Yamaha 2007 FZ6-NA Service Manual Download | Manualshive

Page: 400 / 538

background image

COOLING SYSTEM

8-27

EAS27300

COOLING SYSTEM

EAS27310

CIRCUIT DIAGRAM

Ch

B

P

G/L

Y/L

R/G

Lg

B/W

G/L

Y/L

R/G

Lg

B/W

R/B

R/L

G/B

R/L

G/B

R/L

G/B

R/B

R/L

G/B

R/B

23

R/L

R/L

R/L

R/B

R/L

24

25

26

27

R/W

Br/R

R/W

Br/R

15

L

Y

B/L

D

G/W

G/W

D

Br/W

Br/W

D

P/W

P/W

D

B/L

B/L

B/L

Br/W

L

B/L

P/W

16

20

21

B/L

G/W

B/L

B/L

L

A

B/W

A

Y/L

D

YY

C

LL

C

R/L

C

G/B

C

R/B

B/L

22

R/L

B/L

G/W

Br/W

Y

P/W

B/L

G/W

Br/W

Y

P/W

B/L

18

L

L

P/W

P/W

R/B

R/L

G/B
L

B/Y

B/L

Y/G

L

B/R

Y/B

B/L

W/Y

W/Y

B/L

B/L

L

G/Y

R/B

R/L

G/B

L

B/L

W/Y
L

B/L

29

30

31

31

Y/L

19

Gy

B

Gy

B/L

28

R/B

17

B

B

L

W

R/W

P/B

Gy/G

B/L

R/B

W

L/Y

B/L

Y/L

R/L

Y/G

Y/G

L/Y

R/W

Gy

Gy

Y

Y

Br/W

Br/W

G/W

G/W

R/W

L/R

B/Y
B

B/G

G/W
W

Ch

Dg

B

B

Br/R

R/B

R/B

G/B

G/B

L/W

P/B

P/B

Gy/G

Gy/G

L

O/B

O/B

Gy/B

Gy/B

B/W

R/W

B/W

Y

W/Y

G/W

Gy/G

B/L

B/R

B/Y

L/Y

Y/L

P/B

B

G/Y

R/B

Gy/B

Br/W

Y/G

P/W
L

B/W

R/W

R/L

L/W

Gy

Br/R

B

Y/B

G/B

O/B

Ch

32

33

34

36

37

37

38

39

40

35

B

L/R

B

W

W

B

R/W

R/W

B

G/W

G/W

A

L/R
B

L/R
B

B

R/G

R/G

B/W

Y/L

B

B/G

B

B/Y

B

Dg

A

G/L

G/L

A

Dg

B

Ch

B

Lg

Lg

B/Y

50

53

OFF

RU

N

65

FREE

PUSH

R/Y

55

B

B

7

BB

10

G/Y

L/W

R/W

R/B
B

Br

G/Y

W/L

R/W

R/B

BB

r

R

R/W

L/W

9

66

R

L/G

L/G

R/W

R/W

57

B

Br/L

52

Y

L

B

HI

LO

W/L

W/L

Y/B

Br

Br

OFF

ON

8

L

N

R

51

YL

B

L

L/W

Br/L

Br/L

OFF

ON

ON

Y

Y

B

Dg
Y

L/B

Br/W

R/Y

Ch

L/Y
G

B

B/Y

Br

R/Y

G

Y/B

R/Y

R/Y

Dg

Y

L/B

Br/W

R/Y

Ch

B/R

B

B/Y

Br

13

B

BB

r

Y

Br

G/Y

5

B

R

R

L/W

L/W

R/B

B

72

B/Y

B/Y

12

B

B

L/G

B

59

60

61

62

63

64

58

B/R

B/R

11

R/Y

R/Y

54

Ch

B

73

R

Y

Y

L/B

Dg

B

Br/W

Br/G

Br/G

Br/G

Br/W

Br/W

Ch

Ch

Dg

Dg

Ch

Dg

B

G/W

R/W

B

R/L

G

G

B

B

L/Y

B/Y

Dg

B

W

Br

B

R/W

Sb

Sb

R/L

R/L

41

56

L/R

R/L

W/L

R/B

L/W

R

Lg

B/Y

Sb

B/R

L/G

R/W

L/Y

L/W

Br/R

W

B

R/B

L/Y

Sb

Sb

R/W

B

14

B

L

W

W

G/W

G/W

G/L

Lg

Lg

70

Ch

B

Ch

B

68

67

69

67

71

B

B

B

B

L/R

Dg

B

Dg

B

L/R

BB

BB

B/Y

B

B/G

B

B

B/G

B/Y

Dg

Ch

B

R

R

R

Br/B

Br/B

2

W

W

W

WW

W

4

R

WW

WW

WW

42

43

45

44

46

R

Br/L

BB1

47

R/G

BB3

BB4

BB

BB

Br/L

BB

BB

B2

B1

Br/B

L

G/Y

R/W

BB

B2

BB2

BB3

BB1

BB4

Br/R

B

48

R/W

3

B

L

B

L

L

L

B

G/Y

R/W

R

Br/L

BB

B

R/G

Y/L

G/L

R/W

R

B

W

W

W

B

6

BB2

B2

Y/L

B

B2

R/G

Y/L

Lg

R/W

Br/R

Br/R

ON

OFF

1

49

G/L

R/G

R/G

R/W

L/R

YBG

-

G/W

WC

h

D

g

B/L

WIRE SUB LEAD2

D

MAIN HARNESS

WIRE SUB LEAD1

C

MAIN HARNESS

CORD HEAD LIGHT2

B

MAIN HARNESS

CORD HEAD LIG

H

T

1

A

MAIN HARNESS

OFF

Lg

W

B/W

G/W

Y/L

Dg

G/L

R/W

Ch

R/G

B/Y

Lg

W

B/W

G/W

Y/L

Dg

G/L

R/W

Ch

R/G

Y

«
...
398
399
400
401
402
...
»

Summary of Contents for 2007 FZ6-NA

Page 1: ...2007 FZ6 N S 4S8 28197 E0 SERVICE MANUAL FZ6 NA SA FZ6 NHG W FZ6 SHG W FZ6 NAHG SAHG ...

Page 2: ...6 NHG W SHG W FZ6 NAHG SAHG SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition August 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...nded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable N...

Page 4: ...age 1 Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruc...

Page 5: ...mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE G M E B LS M 9 10 11 12 13 14 15 16 LT New T R 1 2 3 4 5 6 7 8 16 Replace the part ...

Page 6: ......

Page 7: ...1 2 3 4 5 6 7 8 9 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING ...

Page 8: ......

Page 9: ...BS 1 9 ABS COMPONENT FUNCTIONS 1 13 ABS OPERATION 1 19 ABS SELF DIAGNOSIS FUNCTION 1 23 ABS WARNING LIGHT AND OPERATION 1 26 IMPORTANT INFORMATION 1 28 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 28 REPLACEMENT PARTS 1 28 GASKETS OIL SEALS AND O RINGS 1 28 LOCK WASHERS PLATES AND COTTER PINS 1 28 BEARINGS AND OIL SEALS 1 29 CIRCLIPS 1 29 CHECKING THE CONNECTIONS 1 30 SPECIAL TOOLS 1 31 ...

Page 10: ...AS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 11: ...crease it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volu...

Page 12: ...e lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake tempera ture sensor coolant temperature sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the sign...

Page 13: ...to turn the key to ON before using the SELECT and RESET buttons For the U K only To switch the speedometer and odometer tripmeter displays between kilometers and miles press the SELECT button for at least two second FZ6 N FZ6 NA FZ6 S FZ6 SA For the U K only To switch the speedometer and odometer tripmeter displays between kilometers and miles press the SELECT button for at least one second FZ6 NH...

Page 14: ...er modes FZ6 N FZ6 NA FZ6 S FZ6 SA Push the SELECT button to switch the dis play between the odometer mode ODO and the tripmeter modes TRIP A and TRIP B in the following order ODO TRIP 1 TRIP 2 TRIP F E ODO When the fuel amount in the fuel tank decreases to 3 6 L 0 90 US gal 0 79 Imp gal the bottom segment of the fuel meter will start flashing and the odometer display will automatically change to ...

Page 15: ...hing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the f...

Page 16: ...temperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is automatically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed for one second and then the air intake temperature is dis played FZ6 NHG W FZ6 NAHG FZ6 SHG W FZ6 SAHG Self dia...

Page 17: ...e the code re registering key and both standard keys to a Yamaha dealer and have the standard keys re registered If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle CAUTION ECA4S81010 If the display indicates an error code the vehicle should be checked as soon as pos sible in order to avoid engine damage LCD and tachometer brightness contro...

Page 18: ...e lever for operating the front brake and a brake pedal for operating the rear brake When wheel lock is detected during emergency braking hydraulic control is performed by the hydraulic system on the front and rear brakes independently Useful terms Wheel speed The rotation speed of the front and rear wheels Chassis speed The speed of the chassis When the brakes are applied wheel speed and chassis ...

Page 19: ...is is moving i e wheel lock Brake force and vehicle stability When the brake pressure is increased wheel speed is reduced Slipping occurs between the tire and the road surface and brake force is generated The limit of this brake force is determined by the friction force between the tire and the road surface and is closely related to wheel slippage Wheel slippage is represented by the slip ratio Si...

Page 20: ...ABS ECU increases the pressure of the brake fluid in the brake caliper when the tendency to lock has diminished point B in the following figure ABS operation and vehicle control If the ABS starts operating there is a tendency of the wheel to lock and the vehicle is approaching the limit of control To make the rider aware of this condition the ABS has been designed to gener ate a reaction force pul...

Page 21: ...ency of the wheel to lock caused by applying the brakes The ABS cannot prevent wheel lock on slippery surfaces such as ice when it is caused by engine braking even if the ABS is operating Electronic ABS features The Yamaha ABS anti lock brake system has been developed with the most advanced electronic technology The ABS control is processed with good response under various vehicle travel condition...

Page 22: ...e sensor rotors have 42 front 44 rear serrations inside and are installed close to the wheel sensors As the sensor rotor rotates the hall element in the hall IC installed in the wheel sensor generates the voltage which is propor tional to the magnetic flux density and the generated voltage is processed for waveform shaping in the hall IC to output The ABS ECU calculates the wheel rotation speed by...

Page 23: ...light is disconnected and check if the ABS is oper ating properly CAUTION ECA4S81005 If the rear wheel is raced with the vehicle on the suitable stand the ABS warning light may flash or come on If this occurs turn the main switch to OFF then back to ON The ABS operation is normal if the ABS warning light comes on for 2 seconds then goes off 4 At low speed 5 At high speed 6 Wheel sensor 7 Wheel sen...

Page 24: ...ol 3 of the flow control valve does not move and the hydraulic line between the brake master cylinder and brake caliper is open 2 When the ABS is activated the solenoid valve 2 is opened by the power supplied from the ABS ECU signals to decrease the brake fluid pressure and the spool 3 of the flow control valve is moved toward the solenoid valve 3 When the ABS ECU stops transmitting signals to dec...

Page 25: ...r The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 Orifice 2 Solenoid valve 3 Spool 4 Flow control valve 1 Buffer chamber pressurized 2 Buffer chamber depressurized 3 Raised piston ...

Page 26: ...r 2 As shown in the block following diagram the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits 1 Battery 2 Engine stop switch 3 Starting circuit cut off relay 4 Sidestand switch 5 Starter relay 6 Starter motor 7 Start switch 8 Front wheel sensor 9 Rear wheel sensor 10 Main fuse 11 Main switch 12 Generator ...

Page 27: ... failures are not recorded in the memory of the ABS ECU e g a drop in battery volt age ABS motor relay The ABS motor relay 1 controls the power supply of the hydraulic unit and is located on the battery 13 Rectifier regulator 14 ABS fuse 15 ABS motor fuse 16 ABS test coupler 17 ABS ECU 18 Rear brake light switch 19 Front brake light switch 20 Tail brake light 21 Meter assembly 22 ABS warning light...

Page 28: ...e ABS hydraulic circuit consists of two systems the front wheel and rear wheel The following describes the front system only Normal braking ABS not activated When the ABS is not activated port D 11 of the solenoid valve is closed because a control signal has not been transmitted from the ABS ECU and port A 7 and port B 9 of the flow control valve are open 1 ABS motor relay 2 Solenoid valves 3 ABS ...

Page 29: ...id is not sent As a result the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake master cyl inder via port A 7 and port B 9 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 Port B 10 Orifice 11 ...

Page 30: ... the return spring and closes port B 9 Brake fluid that has entered through port A 7 is restricted by the orifice 10 and the brake fluid is sent to the brake caliper via port C 13 and port D 11 and the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the fluid pressure pump ...

Page 31: ...t A 7 and port C 13 At this time the brake is pressur ized at a constant speed regardless of the brake fluid pressure level since restriction of port A 7 changes so that a constant pressure difference is maintained between chamber A 20 and cham ber B 21 of the flow control valve 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A...

Page 32: ...ted in the meter assembly 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Flow control valve 7 Port A 8 Spool 9 Port B 10 Orifice 11 Port D 12 Solenoid valve 13 Port C 14 Brake caliper 15 ABS ECU 16 ABS warning light 17 Brake fluid pressure 18 Time 19 Repressurizing 20 Chamber A 21 Chamber B A FZ6 NA FZ6 SA B FZ6 NAHG FZ6 SAHG ...

Page 33: ...raking if this occurs 3 The ABS warning light flashes while riding If the ABS warning light flashes while riding there is no problem with the function of the ABS However the ABS ECU input has unstable factors For details refer to ABS TROUBLESHOOTING OUTLINE on page 8 78 NOTE The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter connected to the ABS test c...

Page 34: ...r panel front cowling When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing and the multi function display indicates all the malfunction codes recorded in the ABS ECU NOTE The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler a ABS warning light b Comes on c Goes off d P...

Page 35: ...hen goes off The ABS operation is normal if the ABS warning light flashes Even if the ABS warning light remains on and does not go off or if it comes on after riding conven tional braking performance of the vehicle is maintained ABS function A brake system in which the hydraulic control has been performed by the ABS alerts a rider that the wheels had a tendency to lock by generating a reaction for...

Page 36: ...ble to cause a loss of traction of the tires Even vehicles equipped with ABS cannot be prevented from falling over if braked suddenly The ABS does not work when the main switch is turned to OFF The conventional braking func tion can be used Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel ...

Page 37: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 38: ...rease Oil bearings liberally when installing if appro priate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned op...

Page 39: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at ...

Page 40: ...mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 30 Flywheel puller attachment 90890 04089 Crankshaft protector YM 33282 5 30 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 30 5 31 5 32 5 34 Piston pin pu...

Page 41: ... 4 66 4 68 Oil filter wrench 90890 01426 YU 38411 3 15 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 68 4 69 Fork seal driver attachment ø43 90890 01374 Replacement 43 mm YM A5142 3 4 68 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 7 Compression gauge 90890 03081 Engine compression tester YU 33223 3 12 Tool name Tool No Illustration Reference pages ...

Page 42: ...uge 90890 03153 YU 03153 3 16 7 6 Oil pressure adapter H 90890 03139 3 16 Fuel pressure adapter 90890 03176 YM 03176 7 6 Valve spring compressor 90890 04019 YM 04019 5 21 5 27 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 21 5 27 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 12 Tool name Tool No Illustration Referen...

