Yamaha Fazer User manual

SERVICE
MANUAL

L-1
FAZER
SERVICEMANUAL
YAMAHAMOTORINDIAPVT.LIMITED
All rights reserved.
Any reprinting or unauthorised use without
the written permission of
YAMAHAMOTORINDIAPVT.LIMITED
is expressly prohibited.

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FOREWORD
This Workshop Manual has been prepared for use by the Yamaha Motor
India Private Ltd. Authorised Dealerships and their service personnel to attend
to servicing of Fazer Motorcycles. It is not possible to include entire service
education into this Manual. It is assumed that persons using this book to
perform maintenance and repairs on Fazer Motorcycles have a basic
understanding of mechanical concepts and procedures inherent to Motorcycle
repair technology. Without such knowledge, attempted repairs or service of
this model may render it unfit for use and / or unsafe.
Yamaha Motor India Private Ltd. continually strives to improve all its
models. Modifications and significant changes in specifications or procedures
will be informed to all Yamaha Motor India Private Ltd. Authorised Dealerships
through Service Actions and will wherever considered necessary, appear in
future editions of this Workshop Manual.
Service Department
Yamaha Motor India Private Ltd.

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ENG
ENGINE ASSEMBLY AND ADJUSTMENTS
Piston Pin replacer tool
YSST - 607
ENGINE ASSEMBLY
1
3
HOW TO USE THIS MANUAL
MANUAL ORGANISATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the Title of the Chapter with its symbol on the upper right corner of each page.
2nd title 2 : This title indicates the Section of the chapter and only appears on the first
page of each section. It is located in the centre of the page.
3rd title 3 : This title indicates a Subsection that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are Exploded Diagrams at start of
each Removal and Disassembly section.
1. An easy-to-see Exploded Diagram 4 is provided for Disassembly and Assembly jobs.
2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is en-
closed by a circle indicates a part.
3. An explanation of jobs and notes are presented in an easy-to-read way by the use of Symbol
Marks 6. The meaning of the Symbol Marks are given on the next page.
4. For jobs requiring more information, the step-by-step format supplements 7are given in
addition to the exploded diagram.
4
2
5
7
6
PISTON RING, PISTON AND CYLINDER
INSTALLATION
1. Install in following sequence
• Expander Spacer (Oil Ring) ¿
• Side Rails (Oil Ring) À
• 2nd Ring Á
• Top Ring Â
NOTE :
• Make sure to install the Piston Rings so that
the RN marks are located on the upper side
of the 2nd Ring.
• Lubricate the Piston and Piston Rings with
Engine Oil.
2. Install :
• Piston ¿
• Piston Pin Àusing piston pin tool
• Piston Pin Circlip ÁNew
¿À
Á

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10.Lubricant
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number
and content.
GEN
INFO SPEC
INSP
ADJ ENG
CARB CHAS
ELEC TRBL
SHTG
Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and
lubrication points.
1. General
Information 2. Specifications
7. Electrical 8. Troubleshooting
5. Carburetion 6. Chassis
3. Periodic inspection
and adjustment 4. Engine
9. Filling fluid 11.Special Tool
15.Resistance,
Voltage, Current
12.Torque 13.Wear Limit,
Clearance 14.Engine speed
Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.
16. Apply engine oil 17. Apply gear oil 18. Apply molybdenum
disulfide oil
19. Apply wheel
bearing grease 20.Apply lightweight
lithium-soap base
grease
21. Apply molyb-
denum disulfide
grease
22. Apply locking
agent (LOCKTITE*)
Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking
agent and when to install new parts
23. Use New One

INDEX
GENERAL INFORMATION GEN
INFO 1
TROUBLE SHOOTING TRBL
SHTG 8
ELECTRICAL ELEC 7
CHASSIS CHAS 6
CARBURETION CARB 5
ENGINE ENG 4
PERIODIC INSPECTION AND
ADJUSTMENTS INSP
ADJ 3
SPECIFICATIONS SPEC 2

