SERVICE

MANUAL

L-1

FAZER

SERVICE 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.

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

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 7 are 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 À using piston pin tool

• Piston Pin Circlip Á New

¿

À

Á

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

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

X

5YY

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.

WARNING

CAUTION:

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.

GEN

INFO

YAMAHA SPECIAL SERVICE TOOLS

YAMAHA SPECIAL SERVICE TOOLS

1-4

The appropriate Yamaha Special Service Tools are necessary for proper maintenance of the Motorcycle.

Using the correct Yamaha Special Service Tool will help to prevent damage caused by the use of

improper tools or improvised techniques. The following is the detailed list of all Yamaha Special Service

Tools with their application.

Refer to the list provided to avoid errors when placing an order for Yamaha Special service tools.

This tool is used to hold the Magneto when

removing or installing the Magneto Securing

Nut and Primary Drive Gear Nut

1. Magneto Holder

YSST -627

This tool is used to adjust Valve

clearance.

5. Valve Clearance Adjusting Tool.

YSST - 606

This tool is used to replace Piston Pin.

6. Piston Pin Replacer

YSST -607

This tool is needed to support the Piston

while installing Cylinder.

4. Piston Base

YSST - 604

This tool is used to hold the Clutch Hub when

removing or installing Clutch Main Shaft Nut.

8. Clutch Hub Holder

YSST - 233

This tool is used to remove the Magneto

2. Magneto Puller with Spacer

YSST-628

This tool is used to remove/install

Rocker Arm Shaft.

7. Rocker Arm Shaft Puller

YSST - 608 B

This tool is used to to remove and install

Valve Spring Assemblies.

3. Valve Spring Compressor

YSST - 603

GEN

INFO

YAMAHA SPECIAL SERVICE TOOLS

1-5

18.

T.F.F. Oil Seal Installation Tool

YSST-275

This tool is used to remove the Crank Shaft

from the Crank Case.

9. Crank Shaft Removal Tool.

YSST - 265

This tool is used for scraping the sealent

from Crankcase surface.

14.

Scraper

YSST - 612

These tools are used for installation of

Crank Shaft.

10. Crank Shaft Installing Tool with spacer

(a) YSST - 266

(b) YSST - 267

This tool is used to check Valve

Clearance.

15.

Feeler Gauge

YSST - 615

ç

è

This tool is used to hold the Driving Sprocket when

removing or installing Driving Sprocket Nut

11. Driving Sprocket Holder

YSST- 605

This tool is used to hold the TFF plunger

for loosening and tightening of Hex

Socket Head Bolt

17

T -Handle

YSST - 213

This tool is used to loosen or tighten the

Cam Shifter Segment Screw.

12. Torx Bit (T - 30)

YSST - 611

This tool is used to remove T.F.F. oil seal.

16.

T.F.F. Oil Seal Removing Tool.

YSST - 270

This tool is used to loosen or tighten the

Steering Ring Nut.

13.

Steering Nut Socket

YSST - 621

This tool is used when installing the TFF

Oil Seal.

GEN

INFO

SPECIAL SERVICE TOOLS

1-6

This tool is used to loosen or tighten the

Speedometer Gear Nut.

21. Spanner - Speedometer Gear Nut.

YSST - 237

This fixture is used to hold the Engine

for its disassembly and assembly.

22. Engine Stand

This tool is used to remove/install the Center

Plug from Crank case Cover#1 (L.H.)

26. Center Plug Spanner

YSST-625

This tool is used to remove the Bearing

6201 of the Axle Main.

24. Bearing Puller

YSST - 623

This tool is used to remove the Bearing

6202 of the Axle Drive

25. Bearing Puller

YSST - 624

To Tighten / Loosen the Spoke.

27. Spoke Tighting Tool

YSST- 629

This tool is used to install Oil Seal in

Crank Case Cover#2.

23. Oil Seal Installing Tool.

YSST - 622

To install upper and lower Racer Bearing

19 Racer Installing Tool

YSST-626

20 TFF Top Plug Spanner

YSST-214

To loosen & tighten the front fork top plug.

28. Plastic Bush - Rear Shock Absorber

YSST-703

This tool is used to protect the plastic shell

and painted parts.

GEN

INFO

SERVICE INSTRUMENTS

The following Service Instruments are necessary for complete and accurate tune up of Motorcycle

SERVICE INSTRUMENTS

1-7

5. Vernier Calliper

(150 mm)

This instrument is used for measuring

length, width & thickness of components

This Instrument is

used for checking the Engine RPM

1. Tachometer

YSST - 613

6. Micrometer

(0-25 mm) & (50-75 mm)

This instrument is used for measuring

Piston size, Valve stem size etc.

2. Timing light

This instrument is used for

checking ignition timing

(SKC S14-121)

OR NATIONAL

3. Compression Gauge

7. ’CO’ Gas Analyser

This instrument is used for checking the

engine compression

This instrument is used for measuring ‘CO’

concentration in exhaust of motorcycle

4. Mutimeter

This instrument is

used for checking the

electrical system.

8.Hydrometer

This instrument is used for measuring

specific gravity of Battery Electrolyte

GEN

INFO

SERVICE INSTRUMENTS

1-8

9. Tyre pressure gauge

10. Vaccum Gauge

11. Torque Wrench

(10-50 Ft-Lb)

(20-100 Ft-Lb)

12. Feeler gauge

This instrument is used for checking the

Tyre Pressure

This instrument is used for checking intake

vaccum.

This tool is used to tighten the Nuts/Bolts

at a specified torque.

This instrument is used to check clearance/

gaps between parts.

SPECIAL SERVICE MATERIAL

The following Service material are necessary to use at the time of assembly of various parts.

1. YAMAHA Bond

TG-1215

This adhesive is used on mating surfaces

while assembling Crankcase#1 and #2.

This adhesive is used for

Torx Screw tightening.

2. LOCTITE

Three Bond 1322

13. Temperature Meter

This instrument is used for measuring the

oil temperature of Engine