Page 43: ...e guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 23 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm YM 04112 5 23 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 23 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 8 122 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 32 5 35 5 58 6 12 Tool name Tool No Illustration...

Page 44: ...circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 7 Test coupler adapter 90890 03149 1 25 4 57 4 58 Thickness gauge 90890 03079 Narrow gauge set YM 34483 4 21 Tool name Tool No Illustration Reference pages ...

Page 45: ...TORQUES 2 15 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 15 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 24 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 39 CABLE ROUTING 2 47 ...

Page 46: ...width 750 mm 29 5 in FZ6 S FZ6 SA FZ6 SHG W FZ6 SAHG 755 mm 29 7 in FZ6 N FZ6 NA FZ6 NHG W FZ6 NAHG Overall height 1085 mm 42 7 in FZ6 N FZ6 NA FZ6 NHG W FZ6 NAHG 1210 mm 47 6 in FZ6 SHG W FZ6 SAHG 1215 mm 47 8 in FZ6 S FZ6 SA Seat height 795 mm 31 3 in Wheelbase 1440 mm 56 7 in Ground clearance 145 mm 5 71 in Minimum turning radius 2800 mm 110 2 in Weight With oil and fuel 201 0 kg 443 lb FZ6 N F...

Page 47: ...30 SAE10W40 SAE15W40 SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 3 40 L 3 59 US qt 2 99 Imp qt Without oil filter cartridge replacement 2 50 L 2 64 US qt 2 20 Imp qt With oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Oil pressure 240 kPa at 6 600 r min 2 4 kg cm at 6 600 r min 2 4 bar at 6 600 r ...

Page 48: ...n Spark plug s Manufacturer model NGK CR9EK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cylinder head Volume 10 33 10 93 cm 0 63 0 67 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive right Camshaft cap inside diameter 23 008 23 029 mm 0 9058 0 9067 in Camshaft journal diameter 22 967 22 980 mm 0 9042 0 9047 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0...

Page 49: ... 0 0780 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve margin thickness D intake 0 60 0 80 mm 0 0236 0 0315 in Limit 0 5 mm 0 02 in Valve margin thickness D exhaust 0 60 0 80 mm 0 0236 0 0315 in Limit 0 5 mm 0 02 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 ...

Page 50: ...7 07 lb in 1 73 kgf mm Spring rate K1 exhaust 30 26 N mm 172 78 lb in 3 09 kgf mm Spring rate K2 exhaust 49 53 N mm 282 82 lb in 5 05 kgf mm Installed compression spring force intake 69 79 N 15 51 17 76 lbf 7 04 8 06 kgf Installed compression spring force exhaust 160 184 N 35 97 41 36 lbf 16 32 18 76 kgf Spring tilt intake 2 5 1 6 mm 0 06 in Spring tilt exhaust 2 5 1 8 mm 0 07 in Winding direction...

Page 51: ... 6296 0 6299 in Limit 15 971 mm 0 6288 in Piston pin to piston pin bore clearance 0 002 0 022 mm 0 0001 0 0009 in Limit 0 072 mm 0 0028 in Piston ring Top ring Ring type Barrel Dimensions B T 0 90 2 45 mm 0 04 0 10 in End gap installed 0 25 0 35 mm 0 0098 0 0138 in Limit 0 60 mm 0 0236 in Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring Ring type Taper Dimensio...

Page 52: ...g plastigauge 0 028 0 052 mm 0 0011 0 0020 in Limit 0 10 mm 0 0039 in Bearing color code 0 White 1 Blue 2 Black 3 Brown 4 Green Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Clutch release method operation Cable operation Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Wear limit 2 80 mm 0 1102 in Pl...

Page 53: ...r element Fuel pump Pump type Electrical Model manufacturer 5VX DENSO Maximum consumption amperage 5 5 A Output pressure 250 0 kPa 36 3 psi 2 50 kgf cm Fuel injector Model quantity 0290 x 4 Manufacturer DENSO Throttle body Type quantity 36EIDW B1 1 FZ6 SHG W FZ6 SAHG FZ6 NHG W FZ6 NAHG 36EIDW B7 1 FZ6 S FZ6 SA 4P53 FZ6 N FZ6 NA 36EIDW B10 1 FZ6 SA 4P54 Manufacturer MIKUNI ID mark 4P54 00 FZ6 SA 4P...

Page 54: ...acturer model BRIDGESTONE BT020R GG Manufacturer model DUNLOP D252 Wear limit rear 0 8 mm 0 03 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 33 psi 2 25 kgf cm 2 25 bar Rear 250 kPa 36 psi 2 50 kgf cm 2 50 bar Loading condition 90 185 kg 198 408 lb FZ6 SA FZ6 SAHG 90 190 kg 198 419 lb FZ6 S FZ6 SHG W 90 191 kg 198 421 lb FZ6 NA FZ6 NAHG 90 196 kg 198 ...

Page 55: ...t 4 5 mm 0 18 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 7 mm 0 50 in Caliper cylinder inside diameter 38 10 mm 1 50 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Lock to lock angle left 35 0 L...

Page 56: ... mm Spring stroke K1 0 0 50 0 mm 0 00 1 97 in Optional spring available No Enclosed gas air pressure STD 1200 kPa 170 7 psi 12 0 kgf cm Spring preload adjusting positions Minimum 1 Spring preload adjusting positions Standard 3 Spring preload adjusting positions Maximum 7 Swingarm radial free play 1 0 mm 0 039 in Swingarm axial free play 1 0 mm 0 039 in Drive chain Type manufacturer 50V4 DAIDO Link...

Page 57: ...condary coil resistance 12 0 18 0 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer F5VX MORIC Stator coil resistance 0 22 0 34 Ω at 20 C 68 F Standard output 14 0 V310 W5000 r min Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer SH719AA SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 25 0 A Withstan...

Page 58: ...lectric starting system System type Constant mesh Starter motor Model manufacturer SM 14 MITSUBA Power output 0 60 kW Armature coil resistance 0 0012 0 0022 Ω Brush overall length 10 0 mm 0 39 in Limit 3 50 mm 0 14 in Brush spring force 7 16 9 52 N 25 77 34 27 oz 730 971 gf Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacture...

Page 59: ...M33211M05 MATSUSHITA Coil resistance 86 4 105 6 Ω Fuel injection system relay Model manufacturer G8R 30Y R OMRON Resistance 162 198 Ω Thermo unit Model manufacturer 8CC MITSUBISHI Resistance at 80 C 290 0 354 0 Ω Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Radiator fan fuse 20 0 A Fuel injection system fuse 10 0 A Backup fuse...

Page 60: ...al To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 ...

Page 61: ... 2 12 Nm 1 2 m kg 8 7 ft lb Thermo sensor M12 1 18 Nm 1 8 m kg 13 ft lb Coolant drain bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator bolt M6 2 7 Nm 0 7 m kg 5 0 ft lb Radiator stay and crankcase M6 1 10 Nm 1 0 m kg 7 2 ft lb Radiator cap stopper bolt M5 1 5 Nm 0 5 m kg 3 6 ft lb Radiator hose stay bolt M10 1 10 Nm 1 0 m kg 7 2 ft lb Oil pump cover bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Oil pump bolt M6 3...

Page 62: ...kup coil rotor cover bolt M8 1 15 Nm 1 5 m kg 11 ft lb Shift shaft cover bolt M6 6 12 Nm 1 2 m kg 8 7 ft lb Breather plate screw M6 3 12 Nm 1 2 m kg 8 7 ft lb Stator coil screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Pickup rotor cover clamp screw M6 1 7 Nm 0 7 m kg 5 0 ft lb Drive sprocket cover bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Oil gallery bolt M16 2 8 Nm 0 8 m kg 5 8 ft lb Generator rotor cover and stat...

Page 63: ... to 27 Nm 2 7 m kg 20 ft lb again Muffler joint bolt Retighten the bolt at 1000 km 600 ml Catalyst joint bolt Retighten the bolt at 1000 km 600 ml O2 sensor M18 1 45 Nm 4 5 m kg 33 ft lb Shift shaft spring stopper screw M8 1 22 Nm 2 2 m kg 16 ft lb Shift rod nut M6 1 7 Nm 0 7 m kg 5 0 ft lb Left thread Shift rod nut M6 1 7 Nm 0 7 m kg 5 0 ft lb Shift rod joint M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift a...

Page 64: ...TIGHTENING TORQUES 2 19 Cylinder head tightening sequence Crankcase tightening sequence ...

Page 65: ... 2 6 Nm 0 6 m kg 4 3 ft lb Clutch lever holder pinch bolt M6 1 11 Nm 1 1 m kg 8 0 ft lb Engine mount bolts left of front side M10 1 55 Nm 5 5 m kg 40 ft lb See NOTE Engine mount bolts left of rear side M10 1 55 Nm 5 5 m kg 40 ft lb See NOTE Engine mount bolts right of front side M10 1 55 Nm 5 5 m kg 40 ft lb See NOTE Engine mount self locking nut upper M10 1 55 Nm 5 5 m kg 40 ft lb See NOTE Engine...

Page 66: ...lb Rear brake caliper bolt front and rear brake caliper bracket M8 1 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt rear and rear brake caliper bracket M8 1 22 Nm 2 2 m kg 16 ft lb Rear wheel sprocket and rear wheel drive hub M10 6 100 Nm 10 m kg 72 ft lb Chain adjusting bolt lock nut M8 2 16 Nm 1 6 m kg 12 ft lb Rear brake hose union bolt M10 1 30 Nm 3 0 m kg 22 ft lb Sidestand bolt M10 1 46 Nm ...

Page 67: ...Engine mount bolts and engine mount self locking nut Refer to INSTALLING THE ENGINE on page 5 6 Hydraulic unit bracket 1 and stay bolt with ABS M6 2 10 Nm 1 0 m kg 7 2 ft lb Rear wheel sensor rotor bolt with ABS M5 5 6 Nm 0 6 m kg 4 3 ft lb Stay and frame bolt M6 4 10 Nm 1 0 m kg 7 2 ft lb Hydraulic unit and brake hose union bolt with ABS M10 4 30 Nm 3 0 m kg 22 ft lb Item Thread size Q ty Tighten...

Page 68: ...er Oil pump housing Oil strainer Clutch pull rod Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Cylinder head cover semicircular Yamaha bond No 1215 Crankcase mating surf...

Page 69: ...l moving parts Link and sidestand switch contact point Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end oil seal and bush Engine mount bolts rear upper and lower Shift pedal shaft Shift shaft joint Rear footrest ball ...

Page 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 71: ...N SYSTEM CHART AND DIAGRAMS 2 26 1 Oil strainer 2 Oil pump 3 Relief valve 4 Oil filter 5 Oil cooler 6 Main axle 7 Mission cooler 8 Drive axle 9 Main gallery 10 Piston cooler 11 Intake camshaft 12 Exhaust camshaft ...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20410 LUBRICATION DIAGRAMS ...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil level switch 2 Oil cooler 3 Relief valve ...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil pump 2 Exhaust camshaft 3 Intake camshaft 4 Oil strainer ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil cooler 2 Oil strainer 3 Oil level switch 4 Oil pump ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Oil pump 3 Relief valve ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Cylinder head 2 Intake camshaft 3 Exhaust camshaft 4 Crankshaft ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Main axle 2 Drive axle ...

Page 84: ...COOLING SYSTEM DIAGRAMS 2 39 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 85: ...COOLING SYSTEM DIAGRAMS 2 40 1 Radiator 2 Oil cooler ...

Page 86: ...COOLING SYSTEM DIAGRAMS 2 41 ...

Page 87: ...COOLING SYSTEM DIAGRAMS 2 42 1 Water pump 2 Oil cooler 3 Radiator ...

Page 88: ...COOLING SYSTEM DIAGRAMS 2 43 ...

Page 89: ...COOLING SYSTEM DIAGRAMS 2 44 1 Oil cooler 2 Water pump ...

Page 90: ...COOLING SYSTEM DIAGRAMS 2 45 ...

Page 91: ...COOLING SYSTEM DIAGRAMS 2 46 1 Radiator 2 Thermostat ...

Page 92: ...CABLE ROUTING 2 47 EAS20430 CABLE ROUTING FZ6 S FZ6 SHG W FZ6 SA FZ6 SAHG ...

Page 93: ... in F Clamp the horn lead to the inner tube Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm 0 04 to 0 20 in G Pass the throttle cables wire harness lead clutch cable main switch and immobilizer lead and left handlebar switch lead in order through the frame hole from the lower side of the vehicle H Point the lead which comes from the ter ...

Page 94: ...CABLE ROUTING 2 49 FZ6 N FZ6 NA ...

Page 95: ... the branched lead behind the main switch and immobilizer lead E Pass the leads through the hole of the frame from the vehicle down side in order of the main switch lead immobilizer lead left handlebar switch lead and clutch cable F To the headlight and meter G Pass the right handlebar switch lead and throttle cable clutch cable through the meter cover hole H Install the clamp in the direction as ...

Page 96: ...CABLE ROUTING 2 51 FZ6 NHG W FZ6 NAHG ...

Page 97: ... To the left handlebar switch lead F Route the branched lead behind the main switch and immobilizer lead G Pass the main switch lead immobilizer lead left handlebar switch lead and clutch cable in order through the frame hole from the lower side of the vehicle H To the headlight and wire harness I Pass the right handlebar switch lead and throttle cable clutch cable through the opening section of t...

Page 98: ...CABLE ROUTING 2 53 FZ6 S FZ6 SHG W ...

Page 99: ...t side of the frame H Route the right handlebar switch lead under the bracket 2 I Route the coolant reservoir tank hose under the cover 2 Route the radiator hose outside outside J Route the radiator hoses 2 pieces under the cover 2 K Route the crankshaft position sensor lead inner side of the radiator hose L Pull down the mark painted sections of the fuel tank breather hose and fuel tank drain hos...

Page 100: ...CABLE ROUTING 2 55 FZ6 SA FZ6 SAHG ...

Page 101: ...ute the coolant reservoir tank hose under the cover 2 Route the radiator hose outside outside J Route the radiator hoses 2 pieces under the cover 2 K Route the crankshaft position sensor lead inner side of the radiator hose L Pass the hydraulic unit drain hose through the clamp of muffler stay Align the protrusion allowance from the clamp with the fuel tank drain hose M Pull down the mark painted ...

Page 102: ...CABLE ROUTING 2 57 FZ6 N FZ6 NHG W ...

Page 103: ... right side of the frame Route it under the inside of the throttle cable and wire harness J Route the right handlebar switch lead under the bracket 2 K Route the coolant reservoir tank hose under the cover 2 Route the radiator hose outside outside L Route the radiator hoses 2 pieces under the cover 2 M Route the crankshaft position sensor lead inner side of the radiator hose N Pull down the mark p...

Page 104: ...CABLE ROUTING 2 59 FZ6 NA FZ6 NAHG ...

Page 105: ... handlebar switch lead under the bracket 2 K Route the coolant reservoir tank hose under the cover 2 Route the radiator hose outside outside L Route the radiator hoses 2 pieces under the cover 2 M Route the crankshaft position sensor lead inner side of the radiator hose N Pass the hydraulic unit drain hose through the clamp of muffler stay Align the protru sion allowance from the clamp with the fu...

Page 106: ...CABLE ROUTING 2 61 FZ6 S FZ6 SHG W ...

