Yamaha FZ6-SS User manual

CONCERNING CRATE DAMAGE:
WARNING
CAUTION:
EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha motor-
cycle prior to delivery to the customer. Since some external parts of the motorcycle 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 motorcycle 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 signifi-
cant 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 com-
pletely. Failure to do so can result in poor performance and possible harm to the motorcycle and/or rider.
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!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person checking or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
EAA00001
FZ6-SS
FZ6-SSC
ASSEMBLY MANUAL
E2003 by Yamaha Motor Corporation,
U.S.A. First Edition, November 2003
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-11666-17-50

(1) (2)
(3) (4)
(5) (6)
(7)
(8)
EAA00008
SYMBOLS USED IN THE
ASSEMBLY MANUAL
In order to simplify descriptions in this as-
sembly 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 motorcycle
(4): Clearance required
(5): Install so that the arrow mark faces up-
ward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of op-
erations.)
B: Part name
C: Quantity of parts per motorcycle
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 Styro-
foam tray (upper or lower)
*: Temporarily installed or secured
E: Size or material of parts
d / D: Diameter of part
ȏ: Length of part
e.g., 5 = 5 mm (0.2 in)

(1) (2)
(3) (4)
(5) (5)
EAA00040
PREPARATION
To assemble the motorcycle correctly, sup-
plies (e.g. oils, greases, and shop rags) and
sufficient working space are required.
Workshop
The workshop where the motorcycle is as-
sembled 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 opera-
tion which may cause particles to fly off.
Protect hands and feet by wearing safety
gloves or shoes.
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) Insertion of the forklift arms from this
side can cause damage.
(5) 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 dam-
age the package contents.

–1–
NOTE:
NOTE:
NOTE:
EAA00060
UNPACKING
1. Remove the frame cover (1).
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.)
Remove the bolts while holding the frame.
Before starting the assembly, check for
damaged or missing parts. Check both the
parts contained in the carton boxes and on
the motorcycle for damage, scratches, and
other defects.

–2–
EAA00070
PARTS LOCATION
(1) Carton box 1.
(2) Carton box 2.
(3) Front tire.

–3–
7EAA00080
(1) Carton box 1
1. Screws and special nuts (windshield)
2. Upper handlebar holders
3. Rivets
4. Screws
5. Bolts
6. Plugs
7. Nuts
8. Screws
9. Washers
10.Screws
11. Nuts
12.Bands
13.Inner panels
14.Windshield trims
15.Rear view mirrors
16.Windshield
17.Front fender
18.Owner’s manual
(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 brack-
et)
6. Screws (left handlebar switch)
7. Collars
(3) Front tire

–4–
EAA00100
SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

–5–
1 Handlebar holders 2 V
2 Hexagon head bolt 4 V d = 8 (0.31), ȏ= 30 (1.18)
3 Plug 4 V
4 Handlebar 1 C
1 Screw 1 d = 5 (0.20), ȏ= 45 (1.77)
2 Screw 1 d = 5 (0.20), ȏ= 20 (0.79)
3 Grip end 1 V
1 Front tire 1 S
2 Collar 2 V
3 Axle 1
4 Hexagon head bolt 1
CAUTION:
WARNING
WARNING
NOTE:
CAUTION:
EAA00014
EAA00102
1. HANDLEBAR
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
C: Align the punch mark on the
handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specifica-
tion.
Bolt:
23 Nm (2.3 mSkg, 17 ftSlb)
EAA00016
EAA00104
2. THROTTLE GRIP
A: Align the projection on the han-
dlebar switch with the hole in
the handlebar.
B: Tighten the bolt to specifica-
tion.
Bolt:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)
C: Check the throttle grip for
smooth action.
Proper cable routing is essen-
tial to assure safe motorcycle
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:
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.
E: Lift the front wheel and install
the front wheel axle. Be sure
the arrow on the tire is pointed
in the rotating direction.
Do not depress the brake lever
when the calipers are off the brake
discs.
F: Tighten the wheel axle to speci-
fication.
Wheel axle:
72 Nm (7.2 mSkg, 52 ftSlb)
Before tightening the wheel axle
pinch bolt, stroke the front forks
several times to make sure of
proper fork operation.
G: Tighten the wheel axle pinch
bolt to specification.
Wheel axle pinch bolt:
23 Nm (2.3 mSkg, 17 ftSlb)

