCMYKprinterprofile CompositeDefaultscreen CUSTOMER INFORMATION Key identification number Frame serial number Engine serial number Key identification number Frame serial number Engine serial number The key identification number is The frame serial number is stamped The engine serial number is stamped on the Tag. into the steering head pipe on right stamped into the right hand hand side.
PRE-DELIVERY INSPECTION REPORT (To be filled in by the Dealer on receipt of the Motorcycle from YMI) Frame Engine Odo-Meter Date of Date of Reading Inspection Sale 1. Check for any missing item(s), scratches in painted/plated part(s), saddle or other external visual damages and take corrective action.
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PRE-DELIVERY INSPECTION REPORT f. Wheels Tyre Tyre pressure Solo Double (PSI) Front Rear Runout - Radial - 1.5 mm (Max) - Lateral - 1.5 mm (Max) Spokes No loosenes g. Locks Operation • Ignition • Steering • Fuel Tank Cap •...
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PRE-DELIVERY INSPECTION REPORT b. Spark Plug Recommended No. (CR7HSA-NGK) 0.6-0.7 mm c. Valve Clearance (Cold condition) (If required) Inlet 0.08 ~ 0.12 mm Exhaust 0.10 ~ 0.14 mm (After matching of the mark on sprocket cam chain with mark on Cylinder Head Casting and ensuring the Piston at TDC of compression stroke.) d.
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PRE-DELIVERY INSPECTION REPORT C. ELECTRICAL a. Ignition Switch Operation b. Left Hand Switch Operation & Pass Beam • Horn • Indicator • Head Light c. All Bulbs - Functioning d. Battery • Electrolyte Level • Specific Gravity • Routing of Breather Pipe •...
INSTALLATION Procedures to be explained to the customer on delivery of the Motorcycle by the Dealer's Representative. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.). Fuel Cock Lever Operation and its reserve position; Fuel Tank Capacity including reserve. Operation and function of Starter Lever.
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INSTALLATION Location of Storage and Tool Kit compartments and their use. Procedure of opening and closing of L. H. Side Panel. Battery Maintenance : Checking of electrolyte level (To add only distilled water if required & to maintain its Specified Level) Correct Drive Chain Slackness (20 ~30 mm).
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NOTES NOTES IF REQUIRED.pmd 10/1/2005, 1:14 PM...
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NOTES NOTES IF REQUIRED.pmd 10/1/2005, 1:14 PM...
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CONTENTS • DO’S & DON’TS for the Motorcycle • Procedure for measurement of ‘CO’ Emission Level. • List of Components impacting Emission greenbook.PMD 10/1/2005, 12:57 PM...
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• 4T - 20W/40 SG grade - YAMALUBE 4T Always keep your engine well turned. Save environment and also improve Fuel Efficiency • ALWAYS GET YOUR MOTORCYCLE REPAIRED AND MAINTAINED ONLY AT YAMAHA AUTHORISED DEALER. • YAMAHA serves you through a wide network of Authorised Dealers.
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DO’S AND DON’TS FOR THE MOTORCYCLE 6 Always drive with Starter Lever in OFF position. Use Starter Lever for minimum possible period (1 to 2 minutes) only to start and warm up Engine (may be required only in winter) If misfiring, get your Motorcycle diagnosed & attended immediately without running even for a KM. Get Motorcycle maintained regularly as per details and schedule given in Owner’s Manual.
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Insert the Sampling probe of the Exhaust Gas Analyser inside the Exhaust Muffler of the Motorcycle. • If the reading is within specified limits then it is acceptable. • If the reading exceeds the norm of 3.5% (by volume) have it adjusted by YAMAHA Authorised Dealer. 3. LIST OF COMPONENTS IMPACTING “EMISSION” Air Filter...
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4 STROKE MOTOR OIL 20W40 • Longer Engine Life • Lower Maintenance Cost • Lower Exhaust Smoke • Reduces Wear and Tear YAMAHA MOTOR INDIA PRIVATE LIMITED 19/6, Mathura Road, Faridabad - 121 006 INDIA PRINTED IN INDIA 5P41- FAZER 2Y16(OM-01)-234-10-05...