Page 107: ... the fuel tank K Either installation position can be accepted but make sure that the leads are not crossed L Clamp the rear turn signal lead and license plate light lead to the frame Hook the clamp to the bracket Pull out the lead suffi ciently to the frame side and route it along with the side of the back stay Cut the tip of the clamp to be between 1 and 5 mm 0 04 and 0 20 in upward M Clamp the r...

Page 108: ...CABLE ROUTING 2 63 FZ6 SA FZ6 SAHG ...

Page 109: ... no excessive slack on the wire leads K To the fuel tank L Either installation position can be accepted but make sure that the leads are not crossed M Clamp the rear turn signal lead and license plate light lead to the frame Hook the clamp to the bracket Pull out the lead suffi ciently to the frame side and route it along with the side of the back stay Cut the tip of the clamp to be between 1 and ...

Page 110: ...CABLE ROUTING 2 65 FZ6 N FZ6 NHG W ...

Page 111: ... but make sure that the leads are not crossed M Clamp the rear turn signal lead and license plate light lead to the frame Hook the clamp to the bracket Pull out the lead suffi ciently to the frame side and route it along with the side of the back stay Cut the tip of the clamp to be between 1 and 5 mm 0 04 and 0 20 in upward N Clamp the rear turn signal light lead and license plate light lead to th...

Page 112: ...CABLE ROUTING 2 67 FZ6 NA FZ6 NAHG ...

Page 113: ...ad and license plate light lead to the frame Hook the clamp to the bracket Pull out the lead suffi ciently to the frame side and route it along with the side of the back stay Cut the tip of the clamp to be between 1 and 5 mm 0 04 and 0 20 in upward O Clamp the rear turn signal light lead and license plate light lead to the frame Cut the tip of the clamp to be between 1 and 5 mm 0 04 and 0 20 in P ...

Page 114: ...CABLE ROUTING 2 69 FZ6 S FZ6 SHG W ...

Page 115: ...ral switch lead tail brake light lead and O2 sensor lead Point the clamp opening to the rear side R Push the wire harness in the groove of the mud guard S Point the opening section of the clamp upward T To the tail brake light U To the license plate light V To the rear left turn signal light W To the rear right turn signal light X Point the tip of the clamp to the outside of the vehicle Y Insert t...

Page 116: ...CABLE ROUTING 2 71 FZ6 SA FZ6 SAHG ...

Page 117: ...at it is not seen through the frame open ings N To the tail brake light switch O To the rear wheel sensor P To the O2 sensor Q Clamp the neutral switch lead tail brake light lead rear wheel sensor lead and O2 sensor lead Point the clamp opening to the rear side R Push the wire harness in the groove of the mud guard S Point the opening section of the clamp upward T To the tail brake light U To the ...

Page 118: ...CABLE ROUTING 2 73 ...

Page 119: ... under the air cut off valve hose AT Route the spark plug lead 2 behind the air cut off valve hose AU Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 AV Route the spark plug leads 2 and 3 behind the air cut off valve hose ...

Page 120: ...CABLE ROUTING 2 75 FZ6 N FZ6 NHG W ...

Page 121: ... the clamp opening to the rear side Q Push the wire harness in the groove of the mud guard R Point the opening section of the clamp upward S To the tail brake light T To the license plate light U To the rear left turn signal light V To the rear right turn signal light W Point the tip of the clamp to the outside of the vehicle X Insert the enwinding clamp of the wire har ness into the hole of the r...

Page 122: ...CABLE ROUTING 2 77 ...

Page 123: ...o the direction as shown in the illustration AX Route the spark plug lead 3 under the air cut off valve hose AY Route the spark plug lead 2 behind the air cut off valve hose AZ Route the spark plug lead 4 by the front side of the spark plug leads 2 and 3 BA Route the spark plug leads 2 and 3 behind the air cut off valve hose ...

Page 124: ...CABLE ROUTING 2 79 FZ6 NA FZ6 NAHG ...

Page 125: ...her leads so that it is not seen through the frame open ings M To the tail brake light switch N To the rear wheel sensor O To the O2 sensor P Clamp the neutral switch lead tail brake light lead rear wheel sensor lead and O2 sensor lead Point the clamp opening to the rear side Q Push the wire harness in the groove of the mud guard R Point the opening section of the clamp upward S To the tail brake ...

Page 126: ...CABLE ROUTING 2 81 ...

Page 127: ...ough the outer hole of the cover 2 AW Pass the spark plug lead 2 through the inner hole of the cover 2 AX Route the spark plug lead 4 behind the air cut off valve hose AY Point the spark plug caps of 1 to 4 to the direction as shown in the illustration AZ Route the spark plug lead 3 under the air cut off valve hose BA Route the spark plug lead 2 behind the air cut off valve hose BB Route the spark...

Page 128: ...CABLE ROUTING 2 83 ...

Page 129: ... of clip front side a Fuel piping connector attachment direc tions fuel pump side Don t use tool 1 It is inserted until it makes a click sound the connector and it checks that a connector does not fall out It takes care that a foreign substance does not enter into a seal por tion Working groves should not be used at the time of work E It prevents that this portion falls out 2 The clamp is attached...

Page 130: ...CABLE ROUTING 2 85 ...

Page 131: ...T SYSTEM 3 19 CHECKING THE COOLANT LEVEL 3 19 CHECKING THE COOLING SYSTEM 3 20 CHANGING THE COOLANT 3 20 CHASSIS 3 23 ADJUSTING THE FRONT DISC BRAKE 3 23 ADJUSTING THE REAR DISC BRAKE 3 23 CHECKING THE BRAKE FLUID LEVEL 3 24 CHECKING THE FRONT BRAKE PADS 3 24 CHECKING THE REAR BRAKE PADS 3 25 CHECKING THE FRONT BRAKE HOSES 3 25 CHECKING THE REAR BRAKE HOSE 3 25 ADJUSTING THE REAR BRAKE LIGHT SWITC...

Page 132: ...ELECTRICAL SYSTEM 3 35 REPLACING THE HEADLIGHT BULBS 3 35 ADJUSTING THE HEADLIGHT BEAMS 3 35 ...

Page 133: ......

Page 134: ...r as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READ ING X 1000 km Annual check 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or dam age 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter ele ment Replace 5 Clutch Check operation Adjust 6 Front brake Check operation flui...

Page 135: ...l injection Adjust engine idling speed and syn chronization 21 Engine oil Change Check oil level and vehicle for oil leakage 22 Engine oil filter cartridge Replace 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Throttle grip housing and cable Check operation and free...

Page 136: ...ing it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 137: ...S on page 7 4 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 Radiator Radiator fan motor Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 8 3 Remove Pickup rotor cover 1 4 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When piston 1 is at TDC on th...

Page 138: ... pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the follow ing table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Valve clearance measuring sequence Cylinder 1 2 4 3 A Front A Degrees...

Page 139: ... the valve lifter and the valve pad in the correct place f Install the exhaust and intake camshafts timing chain and camshaft caps NOTE Refer to CAMSHAFTS on page 5 8 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the camshaft cap marks Turn the crankshaft counterclockwise several full turns to seat the parts g ...

Page 140: ... second and check the synchronization again If the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body CAUTION ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body syncroni zation NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10 mmHg 8 Measure Engine idling speed Out of specifica...

Page 141: ...crease the selected cylinder number press the RESET button To increase the selected cylinder number press the SELECT button 5 After selecting the cylinder simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selec tion 6 Change the CO adjustment volume by pressing the SELECT and RESET but tons NOTE The CO adjustment volume appears on the tripmeter LCD To decrease ...

Page 142: ...execute the selec tion 6 Change the CO adjustment volume by pressing the SELECT and RESET but tons NOTE The CO adjustment volume appears on the tripmeter LCD To decrease the CO adjustment volume press the RESET button To increase the CO adjustment volume press the SELECT button 7 Release the switch to execute the selec tion 8 Simultaneously press the SELECT and RESET buttons to return to the cylin...

Page 143: ...AL CHASSIS on page 4 1 and CHECKING AND CHARGING THE BATTERY on page 8 114 3 Adjust Throttle cable free play NOTE When the throttle is opened the accelerator cable 1 is pulled Throttle body side a Loosen the locknut 2 on the decelerator cable b Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable c Tighten the locknuts NOTE If the specified throttle cable free...

Page 144: ...he engine idling speed to change EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Radiator lower bolt 1 Radiator lower hose bracket bolt 2 Refer to RADIATOR on page 6 1 2 Disconnect Spark plug caps 3 Remove Spark plugs CAUTION ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to pr...

Page 145: ...CLEARANCE on page 3 4 2 Start the engine warm it up for several minutes and then turn it off 3 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Battery Refer to GENERAL CHASSIS on page 4 1 and CHECKING AND CHARGING THE BATTERY on page 8 114 Battery box Battery box bracket Refer to GENERAL CHASSIS on page ...

Page 146: ...r Heat protector plate Battery box bracket Battery box Refer to GENERAL CHASSIS on page 4 1 Battery Refer to GENERAL CHASSIS on page 4 1 and CHECKING AND CHARGING THE BATTERY on page 8 114 Air filter case Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Seat Refer to GENERAL CHASSIS on page 4 1 EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surfa...

Page 147: ...rn it off 5 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled EAS20790 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several minutes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely fro...

Page 148: ...age 3 13 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark Add the recommended engine oil to the proper level 2 Start the engine warm it up for several minutes and then turn it off CAUTION ECA13410 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil...

Page 149: ...pecified clutch cable free play is obtained Pressure gauge 90890 03153 YU 03153 Oil pressure adapter H 90890 03139 Engine oil pressure 240 kPa 34 1 psi 2 4 kg cm2 Engine speed Approx 6 600 r min Oil temperature 75 0 85 0 C 167 00 185 00 F Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Lea...

Page 150: ...eplace 5 Install Air filter element Air filter case cover CAUTION ECA4S81008 Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle bodies synchronization leading to poor engine performance and possible overheating NOTE When instal...

Page 151: ...ose 1 Fuel hose 2 Cracks damage Replace Loose connection Connect properly NOTE Before removing the fuel hose place a few rags in the area under where it will be removed There is a white mark on the fuel tank breather hose Refer to CABLE ROUTING on page 2 47 CAUTION ECA14940 Make sure the fuel tank breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Seat Refer to GE...

Page 152: ...Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Coolant 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 CAUTION ECA13470 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if n...

Page 153: ...r 1 Radiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Water jacket joint 7 Water jacket joint hose 8 Oil cooler inlet pipe 9 Water pump outlet hose 10 Cracks damage Replace Refer to RADIATOR on page 6 1 EAS21130 CHANGING THE COOLANT 1 Remove Coolant reservoir 1 Coolant reservoir cap 2 2 Drain Coolant from the coolant reservoir 3 Remove Radia...

Page 154: ...h special care WARNING EWA13040 If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention CAUTION ECA13480 Adding water instead of coolant lowers the antifreeze content of the coolant If water is us...

Page 155: ...rvoir cap 13 Start the engine warm it up for several minutes and then stop it 14 Check Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3 19 NOTE Before checking the coolant level wait a few minutes until the coolant has settled ...

Page 156: ... will considerably reduce in loss of control and possibly an accident Therefore check and if necessary bleed the brake system CAUTION ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Check Brake pedal position distance a from the top of the rider foot rest to the top of the brake pedal Out of specification Adjust 2 Adjust B...

Page 157: ... the rubber seals to deteriorate causing leakage and poor brake performance Refill 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 perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could ...

Page 158: ... 1 Check Brake hose Cracks damage wear Replace 2 Check Brake hose clamp Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to REAR BRAKE on page 4 41 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal T...

Page 159: ...ake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylin der reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever several times f Fully pull the brake lever or fully press down the brake ped...

Page 160: ...r plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever or fully depress the brake pedal and hold it in posi tion g Loosen the bleed screw NOTE Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h...

Page 161: ...e and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Spin the rear wheel...

Page 162: ...n sol vents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Bind...

Page 163: ...all of the cables and wires are prop erly routed a Point the front wheel straight ahead b Install a plastic locking tie 1 loosely around the end of the handlebar as shown c Hook a spring gauge 2 onto the plastic locking tie d Hold the spring gauge at a 90 angle from the handlebar pull the spring gauge and then record the measurement when the handlebar starts to run e Repeat the above procedure on ...

Page 164: ...le so that there is no danger of it falling over Spring preload CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Adjust the spring preload with the special wrench and extension bar included in the owner s tool kit b Turn the adjusting ring 1 in direction a or b c Align the desired position on the adjusting ring with the stopper 2 EAS21650 CHECK...

Page 165: ...Tire surfaces Damage wear Replace the tire Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 33 psi 2 25 kgf cm 2 25 bar Rear 250 kPa 36 psi 2 50 kgf cm 2 50 bar Loading condition 90 185 kg 198 408 lb FZ6 SA FZ6 SHGW FZ6 SAHG 90 190 kg 198 419 lb FZ6 S FZ6 SHG 90 191 kg 198 421 lb FZ6 NA FZ6 NAHG 90 196 kg 198 432 lb FZ6 N FZ6 NHG FZ6 NHGW Front 250 kPa 36 p...

Page 166: ...same design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi cle WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction o...

Page 167: ... cable sheath or use a suitable lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21730 LUBRICATING THE...

Page 168: ... of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install Headlight bulb holder 7 Install Headlight bulb cover 8 Connect Headlight coupler EAS21810 ADJUSTING THE HEADLIGHT BEAMS Th...

Page 169: ...the adjusting screw 1 in direction a or b A FZ6 S FZ6 SHG W FZ6 SA FZ6 SAHG B FZ6 N FZ6 NHG W FZ6 NA FZ6 NAHG Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left A FZ6 S FZ6 SHG W FZ6 SA FZ6 SAHG B FZ6 N FZ6 NHG W FZ6 NA FZ6 NAHG ...

Page 170: ...ELECTRICAL SYSTEM 3 37 ...

Page 171: ...NG THE FRONT BRAKE CALIPERS 4 34 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 34 CHECKING THE FRONT BRAKE CALIPERS 4 35 ASSEMBLING THE FRONT BRAKE CALIPERS 4 36 INSTALLING THE FRONT BRAKE CALIPERS 4 36 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 38 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 38 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 39 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 39 REAR BRAKE 4 4...

Page 172: ...HE LOWER BRACKET 4 74 CHECKING THE STEERING HEAD 4 74 INSTALLING THE STEERING HEAD 4 75 REAR SHOCK ABSORBER ASSEMBLY 4 76 HANDLING THE REAR SHOCK ABSORBER 4 77 DISPOSING OF A REAR SHOCK ABSORBER 4 77 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 77 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 77 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 78 SWINGARM 4 79 REMOVING THE SWINGARM 4 81 CHECKING THE SWI...

Page 173: ......

Page 174: ...GENERAL CHASSIS 4 1 EAS21830 GENERAL CHASSIS Removing the seat Order Job Parts to remove Q ty Remarks 1 Seat 1 For installation reverse the removal proce dure ...

Page 175: ...4 2 Removing the cowlings FZ6 N FZ6 NHG W FZ6 NA FZ6 NAHG Order Job Parts to remove Q ty Remarks Seat Refer to GENERAL CHASSIS on page 4 1 1 Side cover 2 2 Rear cowling 1 For installation reverse the removal proce dure ...