–6–
1 Front fender 1 S
2 Bolt 2 V d = 6 (0.24), ȏ= 22 (0.87)
3 Bolt 2 V d = 6 (0.24), ȏ= 25 (0.98)
4 Collar 2 V d = 6 (0.24)
1 Bolt 1 V d = 5 (0.20), ȏ= 45 (1.77)
2 Bolt 1 V d = 5 (0.20), ȏ= 30 (1.18)
1 Bracket 1 V
2 Hexagon head bolt 2 V d = 6 (0.24), ȏ= 20 (0.79)
3 Master cylinder 1
4Brake light switch connector 2
CAUTION:
WARNING
WARNING
WARNING
EAA00022
EAA00110
4. FRONT FENDER
A: Tighten the front fender bolts to
specification.
Bolt:
6 Nm (0.6 mSkg, 4.3 ftSlb)
B:
Make sure the brake hose is
routed outside of the front fend-
er.
Be careful not to scratch the
front fender with the front fork
outer tube.
Proper cable routing is essen-
tial to assure safe motorcycle
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
B: Make sure that the “UP” mark
with the bracket is pointed up-
ward.
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 specifica-
tion.
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.
Proper cable and hose routing
is essential to assure safe mo-
torcycle 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.
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to “CABLE ROUTING”.
B: Tighten the bolts to specifica-
tion.
Bolt:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)

–7–
1 Band 2 V
1 Clutch cable 1
2 Clutch switch lead coupler 1
1 Windshield 1 C
2 Special nut 5 V
3 Screw 5 V
4 Windshield trims 2 C
NOTE:
WARNING
WARNING
CAUTION:
EAA00049
EAA00137
7. CLUTCH CABLE
A: Lubricate the pivoting part of
the clutch lever.
Recommended lubricants:
Yamaha cable lube or motor
oil
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 le-
ver hole. Next, while pulling the
outer cable in the direction op-
posite to the lever, seat the out-
er cable into the cable socket.
Check the clutch lever for smooth
action.
Refer to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.
C: Install the clutch switch lead
coupler.
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to “CABLE ROUTING”.
8. BAND
A: Clamp the left handlebar
switch lead.
B: Clamp the right handlebar
switch lead.
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to “CABLE ROUTING”.
EAA00053
EAA00141
9. WINDSHIELD
The windshield is made of an
acrylate resin. Take care so that
it is not scratched.
A: Tighten the bolt to specifica-
tion.
Bolt:
0.4 Nm (0.04 mSkg, 0.3 ftSlb)

–8–
1 Rear view mirror 2 C
2 NUT 4 V
1 Inner panel 2 C
2 Screw 2 V d = 6 (0.24), ȏ= 16 (0.63)
3 Washer 2 V d = 6 (0.24)
4 Screw 2 V d = 5 (0.20), ȏ= 12 (0.47)
5Rivet 2 V
6 Screw 2 d = 6 (0.24), ȏ= 16 (0.63)
7 Washer 2 d = 6 (0.24)
1 Battery 1
2 Battery cover 1
3 Bolt 2 d = 6 (0.24), ȏ= 25 (0.98)
4 Bolt 2 d = 6 (0.24), ȏ= 10 (0.39)
NOTE:
NOTE:
NOTE:
NOTE:
10. REAR VIEW MIRRORS
A: Tighten the rear view mirrors
nuts.
Nut:
7 Nm (0.7 mSkg, 5.1 ftSlb)
11. INNER PANEL
Remove the seat and fuel tank.
A: Tighten the bolts to specifica-
tion.
Bolt:
1.3 Nm (0.13 mSkg, 0.9 ftSlb)
B: Tighten the bolts to specifica-
tion.
Bolt:
4.5 Nm (0.45 mSkg, 3.3 ftSlb)
C: Install the rivets.
EAA00189
12. BATTERY
A: Install the battery.
Refer to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.
B: Install the battery cover.
Bolt:
7 Nm (0.7 mSkg, 5.1 ftSlb)
C: First, connect the positive lead
(red lead) to the positive termi-
nal.
D: Second, connect the negative
lead (black lead) to the nega-
tive terminal.
Refer to “CABLE ROUTING”.
Install the fuel tank and seat.

–9–
WARNING
EAA00900
CABLE ROUTING
Proper cable and lead routing are essential to insure safe motor-
cycle operation.
(1) Right handlebar switch lead
(2) Throttle cables
(3) Clutch cable
(4) Left handlebar switch lead
(5) Main switch lead
(6) Battery positive lead
(7) Battery cover
(8) Starter relay lead
(9) Battery negative lead
A Clamp the right and left handlebar switch leads to the handlebar.
Point the tip of the clamp downword 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.
C Route the main switch lead and immobilizer lead above the clutch
cable.
D Route the throttle cables above the stay 1.
E Hook the starter motor lead to the alternate pawls on the battery
cover.
F Route the starter relay lead outside of the main switch and immobi-
lizer lead.

