Yamaha Fazer User manual

SERVICE

MANUAL

L-1

FAZER

SERVICEMANUAL

YAMAHAMOTORINDIAPVT.LIMITED

Any reprinting or unauthorised use without

the written permission of

YAMAHAMOTORINDIAPVT.LIMITED

is expressly prohibited.

R-1

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.

L-2

ENG

ENGINE ASSEMBLY AND ADJUSTMENTS

Piston Pin replacer tool

YSST - 607

ENGINE ASSEMBLY

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.

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

R-3

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

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

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

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.

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