Page 176: ...o GENERAL CHASSIS on page 4 1 1 Left front cowling inner panel with cowling 1 2 Right front cowling inner panel with cowling 1 3 Front turn signal light coupler 2 Disconnect 4 Front cowling 1 5 Rear view mirrors 2 6 Windshield 1 7 Side cover 2 8 Rear cowling 1 For installation reverse the removal proce dure ...

Page 177: ...S on page 4 1 1 Left front cowling inner panel with cowling 1 2 Right front cowling inner panel with cowling 1 3 Front turn signal light coupler 2 Disconnect 4 Front cowling 1 5 Front cowling inner panel center 1 6 Rear view mirrors 2 7 Windshield 1 8 Side cover 2 9 Rear cowling 1 For installation reverse the removal proce dure ...

Page 178: ...age 4 1 Fuel tank Refer to FUEL TANK on page 7 1 ABS motor relay with ABS Refer to ABS ECU AND ABS MOTOR RELAY on page 8 77 1 Intake air temperature sensor coupler 1 Disconnect 2 Throttle body hose 2 Disconnect 3 Air induction system hose 1 Disconnect 4 Clamp 4 Loosen 5 Crankcase breather hose 1 Disconnect 6 Starter relay 1 7 Battery negative lead 1 Disconnect 8 Battery positive lead 1 Disconnect ...

Page 179: ...ing Refer to GENERAL CHASSIS on page 4 1 Right front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Battery Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Battery box 1 2 Battery box bracket 3 3 Ignition coil 2 For installation reverse the removal proce dure ...

Page 180: ...cs FZ6 N FZ6 NHG W FZ6 S FZ6 SHG W Order Job Parts to remove Q ty Remarks 1 Brake hose holder 2 2 Brake hose holder 1 3 Front brake caliper 2 4 Front wheel axle pinch bolt 1 Loosen 5 Front wheel axle 1 6 Collar 2 7 Front wheel 1 8 Front brake disc 2 For installation reverse the removal proce dure ...

Page 181: ...Order Job Parts to remove Q ty Remarks 1 Brake hose holder 2 2 Brake hose holder 1 3 Front brake caliper 2 4 Front wheel sensor 1 5 Front wheel axle pinch bolt 1 Loosen 6 Front wheel axle 1 7 Collar 1 8 Sensor housing 1 9 Front wheel 1 10 Front brake disc 2 11 Clamp 1 For installation reverse the removal proce dure ...

Page 182: ...FRONT WHEEL 4 9 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure ...

Page 183: ... THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel axle 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 31 and CHECKING THE WHEELS on page 3 34 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel t...

Page 184: ...with care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The ABS wheel sensor cannot be disas sembled Do not attempt to disassemble it If faulty replace with a new one Removing the front wheel sensor 1 Remove Brake hose holder 1 Front wheel sensor lead holder 2 Brake caliper 3 Front wheel sensor 4 CAUTION ECA4S81011 Be sure not to contact the s...

Page 185: ...on of the front fork before assembly CAUTION ECA14470 Make sure there are no foreign materials in the wheel hub Foreign materials cause damage to the inner sensor rotor and wheel sensor 2 Install Front wheel sensor 1 Front wheel sensor lead holder 2 Brake caliper 3 Brake hose holder 4 NOTE When installing the front wheel sensor check the wheel sensor lead for twists and the sensor electrode for fo...

Page 186: ...table balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to rest at the same spot g The spot where all the marks co...

Page 187: ...ake discs 1 Lubricate Wheel axle Oil seal lips 2 Install Collar Wheel axle NOTE Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation 3 Tighten Wheel axle Wheel axle pinch bolt CAUTION ECA14140 Before tightening the wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Install Brake calipers WARNING EWA13490 ...

Page 188: ...W Order Job Parts to remove Q ty Remarks 1 Rear brake caliper 1 2 Locknut 2 Loosen 3 Adjusting nut 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Washer 1 8 Drive chain puller 2 9 Rear wheel 1 10 Rear brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 189: ...s to remove Q ty Remarks 1 Rear wheel sensor 1 2 Rear brake caliper 1 3 Lock nut 2 Loosen 4 Adjusting nut 2 Loosen 5 Wheel axle nut 1 6 Washer 1 7 Rear wheel axle 1 8 Washer 1 9 Drive chain puller 2 10 Rear wheel 1 11 Rear brake caliper bracket 1 12 Sensor rotor 1 For installation reverse the removal proce dure ...

Page 190: ... wheel sprocket Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Oil seal 2 5 Bearing 2 6 Rear wheel drive hub 1 7 Rear wheel drive hub damper 6 8 Rear wheel 1 For installation reverse the removal proce dure ...

Page 191: ...REAR WHEEL 4 18 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 192: ...ear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel drive hub damper Right collar EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 10 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 31 and CHECKING THE WH...

Page 193: ...ocket NOTE Tighten the self locking nuts in stages and in a crisscross pattern EAS22200 D 4 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR CAUTION ECA4S81012 Be sure not to contact the sensor elec trode to any metal part when removing the rear wheel sensor from the sensor housing Do not operate the brake lever when removing the brake caliper Removing the rear wheel sensor 1 Disconnect Rear ...

Page 194: ...inner sensor rotor and wheel sensor 3 Install Rear wheel sensor 2 NOTE When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials CAUTION ECA14500 To route the rear wheel sensor lead refer to CABLE ROUTING on page 2 47 4 Check Check the clearance a between the rear wheel sensor and sensor rotor Out of specification Check the exi...

Page 195: ... and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 13 EAS22160 INSTALLING THE REAR WHEEL 1 Lubricate Wheel axle Wheel bearings Oil seal lips 2 Install Collars Rear brake caliper bracket Rear wheel Washer Rear wheel axle 3 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 4 Tighten Wheel axl...

Page 196: ...RONT BRAKE Removing the front brake pads FZ6 N FZ6 NA FZ6 S FZ6 SA Order Job Parts to remove Q ty Remarks 1 Front brake caliper 1 2 Brake pad 2 3 Brake pad spring 2 4 Bleed screw 1 For installation reverse the removal proce dure ...

Page 197: ...Z6 NHG W FZ6 NAHG FZ6 SHG W FZ6 SAHG Order Job Parts to remove Q ty Remarks 1 Brake hose holder 2 2 Front brake caliper 2 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Bleed screw 1 8 Clamp 1 For installation reverse the removal proce dure ...

Page 198: ... master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch lead coupler 1 Disconnect 6 Front brake light switch 1 7 Union bolt 1 8 Copper washer 2 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 For installation reverse the removal proce dure ...

Page 199: ...ssembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Master cylinder kit 1 4 Spring 1 5 Master cylinder 1 6 Push rod 1 For assembly reverse the disassembly pro cedure ...

Page 200: ...6 SA Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 5 Brake pad 2 6 Brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 201: ...NAHG FZ6 SHG W FZ6 SAHG Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Union bolt 2 2 Copper washer 5 3 Brake hose 2 4 Brake caliper 1 5 Clamp 1 6 Brake hose holder 2 For installation reverse the removal proce dure ...

Page 202: ...ront brake calipers FZ6 N FZ6 NA FZ6 S FZ6 SA Order Job Parts to remove Q ty Remarks 1 Brake pad 2 2 Brake caliper piston 2 3 Brake caliper piston seal 4 4 Brake pad spring 1 5 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 203: ...HG W FZ6 NAHG FZ6 SHG W FZ6 SAHG Order Job Parts to remove Q ty Remarks 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 204: ...ING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Check Brake disc Damage galling Replace 2 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the handlebar to the left or right ...

Page 205: ...ads Brake pads NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim onto each new brake pad 3 Inst...

Page 206: ...oosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring NOTE The arrow mark b on the brake pad spring must point in the direction of disc rotation 3 Install Brake pad pins Brake pad clips Brake caliper 4 Check Brake fluid level Below the minimum level mark c Add the recommended br...

Page 207: ...carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers FZ6 N FZ6 NA FZ6 S FZ6 SA 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper WARNING...

Page 208: ... side pistons from the brake caliper EAS22390 CHECKING THE FRONT BRAKE CALIPERS 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks damage Replace the brake cali per assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed ...

Page 209: ...he brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake...

Page 210: ...oir with the specified amount of the recom mended brake fluid WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill 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 perfor mance When refillin...

Page 211: ...lect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove Brake lever Brake master cylinder holder Brake master cylinder EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake...

Page 212: ...rake master cylinder make sure that the brake pipe touches the projection b on the brake master cylinder NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mend...

Page 213: ...e fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 5 Check Brake fluid level Below the minimum level mark c Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 24 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 ...

Page 214: ...moving the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad 2 6 Brake screw 1 7 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 215: ...YDRAULIC BRAKE SYSTEM on page 3 26 1 Brake fluid reservoir cap 1 2 Rear brake fluid reservoir diaphragm holder 1 3 Rear brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Union bolt 1 7 Copper washer 1 8 Brake hose 1 9 Rear brake master cylinder 1 For installation reverse the removal proce dure ...

Page 216: ...embling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Spring 1 5 Brake master cylinder body 1 For installation reverse the removal proce dure ...

Page 217: ...caliper Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure ...

Page 218: ...iper Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 219: ...the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 3 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 4 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 EAS22580 REPLACING THE REAR BRAKE PA...

Page 220: ...system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 Brake caliper 4 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CA...

Page 221: ...rake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Rear brake caliper bracket 1 Cracks damage Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean ...

Page 222: ...oor brake performance Refill 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 perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may dama...

Page 223: ...reservoir hose 3 Remove Pin from the brake pedal link 4 Remove Rear brake master cylinder 5 Remove Circlip from the rear brake master cylinder Master cylinder kit EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder 1 Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinde...

Page 224: ...ause the rubber seals to deteriorate causing leakage and poor brake performance Refill 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 perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and co...

Page 225: ...REAR BRAKE 4 52 6 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 25 Brake pedal position 25 8 mm 1 02 in ...

Page 226: ...7 1 ABS ECU Refer to ABS ECU AND ABS MOTOR RELAY on page 8 77 Hydraulic unit solenoid coupler Refer to ABS ECU AND ABS MOTOR RELAY on page 8 77 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 26 1 Rectifier regulator 1 2 ECU 1 3 Cover 1 4 Sub complete bracket 1 1 5 Union bolt 1 6 Copper washer 2 7 Brake hose front brake master cylinder to hydraulic unit 1 8 Union bolt 1 9 ...

Page 227: ...hose rear brake master cylinder to hydraulic unit 1 14 Union bolt 1 15 Copper washer 2 16 Brake hose hydraulic unit to rear brake caliper 1 17 Hydraulic unit 1 18 Hydraulic unit bracket 1 1 19 Hydraulic unit bracket 2 1 For installation reverse the removal proce dure Removing the hydraulic unit Order Job Parts to remove Q ty Remarks ...

Page 228: ...iately Do not allow any brake fluid to contact the couplers Brake fluid may damage the couplers and cause bad contacts If the union bolts for the hydraulic unit have been removed be sure to tighten them to the specified torque and bleed the brake system Removing the hydraulic unit 1 Remove Brake hose 1 from the front brake master cylinder Brake hose 2 to the front brake caliper Brake hose 3 from t...

Page 229: ...be distinguished by the rubber at the end of each hose Be sure to connect each brake hose to the correct union bolt hole CAUTION ECA14760 To route the front and rear brake hoses refer to CABLE ROUTING on page 2 47 5 Fill Brake master cylinder reservoir 6 Bleed the brake system 7 Check the operation of the hydraulic unit according to the brake lever and the brake pedal response Refer to HYDRAULIC U...

Page 230: ...han 12 8 V charge the battery and perform hydraulic unit operation test 2 If the battery voltage is lower than 10 V the ABS warning light comes on and the ABS does not operate 5 Connect the test coupler adaptor 1 to the test coupler 2 6 Set the main switch to ON while operating the brake lever and the brake pedal simul taneously CAUTION ECA4S81014 When the main switch is set to ON be sure to opera...

Page 231: ...ort the vehicle so that there is no danger of it falling over 1 Place the vehicle on the centerstand 2 Set the main switch to OFF 3 Remove Seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 4 Check Battery voltage Lower than 12 8 V Charge or replace the battery NOTE If the battery voltage is lower than 12 8 V charge the battery and perform hydraulic unit operation t...

Page 232: ... to continue to operate the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopped in the brake pedal it is generated in the brake lever 0 5 second after and continues for approximately 1 second CAUTION ECA14800 Check that the pulsating action is felt in the brake lever brake pedal and again in the brake lever respectively If the pulsating...

Page 233: ...nector 1 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 6 Clutch lever 1 7 Right handlebar switch 1 8 Throttle grip 1 9 Throttle cable 2 10 Front brake light switch connector 1 Disconnect 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 13 Upper handlebar holder 2 14 Upper handlebar holder 1 15 Handlebar 1 For installation reverse the removal proce dure ...

Page 234: ...move Front brake master cylinder holder 3 Front brake master cylinder Upper handlebar holder Handlebar EAS22880 CHECKING THE HANDLEBAR 1 Check Handlebar 1 Bends cracks damage Replace WARNING EWA13690 Do not attempt to straighten a bent handle bar as this may dangerously weaken it 2 Install Handlebar grip a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Slide the handleba...

Page 235: ...ace of the lower handlebar holders 3 Install Throttle cables Right handlebar switch 1 Throttle grip 2 NOTE Align the projections a on the handlebar switch with the holes b in the handlebar 4 Install Brake master cylinder 1 Brake master cylinder holder 2 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER on page 4 39 NOTE Align the mating surfaces of the brake master cylinder bracket with the punc...

Page 236: ...onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried 8 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 10 9 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH ...

Page 237: ...e Q ty Remarks Front wheel Refer to FRONT WHEEL on page 4 7 Front brake calipers Refer to FRONT BRAKE on page 4 23 1 Front fender 1 2 Cap bolt 1 Loosen 3 Upper bracket pinch bolt 1 Loosen 4 Under bracket pinch bolt 1 Loosen 5 Front fork leg 1 For installation reverse the removal proce dure ...

Page 238: ...acer 1 4 Washer 1 5 Front fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod assembly bolt 1 9 Copper washer 1 10 Damper rod assembly 1 11 Oil seal 1 12 Washer 1 13 Inner tube 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Oil flow stopper 1 17 Outer tube 1 For assembly reverse the disassembly pro cedure ...

Page 239: ...wing procedure applies to both of the front fork legs 1 Remove Cap bolt Washer Spacer Fork spring 2 Drain Fork oil NOTE Stroke the inner tube several times while drain ing the fork oil 3 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver CAUTION ECA14180 Do not scratch the inner tube 4 Remove Damper rod assembly bolt Damper rod assembly NOTE While holding the damper rod with the dampe...

Page 240: ...traighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Oil flow stopper 2 Damage Replace CAUTION ECA14200 The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu ...

Page 241: ...210 Allow the damper rod assembly to slide slowly down the inner tube until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface 3 Tighten Damper rod assembly bolt 1 NOTE While holding the damper rod assembly with the damper rod holder 2 and T handle 3 tighten the damper rod assembly bolt 4 Install Outer tube bushing 1 with ...

Page 242: ...ion 6 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install Dust seal 1 with the fork seal driver weight 8 Fill Front fork leg with the specified amount of the recom mended fork oil CAUTION ECA4S81015 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the fr...