–10–
EAA01100
ADJUSTMENTS AND PREDELIVERY
SERVICE
Perform the predelivery service in the order indicated by the letters.
Always follow the order as shown.

–11–
NOTE:
WARNING
CAUTION:
WARNING
EAA01000
A. CHECKING AND CHARGING
THE BATTERY
The battery used in this motorcycle 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 dis-
charged 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
DDo not attempt boost charging under
any circumstances.
DBattery 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. In-
ternal-Drink large quantities of water or
milk. Follow with milk of magnesia, beat-
en egg, or vegetable oil. Call physician
immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention. Bat-
teries produce explosive gases. Keep
sparks, flame, cigarettes, etc., away.
Ventilate when charging or using in en-
closed space. Always shield eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
DIf 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.
DNever remove the strip of caps, nor
add any water or electrolyte.
EAA01009
B. CHECKING THE TIRE
PRESSURE
1. Check:
Dtire pressure
Out of specification !Adjust.
DThe tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
DThe tire pressure and the suspension
must be adjusted according to the to-
tal weight (including cargo, rider,
passenger, and accessories) and the
anticipated riding speed.
DOperation of an overloaded motor-
cycle could cause tire damage, an ac-
cident, or an injury.
NEVER OVERLOAD THE MOTOR-
CYCLE.
Basic weight:
With oil and full fuel tank
207 kg (456 lb) (except for CAL)
208 kg (458 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 XMaximum 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, pas-
senger, and accessories.

–12–
NOTE:
NOTE:
CAUTION:
NOTE:
NOTE:
NOTE:
CAUTION:
NOTE:
EAA01013
C. CHECKING THE ENGINE OIL
LEVEL
1. Stand the motorcycle on a level surface.
DPlace the motorcycle on a suitable stand.
DMake sure that the motorcycle is upright.
2. Let the engine idle for a few minutes, and
then turn it off.
3. Remove:
Ddipstick
4. Check:
Dengine oil level
The engine oil level should be between
the minimum level mark (a) and maxi-
mum level mark (b).
Below the minimum level mark !Add
the recommended engine oil to the prop-
er level.
DBefore checking the engine oil level, wait
a few minutes until the oil has settled.
DDo not screw the dipstick in when check-
ing the oil level.
Recommended oil
At 5_C (40_F) or higher A
Yamalube 4 (20W40) or
SAE 20W40 type SE motor oil
At 15_C (60_F) or lower B
Yamalube 4 (10W30) or
SAE 10W30 type SE motor oil
Quantity
Without oil filter cartridge replacement
2.5 L (2.20 Imp qt, 2.64 US qt)
DEngine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. There-
fore, do not add any chemical addi-
tives.
DDo not allow foreign materials to en-
ter the crankcase.
API Service “SE”, “SF” and “SG” type or
equivanlent (e.g., “SF-SE”, “SF-SE-CC”,
“SF-SE-SD”)
5. Start the engine, warm it up for several
minutes, and then turn it off.
6. Check the engine oil level again.
Before checking the engine oil level, wait a
few minutes until the oil has settled.
7. Install:
Ddipstick
EAA01017
D. CHECKING THE COOLANT
LEVEL
1. Stand the motorcycle on a level surface.
DPlace the motorcycle on a suitable
stand.
DMake sure that the motorcycle is upright.
2. Check:
Dcoolant 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.
DAdding water instead of coolant low-
ers the antifreeze content of the cool-
ant. If water is used instead of cool-
ant, check and correct the antifreeze
concentration of the coolant.
DUse only distilled water. Soft water
may be used if distilled water is not
available.
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Check:
Dcoolant level
Before checking the coolant level, wait a few
minutes until it settles.

–13–
NOTE:
NOTE:
WARNING
EAA01020
E. ADJUSTING THE ENGINE
IDLING SPEED
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 ade-
quate compression.
1. Start the engine and let it warm up for
several minutes.
2. Measure:
Dengine idling speed
Out of specification !Adjust.
Engine idling speed
1,250 X1,350 r / min
3. Adjust:
Dengine idling speed
a. Turn the throttle stop screw (1) in direc-
tion (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
F. ADJUSTING THE THROTTLE
CABLE FREE PLAY
Prior to adjusting throttle cable free play, the
engine idling speed should be adjusted.
1. Measure:
Dthrottle cable free play (a)
Out of specification !Adjust.
Throttle cable free play (at the flange
of the throttle grip)
3 X5 mm (0.12 X0.20 in)
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.
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.