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER.........................................................1-1
ENGINE SERIAL NUMBER .......................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY ......................................1-2
ALL REPLACEMENT PARTS ....................................................1-3
GASKETS, OIL SEALS, AND O-RINGS....................................1-3
LOCK WASHERS/PLATES AND COTTER PINS......................1-3
BEARINGS AND OIL SEALS.....................................................1-3
CIRCLIPS ...................................................................................1-3
SPECIAL TOOLS
SPECIAL SERVICE TOOLS ......................................................1-4
SERVICE INSTRUMENTS.........................................................1-7
SPECIAL SERVICE MATERIALS ..............................................1-8

GEN
INFO
FRAME SERIAL NUMBER
The Frame Serial Number ¿ is stamped into the
right side of the Steering Head Pipe.
ENGINE SERIAL NUMBER
The Engine Serial Number À is stamped on the
top portion of RH Crankcase. ( Engine Serial
Number does not contain Year and Month of
production)
NOTE :
Designs and sepecifications are subject to
change without notice.
MOTORCYCLE IDENTIFICATION
MOTORCYCLE IDENTIFICATION
Do not tamper with any of these numbers. It
may lead to legal action.
Year of Production : 2 Digits standing for last two digits of year
Eg. 0 0 - 2000, 0 1 - 2001 ......
Month Code : One alphabet standing for Month
Eg. A- January, B- February........
M- December ( I- Not Used for Month)
Starting Serial Number : 5YY 000001
X5YY
XX
YEAR OF
PRODUCTION MONTH CODE MODEL
CODE UNIT PRODUCTION
NUMBER
XXXXXX
WARNING
1-1

GEN
INFO
PREPARATION FOR DISASSEMBLY
1. Remove all dirt, mud, dust and foreign ma-
terial before disassembly.
2. Use proper Tools and Cleaning Equipment.
Refer to “YAMAHA SPECIAL SERVICE
TOOLS”.
3. When disassembling the Motorcycle, keep
mated parts together. This includes gears,
Cylinder, Piston and other mated parts that
have been “mated” through normal wear.
Mated parts must be reused as an assem-
bly or replaced.
4. During the Motorcycle disassembly, clean
all parts and place them in trays in the or-
der of disassembly. This will speed up as-
sembly time and help assure that all parts
are correctly reinstalled.
5. Keep Motorcycle and its parts away from
any source of fire.
IMPORTANT INFORMATION
IMPORTANT INFORMATION
1-2

GEN
INFO
IMPORTANT INFORMATION
1-3
WARNING
If the Circlip is fitted the wrong way it would
cause it to jump off its groove and damage
related components.
WARNINGCAUTION:
Do not use compressed air to spin the
Bearings dry. This causes damage to the
Bearing surfaces.
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use Yamalube Oil and
Grease recommended by Yamaha for
assembly and adjustment. Other brands
may be similar in function and appearance,
but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS
1. All Gaskets, Seals and O-rings should be
replaced when the Engine is overhauled.
2. All surfaces where Gasket, Oil Seal lips and
O-rings contact must be cleaned and
Lubricated.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All Lock Washers/plates ¿ and Cotter Pins
must be replaced when they are removed.
Lock tab (s) should be bent along the Bolt
BEARINGS AND OIL SEALS
1. Install the bearing (s) ¿ and Oil Seal (s)
À with their manufacturer’s marks or
numbers facing outward. (In other words,
the stamped letters must be on the side
exposed to view.) When installing Oil Seal
(s), lubricate a light coating of lightweight
lithium base grease to the seal lip(s). Oil the
Bearings liberally when installing.
CIRCLIPS
1. All Circlips should be inspected carefully
before reassembly. Always replace Piston
Pin Clips after one use. Replace distorted
Circlips. When installing a circlip ¿, make
sure that the sharp-edged corner À is
positioned opposite to the thrust Á it
receives. See the sectional view of shaft Â.