Page 243: ...rarily tighten the cap bolt EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure t...

Page 244: ...FRONT FORK 4 71 ...

Page 245: ... to HANDLEBAR on page 4 60 Front cowling inner panel left side Refer to GENERAL CHASSIS on page 4 1 Front cowling inner panel right side Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Main switch coupler 2 Disconnect 2 Immobilizer coupler 1 Disconnect 3 Steering stem nut 1 4 Washer 1 5 Upper bracket 1 6 Horn stay 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer...

Page 246: ...73 13 Bearing inner race 2 14 Upper bearing 1 15 Lower bearing 1 16 Dust seal 1 17 Bearing outer race 2 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks ...

Page 247: ...f it falling EAS23130 CHECKING THE STEERING HEAD 1 Wash Bearing balls Bearing races 2 Check Bearing balls 1 Bearing races 2 Damage pitting Replace 3 Replace Bearing balls Bearing races a Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac...

Page 248: ...er bracket Lower ring nut 1 Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING THE STEERING HEAD on page 4 74 3 Install Upper bracket Washer Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4 70 NOTE Temporarily tighten the upper and lower bracket pinch bolts Recommended lubricant Lithium soap b...

Page 249: ... Refer to GENERAL CHASSIS on page 4 1 Side cover Refer to GENERAL CHASSIS on page 4 1 Rear brake caliper Refer to REAR BRAKE on page 4 41 Rear wheel Refer to REAR WHEEL on page 4 15 1 Self locking nut collar bolt 1 1 1 2 Self locking nut washer bolt 1 1 1 3 Rear shock absorber assembly 1 4 Oil seal bearing 2 1 For installation reverse the removal proce dure ...

Page 250: ...s pressure drill a 2 3 mm hole through the rear shock absorber at a point 15 20 mm from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicl...

Page 251: ...ock absorber assembly lift up the swingarm 3 Tighten Rear shock absorber assembly upper nut 1 Rear shock absorber assembly lower nut 2 4 Install Rear wheel Refer to REAR WHEEL on page 4 15 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 Recommended lubricant Molybdenum disulfide grease Rear shock absorber assembly upper nut 40 Nm 4 0 m kg 29 ft lb Rear shock absorb...

Page 252: ...VAL on page 5 1 Rear brake caliper Refer to REAR BRAKE on page 4 41 Rear wheel Refer to REAR WHEEL on page 4 15 Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 76 Drive sprocket cover Refer to ENGINE REMOVAL on page 5 1 1 Locknut 2 Loosen 2 Adjusting nut 2 Loosen 3 Rear fender 1 4 Pivot shaft nut washer 1 1 5 Pivot shaft 1 6 Swingarm 1 7 Drive chain 1 8 Drive chain gui...

Page 253: ...SWINGARM 4 80 For installation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks ...

Page 254: ... spacers bearings washers and dust covers d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the spacers bearings and dust covers EAS23370 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA4S81007 Do n...

Page 255: ...k absorber assembly Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 78 Rear wheel Refer to INSTALLING THE REAR WHEEL on page 4 22 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 28 Recommended lubricant Lithium soap based grease Pivot shaft nut 120 Nm 12 0 m kg 87 ft lb Drive chain slack 45 0 55 0 mm 1 77 2 17 in ...

Page 256: ...e chain Order Job Parts to remove Q ty Remarks Drive sprocket cover Refer to ENGINE REMOVAL on page 5 1 Swingarm Refer to REMOVING THE SWINGARM on page 4 81 1 Rear fender 1 2 Drive chain 1 3 Chain protector 1 For installation reverse the removal proce dure ...

Page 257: ...e chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it CAUTION ECA14290 This vehicle has a drive chain with sma...

Page 258: ...ive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 20 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 19 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive chain 3 Install Swingarm Refer ...

Page 259: ...DES 5 22 CHECKING THE VALVE SEATS 5 23 CHECKING THE VALVE SPRINGS 5 25 CHECKING THE VALVE LIFTERS 5 26 INSTALLING THE VALVES 5 26 GENERATOR AND STARTER CLUTCH 5 28 REMOVING THE GENERATOR 5 30 REMOVING THE STARTER CLUTCH 5 30 CHECKING THE STARTER CLUTCH 5 31 INSTALLING THE STARTER CLUTCH 5 31 INSTALLING THE GENERATOR 5 32 PICKUP ROTOR 5 33 REMOVING THE PICKUP ROTOR 5 34 INSTALLING THE PICKUP ROTOR ...

Page 260: ...FT 5 54 CRANKCASE 5 55 DISASSEMBLING THE CRANKCASE 5 57 CHECKING THE CRANKCASE 5 57 CHECKING THE BEARINGS AND OIL SEALS 5 57 CHECKING THE OIL PUMP DRIVE CHAIN 5 57 ASSEMBLING THE CRANKCASE 5 58 CRANKSHAFT 5 60 REMOVING THE CONNECTING RODS AND PISTONS 5 62 REMOVING THE CRANKSHAFT ASSEMBLY 5 62 CHECKING THE CYLINDER AND PISTON 5 63 CHECKING THE PISTON RINGS 5 63 CHECKING THE PISTON PINS 5 64 CHECKIN...

Page 261: ......

Page 262: ...der Job Parts to remove Q ty Remarks Drive chain Loosen Refer to ADJUSTING THE SHIFT PEDAL on page 3 28 1 Locknut 1 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 For installation reverse the removal proce dure ...

Page 263: ...Removing the exhaust pipe Order Job Parts to remove Q ty Remarks 1 Exhaust pipe assembly 1 2 Exhaust pipe gasket 4 3 Catalytic converter pipe 1 4 Muffler cover 1 5 Muffler 1 For installation reverse the removal proce dure ...

Page 264: ...SIS on page 4 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Battery box Refer to GENERAL CHASSIS on page 4 1 Battery box bracket Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Oil cooler Refer to OIL COOLER on page 6 4 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 Radiator...

Page 265: ...il assembly coupler 1 Disconnect 7 Oil level switch connector 1 Disconnect 8 Neutral switch coupler 1 Disconnect 9 Speed sensor coupler 1 Disconnect For assembly reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks ...

Page 266: ...he engine Order Job Parts to remove Q ty Remarks 1 Right front engine mounting bolt 1 2 Left front engine mounting bolt 2 3 Self locking nut 2 4 Rear engine mounting bolt 2 5 Engine 1 For installation reverse the removal proce dure ...

Page 267: ... bolts 3 NOTE Do not fully tighten the bolts 3 Tighten Self locking nut 4 NOTE First tighten the lower self locking nut 4 Tighten Left front engine mounting bolts 5 5 Tighten Right front engine mounting bolt 6 6 Install Shift arm bolt 7 Self locking nut 55 Nm 5 5 m kg 40 ft lb Left front engine mounting bolt 55 Nm 5 5 m kg 40 ft lb Right front engine mounting bolt 55 Nm 5 5 m kg 40 ft lb Shift arm...

Page 268: ...VAL 5 7 NOTE Before installing make sure to align the punch mark a of the shift shaft with the punch mark b of the shift arm Align the bottom edge of the shift pedal with the mark on the frame to swingarm bracket ...

Page 269: ...y box Refer to FUEL TANK on page 7 1 Battery box bracket Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 Radiator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 1 Ignition coil 2 2 Spark plug 4 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Timing chain guide top side 1 For installation reverse the removal...

Page 270: ...rocket bolt 4 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Timing chain guide exhaust side 1 5 Intake camshaft cap 3 6 Dowel pin 6 7 Exhaust camshaft cap 3 8 Dowel pin 6 9 Intake camshaft 1 10 Exhaust camshaft 1 11 Pin 1 12 Timing chain guide intake side 1 13 Camshaft sprocket 2 For installation reverse the removal proce dure ...

Page 271: ...roke can be found when the camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Loosen Timing chain tensioner cap bolt 1 5 Remove Timing chain tensioner 2 Gasket 6 Remove Timing chain guide exhaust side Camshaft caps 1 Dowel pins CAUTION ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss c...

Page 272: ...shaft into the cylinder head without the dowel pins and camshaft caps b Position strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps Camshaft lobe dimension limit Intake A 32 450 32 550 mm 1 2776 1 2815 in Limit 32 400 mm 1 2756 in Intake B 24 950 25 050 mm 0 9823 0 9862 in Limit 24 900 mm 0 9803 in Exhaust A 32 450 32 550 mm 1 2776 1 2815 in Limit ...

Page 273: ...linder head and the camshaft caps as a set EAS23870 CHECKING THE TIMING CHAIN AND CAM SHAFT SPROCKET 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES 1 Check Timing chain guide exhaust side 1 Timing...

Page 274: ...ioner rod c Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner 3 Check Timing chain tensioner cap bolt Aluminum washer Gasket Damage wear Replace the defective part s EAS24010 INSTALLING THE CAMSHAFTS 1 Align T mark a on the pickup rotor with the crankcase mating surface b a Turn the ...

Page 275: ...r improper valve timing 5 Install Timing chain guide exhaust side NOTE When installing the timing chain guide be sure to keep the timing chain as tight as possible on the exhaust side 6 Install Timing chain tensioner a While lightly pressing the timing chain ten sioner rod by hand turn the tensioner rod fully clockwise with a thin screwdriver 1 b With the timing chain tensioner rod turned all the ...

Page 276: ...igned with the edge of the cylinder head d Out of alignment Adjust Refer to the installation steps above 9 Tighten Camshaft sprocket bolts 1 CAUTION ECA4S81017 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 10 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE ...

Page 277: ...e cylinder head Order Job Parts to remove Q ty Remarks Intake camshaft Refer to CAMSHAFTS on page 5 8 Exhaust camshaft Refer to CAMSHAFTS on page 5 8 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal proce dure ...

Page 278: ...amage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface ...

Page 279: ...e proper tightening sequence as shown and torque them in two stages First tighten the bolts 1 10 to approxi mately 19 Nm 1 9 m kg 14 ft lb with a torque wrench and then tighten the 50 Nm 5 0 m kg 36 ft lb 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 13 Cylinder head bolt 1st 19 Nm 1 9 m kg 14 ft lb Cylinder head bolt 2nd 50 Nm 5 0 m kg 36 ft lb Cylinder he...

Page 280: ...tter 16 4 Intake valve upper spring seat 8 5 Intake valve spring outer 8 6 Intake valve spring inner 8 7 Intake valve stem seal 8 8 Intake valve lower spring seat 8 9 Intake valve 8 10 Intake valve guide 8 11 Exhaust valve lifter 8 12 Exhaust valve pad 8 13 Exhaust valve cotter 16 14 Exhaust valve upper spring seat 8 15 Exhaust valve spring 8 16 Exhaust valve stem seal 8 17 Exhaust valve lower spr...

Page 281: ...VALVES AND VALVE SPRINGS 5 20 For installation reverse the removal proce dure Removing the valves and valve springs Order Job Parts to remove Q ty Remarks ...

Page 282: ...r to CHECKING THE VALVE SEATS on page 5 23 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve springs with the valve spring compressor 2 and the valve spring compressor attach ment 3 4 Remove Upper spring seat 1 Valve spri...

Page 283: ...uide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve ...

Page 284: ...minate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm YM 04112 Valve guide reamer ø4 90890 04113 Valve guide reamer 4 0 mm YM...

Page 285: ...lapping compound a to the valve face CAUTION ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap...

Page 286: ...rce a Out of specification Replace the valve spring Inner spring Free length intake 37 04 mm 1 46 in Limit 35 20 mm 1 39 in Free length exhaust 41 79 mm 1 65 in Limit 39 70 mm 1 56 in Outer spring Free length intake 38 40 mm 1 51 in Limit 36 50 mm 1 44 in b Installed length Inner spring Installed compression spring force intake 69 79 N 15 51 17 76 lbf 7 04 8 06 kgf Installed compression spring for...

Page 287: ...components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring inner intake only 4 Valve spring outer 5 Upper spring seat 6 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Install the valve springs with the larger pitch a facing u...

Page 288: ...13800 Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad 1 Valve lifter 2 with the recommended lubricant NOTE Lubricate the valve lifter and valve pad with molybdenum disulfide oil The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve spring compressor 9...

Page 289: ...oolant Drain Refer to CHANGING THE COOLANT on page 3 20 Coolant reservoir tank Refer to RADIATOR on page 6 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 1 Stator coil assembly lead coupler 1 Disconnect 2 Generator rotor cover 1 3 Generator rotor cover gasket 1 4 Dowel pin 2 5 Stator coil assembly lead holder 2 6 Stator coil assembly 1 7 Generator rotor bolt 1 8 Washer 1 9 Genera...

Page 290: ...TARTER CLUTCH 5 29 11 Idler gear shaft 1 12 Idler gear 1 13 Starter clutch drive gear 1 For installation reverse the removal proce dure Removing the generator and starter clutch Order Job Parts to remove Q ty Remarks ...

Page 291: ...ion on the generator rotor 5 Remove Generator rotor 1 with the flywheel puller 2 and flywheel puller attachment Woodruff key CAUTION ECA13880 To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set s center bolt and the crankshaft NOTE Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Star...

Page 292: ... When turning the starter clutch drive gear clockwise A the starter clutch and the starter clutch drive gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch drive gear counterclockwise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch NOTE Wh...

Page 293: ...he generator rotor 3 Apply Sealant onto the stator coil assembly lead grom met 4 Install Stator coil 5 Install Generator rotor cover NOTE Tighten the generator rotor cover bolts in stages and in a crisscross pattern 6 Fill Engine oil Refer to CHANGING THE ENGINE OIL on page 3 14 Coolant Refer to CHANGING THE COOLANT on page 3 20 7 Install Fuel tank Refer to FUEL TANK on page 7 1 Seat Refer to GENE...

Page 294: ... panel with cowling Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Generator rotor cover Refer to GENERATOR AND STARTER CLUTCH on page 5 28 1 Crankshaft position sensor lead coupler 1 Disconnect 2 Pickup rotor cover 1 3 Pickup rotor cover gasket 1 4 Dowel pin 2 5 Crankshaft position sensor 1 6 Pickup roto...

Page 295: ...lder 5 loosen the pickup rotor bolt EAS4S81042 INSTALLING THE PICKUP ROTOR 1 Install Pickup rotor 1 Washer Pickup rotor bolt NOTE When installing the pickup rotor align the groove a in the crankshaft sprocket with the projection b in the pickup rotor 2 Tighten Pickup rotor bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 tighten the pickup rotor bolt Sheave holder 90890 017...

Page 296: ... rotor cover gasket Pickup rotor cover NOTE When installing the pickup rotor cover align the timing chain guide intake side pin 1 with the hole 2 in the pickup rotor cover Tighten the pickup rotor cover bolts in stages and in a crisscross pattern Yamaha bond No 1215 Three Bond No 1215 90890 85505 New ...

Page 297: ...ge 4 1 Right front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Left front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 298: ... Remarks 1 O ring 1 2 Starter motor front cover 1 3 Lock washer 1 4 Oil seal 1 5 Bearing 1 6 Washer set 1 7 Starter motor rear cover 1 8 Washer set 1 9 O ring 2 10 Brush holder 1 11 Armature assembly 1 12 Starter motor yoke 1 13 O ring 2 For assembly reverse the disassembly pro cedure ...

Page 299: ...commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 27 0 mm 1 06 in Mica u...