–14–
NOTE:
WARNING
CAUTION:
WARNING
WARNING
WARNING
CAUTION:
EAA01023
G. ADJUSTING THE FRONT
BRAKE
1. Adjust:
Dbrake 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.
Be sure to align the setting on the adjusting
dial with the arrow mark (2) on the brake le-
ver holder.
Position #1
Distance (a) is the largest.
Position #5
Distance (b) is the smallest.
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.
After adjusting the brake lever position,
make sure that there is no brake drag.
A soft or spongy feeling in the brake le-
ver can indicate the presence of air in the
brake system. Before the vehicle is oper-
ated, the air must be removed by bleed-
ing 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
H. ADJUSTING THE REAR BRAKE
1. Measure:
Dbrake pedal position (a)
(below the bottom of the footrest brack-
et)
Out of specification !Adjust.
Brake pedal position (top of the footrest)
25.8 mm (1.02 in)
2. Adjust:
Dbrake pedal position
a. Loosen the locknut (1).
b. 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.
After adjusting the brake pedal position,
make sure that the end of the adjusting
bolt (c) is visible through the hole (d).
c. Tighten the locknut (1) to specification.
Locknut
18 Nm (1.8 mSkg, 13 ftSlb)
A soft or spongy feeling in the brake ped-
al can indicate the presence of air in the
brake system. Before the vehicle is oper-
ated, the air must be removed by bleed-
ing the brake system. Air in the brake
system will considerably reduce braking
performance and could result in loss of
control and possibly an accident. There-
fore, check the brake system and bleed if
necessary.
After adjusting the brake pedal position,
make sure that there is no brake drag.

–15–
A
B
A
B
NOTE:
WARNING
CAUTION:
NOTE:
WARNING
NOTE:
WARNING
EAA01032
I. CHECKING THE BRAKE FLUID
LEVEL
1. Stand the motorcycle on a level surface.
DPlace the motorcycle on a suitable
stand.
DMake sure that the motorcycle is upright.
2. Check:
Dbrake fluid level
Below the minimum level mark (a) !
Add the recommended brake fluid to the
proper level.
Recommended brake fluid
DOT 4
AFront brake
BRear brake
DUse only designated brake fluid.
Other brake fluids may cause the rub-
er seals to deteriorate, causing leak-
age and poor brake performance.
DRefill 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.
DWhen 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.
Brake fluid may damage painted sur-
faces and plastic parts. Therefore, al-
ways clean up any split brake fluid im-
mediately.
In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the reservoir is level.
EAA01035
J. BLEEDING THE HYDRAULIC
BRAKE SYSTEM
Bleed the hydraulic brake system when-
ever:
Dthe system was disassembled,
Da brake hose was loosened or re-
moved,
Dthe brake fluid level is very low,
Dbrake operation is faulty.
DBe careful not to spill any brake fluid or
allow the brake fluid reservoir to over-
flow.
DWhen bleeding the hydraulic brake sys-
tem, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could al-
low air to enter the hydraulic brake sys-
tem, considerably lengthening the
bleeding procedure.
DIf bleeding is difficult, it may be neces-
sary 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:
Dhydraulic brake system
a. Add the recommended brake fluid to the
proper level.
b. Install the brake fluid reservoir dia-
phragm.
c. Connect a clear plastic hose (1) tightly to
the bleed screw (2).
AFront
BRear
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 de-
press the brake pedal and hold it in posi-
tion.
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 re-
lease 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”.
After bleeding the hydraulic brake sys-
tem, check the brake operation.

–16–
WARNING
CAUTION:
NOTE:
EAA01036
K. ADJUSTING THE CLUTCH
CABLE FREE PLAY
1. Measure:
Dclutch cable free play (a)
Out of specification !Adjust.
Clutch cable free play (at the end of
the clutch lever)
10 X15 mm (0.39 X0.59 in)
2. Adjust:
Dclutch 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
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
Dspring preload
Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
a. Turn the adjusting ring (1) in direction (a)
or (b).
b. Align the desired position on the adjust-
ing ring with the stopper (2).
Direction (a)
Spring preload is increased
(suspension is harder).
Direction (b)
Spring preload is decreased
(suspension is softer).
Adjusting positions
Standard: 3
Minimum: 1
Maximum: 7