Page 300: ...e starter motor yoke 3 Install Starter motor yoke 1 O ring 2 Starter motor front cover 3 Starter motor rear cover 4 Starter motor assembling bolts 5 NOTE Align the match marks a on the starter motor yoke with the match marks b on the starter motor front and rear covers EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor Starter motor bolts 2 Connect Starter motor lead Starter motor assem...

Page 301: ...CHANGING THE COOLANT on page 3 20 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Water pump Refer to WATER PUMP on page 6 9 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch 1 3 Oil level switch lead holder 1 4 Oil pan 1 5 Oil pan gasket 1 6 Dowel pin 2 7 Oil strainer 1 8 Oil strainer gasket 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Oil pump assembly 1 12 Dowel pin 2 ...

Page 302: ...OIL PUMP 5 41 13 Relief valve assembly 1 For installation reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 303: ...ump Order Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5 Pin 1 6 Washer 1 7 Oil pump rotor housing 1 8 Oil pump driven sprocket 1 For assembly reverse the removal proce dure ...

Page 304: ...ctive part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s Inner rotor to outer rotor tip clearance 0 030 0 090 mm 0 ...

Page 305: ... 1 Damage wear Replace the oil nozzle O ring 2 Damage wear Replace Oil nozzle passage Obstruction Blow out with compressed air EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump housing 1 Oil pump shaft 2 Washer 3 Pin 4 Inner rotor 5 Outer rotor 6 Dowel pins 7 Oil pump cover 8 Oil pump housing screw NOTE When instal...

Page 306: ...he front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine EAS25050 INSTALLING THE OIL PAN 1 Install Oil pipe Oil delivery pipe 2 Install Dowel pins Gasket Oil pan 1 Oil level switch 2 Engine oil drain bolt WARNING EWA12820 Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross patter...

Page 307: ...rts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 20 1 Coolant hose 1 2 Clutch cable 1 3 Clutch cable holder 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 For installation reverse the removal proce dure ...

Page 308: ...ll lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Washer 1 3 Pull lever 1 4 Pull lever spring 1 5 Washer 1 6 Oil seal 1 7 Bearing 2 8 Pull lever shaft 1 9 Washer 1 For installation reverse the removal proce dure ...

Page 309: ...arks 1 Compression spring 6 2 Pressure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 6 6 Clutch plate 1 7 7 Friction plate 2 2 8 Clutch plate 2 1 9 Clutch boss nut 1 10 Lock washer 1 11 Clutch boss 1 12 Thrust plate 1 For assembly reverse the removal proce dure ...

Page 310: ... NOTE While holding the clutch boss 2 with the uni versal clutch holder loosen the clutch boss nut 5 Remove Clutch boss nut 1 Lock washer 2 Clutch boss 3 Thrust plate 4 EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Rep...

Page 311: ...utch springs as a set 2 Measure Clutch spring free length a Out of specification Replace the clutch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs 1 Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing NOTE Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check Bearing Damage wear Replace the bearing and clutch...

Page 312: ...l lever shaft pinion gear as a set 2 Check Pull rod bearing Damage wear Replace EAS25270 INSTALLING THE CLUTCH 1 Install Thrust plate 1 Clutch boss 2 Lock washer 3 Clutch boss nut 4 2 Tighten Clutch boss nut NOTE While holding the clutch boss with the univer sal clutch holder 1 tighten the clutch boss nut 3 Bend the lock washer tab along a flat side of the nut 4 Lubricate Friction plates Clutch pl...

Page 313: ...Clutch cable holder NOTE Install the pull rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply oil onto the bearing Apply molybdenum disulfide grease onto the pull rod When installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull...

Page 314: ...ver Refer to ENGINE REMOVAL on page 5 1 1 Shift shaft cover 1 2 Shift shaft cover gasket 1 3 Dowel pin 2 4 Oil seal 1 5 Shift shaft 1 6 Shift shaft spring 1 7 Collar 1 8 Stopper lever spring 1 9 Circlip 1 10 Washer 1 11 Stopper lever 1 12 Collar 1 13 Washer 1 14 Shift shaft spring stopper 1 For installation reverse the removal proce dure ...

Page 315: ...ghly Replace the stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Shift shaft spring stopper 1 Washers Shift shaft 2 NOTE Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of the stopper lever spring 3 onto the stopper lever 4 and the crankcase boss Mesh the stopper lever with the shift drum segment assembly 2 Install Shift shaft cover NOTE Lubricate the oil s...

Page 316: ...TOR AND STARTER CLUTCH on page 5 28 Shift shaft Refer to SHIFT SHAFT on page 5 53 Crankshaft position sensor Refer to PICKUP ROTOR on page 5 33 Pickup rotor Refer to PICKUP ROTOR on page 5 33 Clutch Refer to CLUTCH on page 5 46 Water pump Refer to WATER PUMP on page 6 9 Oil pan Refer to OIL PUMP on page 5 40 Oil pump Refer to OIL PUMP on page 5 40 1 Timing chain 1 2 Oil pump drive chain 1 3 Oil pu...

Page 317: ...CRANKCASE 5 56 8 Plate 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 318: ... Work slowly and carefully and make sure the crankcase halves separate evenly 4 Remove Dowel pins 5 Remove Crankshaft journal lower bearing from the lower crankcase NOTE Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the...

Page 319: ...ed by hand 6 Install Crankcase bolts NOTE Lubricate the bolt threads with engine oil Install a washer on bolts 1 10 Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase M8 85 mm 3 3 in bolts 1 7 10 M8 115 mm 4 5 in bolts 8 9 M8 65 mm 2 6 in bolts 11 12 M6 65 mm 2 6 in bolts 13 14 M6 55 mm 2 2 in bolts 15 22 26 M6 45 mm 1 8 in bolts 16 19 20 M6 65 mm 2 6 in bolts 17 27 M6...

Page 320: ...CRANKCASE 5 59 ...

Page 321: ... remove Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 55 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal proce dure ...

Page 322: ...remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 55 Connecting rods caps Refer to CRANKSHAFT on page 5 60 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For installation reverse the removal proce dure ...

Page 323: ...ing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are deburred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 3 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS25980 REMOVING THE CRANKSHAFT ASSE...

Page 324: ...h the following formula f If out of specification replace the cylinder and the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 65 500 65 510 m...

Page 325: ...d then check the lubrication system 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston Top ring Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring Ring side clearance 0 030 0 065 mm 0 0012 0 0026 in Limit 0 125 mm 0 0049 in a 5 mm 0 20 in Top ring ...

Page 326: ...into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod or crank shaft until the clearance measurement has been completed Lubricate the bolt threads and seats with molybdenum disulfide...

Page 327: ...ar b NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment j Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi tion k Tighten the connecting rod bolts CAUTION ECA4S81026 Tighten the connecting ro...

Page 328: ...e bolt until it is at the specified angles q Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 62 r Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P4 NOTE The numbers A stamped into the c...

Page 329: ...Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod faces left when the arrow mark b on the piston is pointing up as shown Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Lubricate Crankshaft pins Big end bearings...

Page 330: ...hten the connecting rod bolt while checking that the sections shown a and b are flush with each other by touching the surface NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment e Loosen the connecting rod bolt remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big e...

Page 331: ...new one and perform the proce dure again If they are not flush with each other remove the connecting rod bolt and big end bearing and restart from step 7 In this case make sure to replace the con necting rod bolt CAUTION ECA4S81029 Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angles EAS4S81038 CHECKING THE CRANKSHAFT 1 Measure ...

Page 332: ...nkshaft journal NOTE Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bear ings 1 into the lower crankcase and assemble the crankcase halves NOTE Align the projections a of the crankshaft journal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until the clear ance measurement has been completed f Tight...

Page 333: ...ower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings If the size is the same for all J1 to J5 one digit for that size is indicated Crankcase side only For example if the crankcase J1 and crankshaft web J1 numbers are 6 and 2 respectively ...

Page 334: ... a on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 2 Install Crankshaft 3 Install Lower crankcase Refer to CRANKCASE on page 5 55 ...

Page 335: ...er to CRANKCASE on page 5 55 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Shift drum retainer 1 6 Shift fork guide bar 2 7 Spring 4 8 Shift fork L 1 9 Shift fork R 1 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle assembly 1 13 Oil pipe 1 14 Oil baffle plate 1 15 Thrust plate 1 16 Washer 1 For installation reverse the removal proce dure ...

Page 336: ... 2 2nd pinion gear 1 3 Toothed lock washer 1 4 Toothed lock washer retainer 1 5 6th pinion gear 1 6 Collar 1 7 Washer 1 8 Circlip 1 9 3rd pinion gear 1 10 Circlip 1 11 Washer 1 12 5th pinion gear 1 13 Collar 1 14 Main axle 1 15 Bearing housing 1 16 Bearing 1 For installation reverse the removal proce dure ...

Page 337: ... 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 Collar 1 8 3rd wheel gear 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 16 Circlip 1 17 Washer 1 18 2nd wheel gear 1 19 Collar 1 20 Collar 1 21 Oil seal 1 22 Bearing 1 23 Circlip 1 24 Drive axle 1 ...

Page 338: ...TRANSMISSION 5 77 For installation reverse the removal proce dure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks ...

Page 339: ...t forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as...

Page 340: ...5 Check Transmission gear movement Rough movement Replace the defective part s 6 Check Circlips Bends damage looseness Replace EAS26350 INSTALLING THE TRANSMISSION 1 Install Oil pipe 1 Main axle assembly 2 with the Torx wrench NOTE Make sure to caulk the bolts at three positions after installing the bearing housing 2 Install Shift fork C 3 Shift drum assembly 4 Shift fork guide bar NOTE The emboss...

Page 341: ...roove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Make sure that the drive axle bearing circlip a is inserted into the grooves in the upper crankcase 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly Shift drum retainer bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE ...

Page 342: ...TRANSMISSION 5 81 ...

Page 343: ...COOLER 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP 6 13 ...

Page 344: ... to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 20 1 Coolant reservoir hose 1 2 Thermo wax outlet hose 1 3 Water pump breather hose 1 4 Radiator outlet hose 1 5 Radiator inlet hose 1 6 Oil cooler outlet hose 1 7 Radiator 1 8 Radiator cap 1 9 Radiator fan 1 10 Coolant ...

Page 345: ...RADIATOR 6 2 13 Coolant reservoir drain hose 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks ...

Page 346: ...d make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to ELECTRICAL COMPONENTS on page 8 105 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 20 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pre...

Page 347: ...DIATOR on page 6 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 1 Oil cooler outlet hose 1 2 Union bolt 1 3 Washer 1 4 Oil cooler 1 5 O ring 1 6 Oil cooler inlet hose 1 7 Oil cooler inlet pipe 1 8 Water jacket joint hose 1 9 Water jacket joint 1 10 O ring 1 11 Water pump outlet hose 1 12 Radiator outlet hose 1 For installation reverse the removal proce dure ...

Page 348: ...cooler lubricate the oil cooler bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 20 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 14 4 Check Cooling system Leaks Repair or replac...

Page 349: ... page 4 1 Right front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 1 Radiator inlet hose 1 2 Thermostat cover 1 3 Thermostat 1 For installation reverse the remov...

Page 350: ...racks damage Replace EAS26490 INSTALLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat NOTE Install the thermostat with its breather hole a facing up 2 Install Thermostat cover NOTE Before installing the thermostat cover to the cylinder head lubricate the O rings with a thin coat of lithium soap based grease 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANG...

Page 351: ...THERMOSTAT 6 8 Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 352: ... remove the water pump unless the coolant level is extremely low or the coolant contains engine oil Coolant Drain Refer to CHANGING THE COOLANT on page 3 20 1 Radiator outlet hose 1 Disconnect 2 Water pump outlet hose 1 3 Water pump breather hose 1 Disconnect 4 Water pump 1 For installation reverse the removal proce dure ...

Page 353: ...Order Job Parts to remove Q ty Remarks 1 Water pump cover 1 2 O ring 1 3 Impeller shaft 1 4 Circlip 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8 Water pump housing 1 9 O ring 1 10 Copper washer 1 For assembly reverse the disassembly pro cedure ...

Page 354: ...m the outside of the water pump housing 4 Remove Bearing 4 NOTE Remove the bearing from inside of the water pump housing 5 Remove Rubber damper holder 5 Rubber damper 6 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing cover 2 Impeller 3 Rubber damper 4 Rubber damper hold...

Page 355: ...er pump seal apply Yamaha bond No 1215 or Quick Gasket 2 to the water pump housing 3 3 Install Rubber damper 1 Rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mecha...

Page 356: ...OTE Install the radiator outlet hose with white a mark positioned outside Install the hose clamp with its screw head pointed to the inner side 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 20 4 Check Cooling system Leaks Repair or replace the faulty part 5 Measure Radiator cap opening pressure Below the specified pressure Replac...

Page 357: ...UMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 6 CHECKING THE THROTTLE BODIES 7 6 CHECKING THE FUEL PRESSURE 7 6 ADJUSTING THE THROTTLE POSITION SENSOR 7 6 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 12 INSTALLING THE AIR INDUCTION SYSTEM 7 12 ...

Page 358: ...g inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Right front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 1 Fuel hose 1 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank drain hose 1 5 Fuel tank breather hose 1 6 Fuel tank 1 7 Fuel pump 1 For installation reverse the removal proce dure ...

Page 359: ... tank Be sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump assembly 2 Check Diaphragms and gaskets Turn fatigue cracks Re...

Page 360: ...alled NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose To install the fuel hose from the fuel injection hose slide the cover a on the end of the hose in the direction of arrow shown 2 Install Fuel sender coupler Fuel pump coupler Fuel tank breather hose Fuel tank drain hose NOTE There is a white paint ma...

Page 361: ... CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Battery Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Battery box and battery box bracket Refer to GENERAL CHASSIS on page 4 1 1 Sub wire harness coupler 2 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Throttle body joint clamp screw 4 4 Throttle bodies 1 5 Throttle cable 2 Di...

Page 362: ...jector coupler 1 Disconnect 4 Cylinder 2 injector coupler 1 Disconnect 5 Cylinder 3 injector coupler 1 Disconnect 6 Cylinder 4 injector coupler 1 Disconnect 7 Sub wire harness 1 8 Negative pressure hose 1 9 Intake air pressure sensor 1 10 Fuel distributor 1 11 Injector 4 12 Throttle position sensor 1 13 Fuel pulsation damper 1 14 Throttle bodies 1 For installation reverse the removal proce dure ...

Page 363: ...NING EWA4S81015 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hoses c Connect the pressure gauge 1 and adapter 2 to the fuel hose fuel tank to pri mary injector fuel rail d Start the engine e Measure the fuel pressure Faulty Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR N...

Page 364: ...voltage is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws Positive tester probe Yellow 1 Negative tester probe Black Blue 2 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Output voltage at idle Adjusted by tachometer ...

Page 365: ...THROTTLE BODIES 7 8 ...

Page 366: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM ...

Page 367: ...AIR INDUCTION SYSTEM 7 10 1 Air cut off valve 2 Reed valve 3 To air filter case A To cylinder 1 and 2 B To cylinder 3 and 4 ...

Page 368: ...er to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Battery Refer to GENERAL CHASSIS on page 4 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Battery box and battery box bracket Refer to GENERAL CHASSIS on page 4 1 1 Air cut off valve hose 1 1 Disconnect 2 Air cut off valve hose 2 1 Disconnect 3 Air cut off valve hose 3 1 Disconnect 4 Air cut off valve 1 5 Reed valve...

Page 369: ...and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipes Cracks damage Replace 2 Check Reed valve 1 Reed ...

Page 370: ...AIR INDUCTION SYSTEM 7 13 2 Install Reed valve cover ...

Page 371: ...ROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 FAIL SAFE ACTIONS SUBSTITUTE CHARACTERISTICS OPERATION CONTROL 8 34 TROUBLESHOOTING METHOD 8 36 DIAGNOSTIC MODE 8 37 TROUBLESHOOTING DETAILS 8 43 FUEL PUMP SYSTEM 8 57 CIRCUIT DIAGRAM 8 57 TROUBLESHOOTING 8 59 IMMOBILIZER SYSTEM 8 61 CI...

Page 372: ...EN THE MAIN SWITCH IS SET TO ON 8 86 C 2 ABS WARNING LIGHT AND ALL OTHER INDICATORS DO NOT COME ON 8 86 C 3 ABS WARNING LIGHT FLASHES 8 87 C 4 ABS WARNING LIGHT FLASHES EVERY 0 5 SECOND 8 87 C 5 DIAGNOSIS BY THE MALFUNCTION CODE 8 87 D 6 4 DELETING THE MALFUNCTION CODE 8 101 D 6 6 DELETE FUNCTION TEST 8 103 D 6 FINAL CHECK 8 104 ELECTRICAL COMPONENTS 8 105 CHECKING THE SWITCHES 8 109 CHECKING THE ...

Page 373: ...26 CHECKING THE RADIATOR FAN MOTOR 8 127 CHECKING THE COOLANT TEMPERATURE SENSOR 8 127 CHECKING THE THROTTLE POSITION SENSOR 8 128 CHECKING THE FUEL PUMP 8 128 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 129 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 129 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 130 ...

Page 374: ... B B 10 G Y L W R W R B B Br G Y W L R W R B B Br R R W L W 9 66 R L G L G R W R W 57 B Br L 52 Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 51 Y L B L L W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 72 B Y B Y 12 B B L G B 59 60 61 62 63 64 58 B R B R 11 R Y R Y 54 Ch B 73 R Y Y L B Dg B...

Page 375: ... circuit cut off relay 12 Sidestand switch 13 Neutral switch 18 Lean angle sensor 19 Crankshaft position sensor 22 ECU engine control unit 29 Cylinder 1 4 ignition coil 30 Cylinder 2 3 ignition coil 31 Spark plugs 45 Engine stop switch 52 Ignition fuse 59 Clutch switch ...

Page 376: ...114 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 11 Re gap or replace the spark plugs 4 Check the spark plug caps Refer to CHECKING THE SPARK PLUG CAPS on page 8 121 Replace the spark plug caps 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 121 Replace the ignition coils 6 Check the crank...

Page 377: ...9 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the clutch switch 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 117 Replace the starting circuit cut off relay 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 123 Replace the lean angle sensor 14 Check the entire igniti...

Page 378: ... 55 B B 7 B B 10 G Y L W R W R B B Br G Y W L R W R B B Br R R W L W 9 66 R L G L G R W R W 57 B Br L 52 Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 51 Y L B L L W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 72 B Y B Y 12 B B L G B 59 60 61 62 63 64 58 B R B R 11 R Y R Y 54 Ch B 73 R Y Y...

Page 379: ...STEM 8 6 1 Main switch 7 Main fuse 8 Starter relay 9 Starter motor 10 Battery 11 Starting circuit cut off relay 12 Sidestand switch 13 Neutral switch 45 Engine stop switch 46 Start switch 52 Ignition fuse 59 Clutch switch ...

Page 380: ... prevents the starter motor from operating when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch a WHEN THE TRANSMISSION IS IN NEU TRAL b WHEN T...

Page 381: ...n page 8 114 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 38 Repair or replace the starter motor 4 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 117 Replace the starting circuit cut off relay 5 Check the starter relay Refer to CHECKING THE RELAYS on page 8 117 Replace the starte...

Page 382: ... on page 8 109 Replace the sidestand switch 10 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the clutch switch 11 Check the start switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the right handlebar switch 12 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the starting system s wiring The starting s...

Page 383: ...ELECTRIC STARTING SYSTEM 8 10 ...

Page 384: ...200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM P B B 7 B B 10 R R W L W 9 R 8 5 R L W R R W R R 2 W W W W W W 4 R W W W W W W R Br L R G BB Br L Br R B R W 3 R Br L Y L G L R W R B W W W B Y L Y L Lg R W Br R Br R ON OFF 1 G L R G ...

Page 385: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 7 Main fuse 10 Battery ...

Page 386: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 114 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 124 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE REC TIFIER REGULATOR on page 8 124 Replace the rectifier regulator 5 Check the entire charging sys tem s wiring Refer to CI...

Page 387: ...CHARGING SYSTEM 8 14 ...

Page 388: ... B B 10 G Y L W R W R B B Br G Y W L R W R B B Br R R W L W 9 66 R L G L G R W R W 57 B Br L 52 Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 51 Y L B L L W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 72 B Y B Y 12 B B L G B 59 60 61 62 63 64 58 B R B R 11 R Y R Y 54 Ch B 73 R Y Y L B Dg B...

Page 389: ...Battery 22 ECU engine control unit 38 High beam indicator light 51 Headlight fuse 53 Tail fuse 56 License plate light 57 Tail brake light 60 Pass switch 61 Dimmer switch 66 Headlight relay 67 Auxiliary light 68 Headlight high beam 69 Headlight low beam ...

Page 390: ...s Main headlight and tail Refer to CHECKING THE FUSES on page 8 113 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 114 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the main switch 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 109 The dimmer s...

Page 391: ...LIGHTING SYSTEM 8 18 NG OK 8 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the lighting system s wiring This circuit is OK ...

Page 392: ...L B HI LO W L W L Y B Br Br OFF ON 8 L N R 63 Y L B L L W Br L 61 Br W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 84 B Y B Y 12 B B L G B 71 72 73 74 75 76 70 B R B R 11 R Y R Y 66 Ch B 85 R 28 Br R W2 Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L G G B B L...

Page 393: ...function meter 46 Coolant temperature warning light 48 Left turn signal indicator light 49 Right turn signal indicator light 50 Meter light 52 Oil level switch 55 Front brake light switch 62 Signal fuse 64 Ignition fuse 65 Tail fuse 66 Turn signal relay 67 Rear brake light switch 69 Tail brake light 74 Hazard switch 75 Turn signal switch 76 Horn switch 77 Horn 82 Front left turn signal light 83 Fr...

Page 394: ...o CHECKING THE FUSES on page 8 113 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 114 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the main switch 4 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the si...

Page 395: ...cket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the rear brake light switch 4 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the signal ing system s wiring This circu...

Page 396: ...d 5 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the neutral indicator light bulb and socket Refer to CHECKING THE LEDS on page 8 113 Replace the neutral indicator light bulb socket or both 2 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the neutr...

Page 397: ...n page 8 113 Replace the oil level warning light bulb socket or both 2 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the oil level switch 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the fuel level warning light bulb and socket Refer to CHECKI...

Page 398: ...tween ECU coupler and meter assembly yellow blue yellow blue 3 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 126 Replace the speed sensor 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8...

Page 399: ...SIGNALING SYSTEM 8 26 ...

Page 400: ...B B 10 G Y L W R W R B B Br G Y W L R W R B B Br R R W L W 9 66 R L G L G R W R W 57 B Br L 52 Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 51 Y L B L L W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 72 B Y B Y 12 B B L G B 59 60 61 62 63 64 58 B R B R 11 R Y R Y 54 Ch B 73 R Y Y L B Dg B ...

Page 401: ...8 28 1 Main switch 7 Main fuse 10 Battery 21 Coolant temperature sensor 22 ECU engine control unit 37 Multi function meter 47 Radiator fan motor fuse 48 Radiator fan motor relay 49 Radiator fan motor 52 Ignition fuse ...

Page 402: ... BATTERY on page 8 114 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADI ATOR FAN MOTOR on page 8 127 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 117 Rep...

Page 403: ...COOLING SYSTEM 8 30 NG OK 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the cooling system s wiring This circuit is OK ...

Page 404: ...64 Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 63 Y L B L L W Br L 61 Br W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 84 B Y B Y 12 B B L G B 71 72 73 74 75 76 70 B R B R 11 R Y R Y 66 Ch B 85 R 28 Br R W2 Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L G G ...

Page 405: ...sensor 17 O2 sensor 18 Lean angle sensor 19 Crankshaft position sensor 20 Intake air temperature sensor 21 Coolant temperature sensor 22 ECU engine control unit 23 Injector 1 24 Injector 2 25 Injector 3 26 Injector 4 30 ABS ECU 32 Rear wheel sensor 35 Cylinder 1 4 ignition coil 36 Cylinder 2 3 ignition coil 37 Spark plug 42 Neutral indicator light 44 Multi function meter 45 Engine trouble warning ...

Page 406: ... displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for 1 4 seconds after the main switch has been tu...

Page 407: ...he crankshaft position sen sor Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit detected Able Able 14 Intake air pressure sensor pipe system Intake air pressure sensor pipe system malfunction clogged or detached hose Able Able 15 Throttle position sen sor open or short circuit Throttle position sensor open or short circuit detected ...

Page 408: ...alue Able Able 46 Vehicle system power supply Monitoring voltage Power supply to the fuel injection system is not normal Able Able 50 ECU internal malfunc tion memory check error Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Unable Unable Start unable warning Engine trouble warning light flashes when the start switch is turned ON...

Page 409: ...Sensor operation table Diagnostic code No 62 The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table If malfunction the sensors or actuators repair or replace it If not malfunction the sensors and actua tors check and repair the engine inner parts Er 3 EC...

Page 410: ...electing dIAG simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 6 Set the engine stop switch to OFF 7 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the SELECT and RESET buttons NOTE The diagnostic code number appears on the clock LCD 01 70 To decrease the selected diagnostic code nu...

Page 411: ...mode Diagnostic code table A FZ6 N FZ6 NA FZ6 S FZ6 SA B FZ6 NHG W FZ6 NAHG FZ6 SHG W FZ6 SAHG Fault code No Symptom Probable cause of malfunction Diagnostic code No 12 No normal signals are received from the crank shaft position sensor Open or short circuit in wire harness Defective crankshaft position sensor Malfunction in pickup rotor Malfunction in ECU Improperly installed sensor 13 Intake air...

Page 412: ...circuit detected Open or short circuit in wire harness Defective intake temperature sensor Malfunction in ECU Improperly installed intake air temperature sensor 05 24 No normal signal is received from the O2 sen sor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed O2 sensor 30 Latch up detected No normal signal is received from the lean angle sensor...

Page 413: ...memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Malfunction in ECU The program and data are not properly written on or read from the internal memory Er 1 No signals are received from the ECU Open or short circuit in communication line Malfunction in meter unit Malfunction in ECU Er 2 No signals are received from the ECU within the specified d...

Page 414: ...at the number changes integrating when the rear wheels are rotated 08 Lean angle sensor Remove the lean angle sensor and incline it more than 65 degrees Upright 0 4 1 4 Overturned 3 8 4 2 09 Fuel system voltage battery voltage Approximately 12 0 Compare with the actually measured battery voltage If the battery voltage is lower perform recharging 20 Sidestand switch Turn ON OFF the Sidestand switch...

Page 415: ... ON the engine stop switch 63 Malfunction code reinstate No malfunction code 00 Malfunction code exists Fault code 24 If more than one code number is detected the dis play changes every two seconds to show all the detected code numbers are shown the display repeats To reinstate set the engine stop switch to 70 Control number 00 255 Diag nostic code No Item Actuation Checking method 30 Ignition coi...

Page 416: ...jector 2 3 five times 48 AI system solenoid Actuates the AI system sole noid for five times every sec ond Illuminates the engine trou ble warning light Check the operating sound of the AI system solenoid five times 50 Fuel injection system relay Actuates the fuel injection system relay for five times every second Illuminates the engine trou ble warning light The engine trouble warning light is OFF...

Page 417: ...pler Gray Gray Black Blue Black Blue 4 Defective crankshaft position sensor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 122 Fault code No 13 Symptom Intake air pressure sensor open or short circuit detected Diagnostic code No 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Connected state of...

Page 418: ...Repair or replace the sensor hose Starting the engine and operating it at idle 2 Intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connected state of connector Intake air pressure sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking co...

Page 419: ... Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open circuit output voltage check Check for open circuit and replace the throttle position sen sor Black Blue Yellow Open circuit item Output voltage Ground wire open circuit 5 V Output wire open circuit 0 V Power supply wire open circuit 0 V 5 Defective throttle position sensor Execute the diagnostic monitor ing mode Code No 01 Replace...

Page 420: ...monitor ing mode Code No 20 Replace if defective Refer to CHECKING THE SWITCHES on page 8 109 Fault code No 21 Symptom Coolant temperature sensor open or short circuit detected Diagnostic code No 06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Installed condition of coolant tempera ture sensor Check the installed area for loos...

Page 421: ... Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERATURE SENSOR on page 8 130 Fault code No 24 Symptom No normal signal is received from the O2 sensor Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Installed condition of O2 sensor Check the installed area for looseness or pinching Starting the engine warm ing it up until the c...

Page 422: ...ted in the primary wire of the ignition coil 1 4 Diagnostic code No 30 Ignition coil 1 4 Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Connected state of connector Ignition coil primary side coupler Orange Black Main wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a m...

Page 423: ...e ignition coil 2 3 Execute the diagnostic monitor ing mode Code No 31 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNITION COILS on page 8 121 Fault code No 41 Symptom Lean angle sensor open or short circuit detected Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstate ment method 1 C...

Page 424: ...rcuit in speed sensor lead with out ABS Open or short circuit in wire harness and or ABS wire harness with ABS Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler with out ABS Blue Blue White Yellow White Yellow Black Blue Black Blue Between rear wheel sensor coupler and ABS ECU coupler with ABS Yellow White Yellow White Black Black Between ABS ECU c...

Page 425: ...ction system relay Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Connected state of connector Fuel injection system relay coupler Main wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Starting the engine and operating it ...

Page 426: ...0 to check the faulty cylinder number If mul tiple cylinders are defective the numbers of the faulty cyl inders are displayed alter nately at 2 second intervals 2 Execute the CO adjustment mode and set the exhaust gas volume of the faulty cylinder to 0 If 0 is displayed set the numerical value other than 0 When the malfunction is recovered reset 0 Refer to ADJUSTING THE EXHAUST GAS VOLUME FZ6 N FZ...

Page 427: ...battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 114 3 The malfunction of the rectifier regula tor Replace if defective Refer to CHARGING SYS TEM on page 8 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch Red Red Between main switch and Fuse ignition Brown Blue Brown Blue Between Fuse ignition and ECU Red ...

Page 428: ...lack White 3 Malfunction in meter unit Replace the meter unit 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the speci fied duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Connected state of connector Main wire harness ECU coupler Main wire harness meter coupler Sub wi...

Page 429: ...Black White Black White 3 Malfunction in meter unit Replace the meter unit 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstate ment method 1 Connected state of connector Main wire harness ECU coupler Main wire harness meter coupler Sub wire...

Page 430: ...L B HI LO W L W L Y B Br Br OFF ON 8 L N R 63 Y L B L L W Br L 61 Br W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 84 B Y B Y 12 B B L G B 71 72 73 74 75 76 70 B R B R 11 R Y R Y 66 Ch B 85 R 28 Br R W2 Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L G G B B L...

Page 431: ...FUEL PUMP SYSTEM 8 58 1 Main switch 5 Fuel injection system fuse 7 Main fuse 10 Battery 11 Starting circuit cut off relay 14 Fuel pump 22 ECU engine control unit 56 Engine stop switch 64 Ignition fuse ...

Page 432: ...e battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the right handlebar switch 5 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 117 Replace the starting circuit cut off relay 6 Check the fue...

Page 433: ...FUEL PUMP SYSTEM 8 60 ...

Page 434: ...Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 63 Y L B L L W Br L 61 Br W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 84 B Y B Y 12 B B L G B 71 72 73 74 75 76 70 B R B R 11 R Y R Y 66 Ch B 85 R 28 Br R W2 Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L G G B B...

Page 435: ...IMMOBILIZER SYSTEM 8 62 1 Main switch 4 Backup fuse 6 Immobilizer unit 7 Main fuse 10 Battery 22 ECU engine control unit 39 Immobilizer indicator light 44 Multi function meter 64 Ignition fuse ...

Page 436: ...ey is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recommended to use either standard key for driving and to keep the code re regis tering key in a safe plac...

Page 437: ...registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Parts to be replaced Key registration requirement Main switch immobilizer unit Standard key ECU Acces sory lock and key Main switch Immobi lizer unit Standard key is lost New standard key All keys have been lost including code re registering key Cod...

Page 438: ... key turn the main switch to ON then OFF and then remove the key within 5 seconds 3 Insert the first standard key to be registered into the main switch then turn the key to ON within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer sy...

Page 439: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 440: ...e battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 109 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the immobi lizer system wiring Check the condition of the each immobilizer system circuits Refer to SELF DIAGNOSIS FAULT CODE IN...

Page 441: ...n 4 ECU malfunction 1 Check the wire harness and con nector 2 Replace the main switch immobi lizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU failure The ECU or immob...

Page 442: ...IMMOBILIZER SYSTEM 8 69 a Light on b Light off ...

Page 443: ...IMMOBILIZER SYSTEM 8 70 ...

Page 444: ...Br L 64 Y L B HI LO W L W L Y B Br Br OFF ON 8 L N R 63 Y L B L L W Br L 61 Br W Br L Br L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br 13 B B Br Y Br G Y 5 B R R L W L W R B B 84 B Y B Y 12 B B L G B 71 72 73 74 75 76 70 B R B R 11 R Y R Y 66 Ch B 85 R 28 Br R W2 Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L...

Page 445: ...2 ECU engine control unit 28 ABS motor fuse 29 ABS test coupler 30 ABS ECU 31 Front wheel sensor 32 Rear wheel sensor 33 ABS motor relay 34 Hydraulic unit 44 Multi function meter 51 ABS warning light 55 Front brake light switch 56 Engine stop switch 57 Start switch 61 ABS fuse 62 Signal fuse 64 Ignition fuse 67 Rear brake light switch 69 Tail brake light ...

Page 446: ...ABS ANTI LOCK BRAKE SYSTEM 8 73 EAS27740 ABS COMPONENTS CHART ...

Page 447: ...ANTI LOCK BRAKE SYSTEM 8 74 1 ABS warning light 2 ABS test coupler 3 Front sensor rotor 4 Front wheel sensor 5 Hydraulic unit 6 Rear sensor rotor 7 Rear wheel sensor 8 ABS ECU 9 ABS motor relay 10 Fuse box ...

Page 448: ...ABS ANTI LOCK BRAKE SYSTEM 8 75 EAS27750 ABS CONNECTOR LOCATION CHART ...

Page 449: ...2 ABS ECU coupler 3 Hydraulic unit coupler 4 Rear wheel sensor coupler 5 Front wheel sensor coupler 6 ABS test coupler 7 Multi function coupler FZ6 SA 8 Multi function coupler FZ6 NA 9 Multi function coupler FZ6 SAHG 10 Multi function coupler FZ6 NAHG ...

Page 450: ...IS on page 4 1 Left front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Right front cowling inner panel with cowling Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 ABS motor relay 1 2 ABS motor relay coupler 1 Disconnect 3 Band 1 4 ABS ECU 1 5 ABS ECU coupler 1 Disconnect For installation reverse the removal proce dure ...

Page 451: ...y coupler NOTE Do not pull the ABS motor relay leads to remove the ABS motor relay coupler Always press on the lock to disconnect the ABS motor relay coupler from the ABS motor relay EAS27790 ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details Read carefully this service manual before repairing various malfunctions understand and perform the service Electron...

Page 452: ... any malfunctions are not detected The multifunction display indicates all the malfunction codes recorded in the ABS ECU You can check it by using a pocket tester Note everything if more than two items of malfunction codes are recorded Deleting the malfunction code When the malfunction service is finished check the normal operation of vehicle then delete the mal function code By deleting the malfu...

Page 453: ...g to the ECU s operation C Supposing the malfunction cause and position Find the malfunction cause by reasoning the place and situation where it occurred D ABS system services Execute the final check after disassembly and assembly WARNING EWA14040 Perform the troubleshooting A B C D in order Be sure to follow the order since it results in the wrong diagnosis if the order is differently taken or om...

Page 454: ...ABS ANTI LOCK BRAKE SYSTEM 8 81 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...

Page 455: ...1 2 No C 2 EAS4S81019 B 2 THE ABS WARNING LIGHT REMAINS ON NOTE Check following the steps in sequence 1 Battery voltage low Charge inspect or replace the battery 2 Malfunction codes displayed Check the malfunction codes using the ABS test coupler adaptor Perform troubleshooting corresponding to the malfunction codes B 5 3 Wire harness ABS ECU and meter coupler are disconnected Connect the coupler ...

Page 456: ... T C terminal is grounded Malfunction code which the ECU generated in the malfunction diagnostic mode rise and fall of voltage is output at the T F terminal ABS warning light terminal is used when checking the ABS warning light circuit To ground the T C terminal connect the test coupler adapter A with the test coupler Before con necting check if the battery is sufficiently charged EAS27860 B 4 MAL...

Page 457: ...nd the malfunction code of a past malfunction has not been stored in the memory of the ECU ABS If a malfunction code is displayed on the multi function display the ABS warning light flashes Make sure that the customer understands the pos sible conditions when the ABS warning light comes on A FZ6 N FZ6 NA FZ6 S FZ6 SA B FZ6 NHG W FZ6 NAHG FZ6 SHG W FZ6 SAHG ...

Page 458: ... T C terminal sky blue Figure A Set the range of pocket tester to DC 20 V Connect the negative terminal of tester to the T F ter minal light green and positive terminal to the positive terminal of battery Figure B Read the tester indication Figure C NOTE Read the code through this means so that the currently malfunction code is not indicated on the meter 1 ABS test coupler 2 Lock plate 3 Protectiv...

Page 459: ...e wire harness short circuit Repair or replace the failure part 2 Meter circuit malfunction 1 Remove only the ABS ECU from the connector 2 If the ABS warning light comes on when the main switch is turned ON the meter is nor mal It means the ABS ECU malfunction Replace the ECU EAS4S81023 C 2 ABS WARNING LIGHT AND ALL OTHER INDICATORS DO NOT COME ON NOTE Check following the steps in sequence 1 Check...

Page 460: ...arning light flashes every 0 5 second the malfunction code of a past malfunction has not been stored in the memory of the ABS ECU If a malfunction code is displayed on the multifunc tion display the ABS warning light flashes Make sure that the customer understands the possible conditions when the ABS warning light comes on 1 Voltage drop For the ABS to operate correctly the voltage should be alway...

Page 461: ...Malfunction codes 13 front wheel and 14 rear wheel 15 front 16 rear No continuity in the front or rear wheel sensor circuits Continuity of sensor circuits ABS wire harness circuit Connection of sensor coupler Malfunction codes 15 front wheel sensor and 16 rear wheel sen sor 18 Missing serration of sensor rotor Sensor rotor Malfunction code 18 21 Disconnection and short circuit of hydraulic unit so...

Page 462: ... code 28 31 Disconnection is detected between the battery and ABS ECU system ABS motor fuse ABS wire harness circuit between the battery and ABS ECU ABS ECU coupler Malfunction code 31 32 Circuit malfunction of ABS ECU is detected Upstream side of the solenoid relay Wire harness circuit Replace the ABS ECU Malfunction code 32 33 Defective operation of the ABS motor is detected ABS motor stops and ...

Page 463: ...e when the bat tery voltage is normal Brake dragging Hydraulic unit operation test Rear wheel brake line Malfunction code 42 51 Front wheel will not recover from the locking tendency even though the signal is continuously transmit ted from the ABS ECU to release the hydraulic state when the bat tery voltage is low Brake dragging Hydraulic unit operation test 2 Front wheel brake line Battery voltag...

Page 464: ...el sensor rotor is defective D 3 3 Front wheel sensor circuit is short circuited Front wheel sensor or lead is short circuited D 3 Wire harness ABS sensor circuit is short circuited Refer to CIRCUIT DIAGRAM on page 8 71 4 Front wheel sensor output drops Sensor signal output may drop due to failure on bearings wheel axle wheel or sensor hous ing of front wheel Check these components when installed ...

Page 465: ...llation of the front or rear wheel sensor rotor Check that the sensor rotor is correctly pressed in the front wheel D 3 4 Check that the sensor rotor is correctly install to the rear wheel D 3 4 Check the rotor and inside the rotor housing for foreign materials D 3 4 2 Teeth surfaces of the sensor rotors are defective Check for flaws on the teeth surfaces of the front or rear wheel sensor rotors A...

Page 466: ...ondition does not become normal even if the wheel sensor is replaced Malfunction code 18 Missing serration of sensor rotor 1 Missing serration of the rear sensor rotor Replace the rear sensor rotor Malfunction code 21 Disconnection and short circuit of hydraulic unit solenoid 1 Hydraulic unit solenoid coupler Check if the hydraulic unit solenoid coupler terminal is disconnected Refer to ABS CONNEC...

Page 467: ...t Continuity between A B NOTE If you do not start the engine with the starter switch but repeat push starting the engine excessively this code may be input Malfunction code 24 Step light failure Brake system circuit has failure 1 Disconnection of the wire harness for the brake circuit Check the conductivity of the wire harness and repair or replace the failure part 2 Disconnection of the stop lamp...

Page 468: ...and ABS ECU Connect the coupler securely until a click sound is heard 3 Disconnection of the wire harness between the battery and ABS ECU Check the conductivity of the wire harness and repair or replace the failure part Continuity between A B 4 When the items 1 to 3 are normal replace the ABS ECU Malfunction code 32 Circuit malfunction of ABS ECU is detected Upstream side of the sole noid relay NO...

Page 469: ...awing terminal of the wire harness ABS and the wire harness ABS end terminal A shown in the illustration of the ABS motor fuse terminal beside the battery Refer to CIRCUIT DIAGRAM on page 8 71 Check for continuity between the positive battery terminal and the battery end of the ABS motor fuse terminal terminal B shown in the above illustration Remove the ABS ECU and the ABS motor relay from the wi...

Page 470: ...etween the ABS ECU and HU solenoid Check the conductivity of the wire harness and repair or replace the failure part Continuity between A B A C 3 Battery terminal is disconnected 4 When the items 1 to 3 are normal replace the ABS ECU Malfunction code 41 Front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the ABS ECU to release the hydrauli...

Page 471: ...sating action in the brake lever and brake pedal will be performed in the reverse order when the final check in D 6 is performed 5 Hydraulic unit solenoid coupler terminal Check if the front and rear hydraulic unit solenoid coupler terminals hydraulic unit and wire har ness ABS are reversed 6 Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5 replace the hydraulic uni...

Page 472: ...nections are reversed Rear brake hose 1 inlet from the rear brake master cylinder Rear brake hose 2 outlet to the rear brake caliper NOTE If the rear brake hose inlet and outlet connections are reversed on the hydraulic unit the brake pedal is pressed down to full stroke without responding and will be pushed back slowly without pulsating when the final check is performed If the front and rear brak...

Page 473: ...fer to Malfunction code 41 6 Hydraulic unit Refer to Malfunction code 41 7 Battery voltage Measure the battery voltage Malfunction code 52 Rear wheel will not recover from the locking tendency even though the signal is continuously transmitted from the ABS ECU to release the hydraulic state when the battery voltage is low Check the following 1 Rotation of the rear wheel Refer to Malfunction code 4...

Page 474: ... harness because the cause is the wire harness fail ure Continuity between A C B C 2 Wheel sensor malfunction Check the conductivity between the wheel sensor leads white and GND If short circuit is detected replace the wheel sensor because the cause is the wheel sensor fail ure 3 Battery terminal is disconnected 4 When the items 1 to 3 are normal replace the ABS ECU EAS4S81027 D 6 4 DELETING THE M...

Page 475: ...t be cleared the disconnection of the starter switch monitor leads could be a cause 5 Turn the main switch off 6 Turn the main switch on again Check that the ABS warning light goes on for 2 seconds then goes out for 3 seconds and starts flashing 7 Turn the main switch off 8 Disconnect the test coupler adapter from the test coupler and install the protective cap with the test coupler adapter Deleti...

Page 476: ... or replace the battery 6 Check ECU to start switch lead continuity Connect the pocket tester Ω 1 to the ECU coupler and start switch coupler Tester positive probe White Blue 1 start switch Tester negative probe Green White 2 ECU No continuity Replace or repair the wire harness 7 Check ECU voltage Connect the pocket tester DC 20 V to the ECU coupler Tester positive probe Green Blue 2 Tester negati...

Page 477: ...HECKING THE BRAKE FLUID LEVEL on page 3 24 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL on page 4 14 and INSTALLING THE REAR WHEEL on page 4 22 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TEST on page 4 56 4 Delete the malfunction codes Refer to D 6 4 DELETING THE MALFUNCTION CODE on page 8 101 ...

Page 478: ...ELECTRICAL COMPONENTS 8 105 EAS27970 ELECTRICAL COMPONENTS ...

Page 479: ... 2 Front brake light switch 3 Starter relay 4 Battery 5 ABS motor relay FZ6 NA FZ6 NAHG FZ6 SA FZ6 SAHG 6 Fuse box 7 Rear brake light switch 8 Neutral switch 9 Sidestand switch 10 Oil level switch 11 Radiator fan motor 12 Horn 13 Ignition coil ...

Page 480: ...ELECTRICAL COMPONENTS 8 107 ...

Page 481: ...sor 4 Fuel pump 5 Intake air pressure sensor 6 ECU engine control unit 7 ABS ECU FZ6 NA FZ6 NAHG FZ6 SA FZ6 SAHG 8 Lean angle sensor 9 Starting circuit cut off relay 10 Rear wheel sensor 11 Dimmer relay 12 Radiator fan motor relay 13 Turn signal relay 14 Hydraulic unit 15 Rectifier regulator 16 Front wheel sensor ...

Page 482: ...ELECTRICAL COMPONENTS 8 109 EAS27980 CHECKING THE SWITCHES ...

Page 483: ...Z6 SAHG 6 Pass switch FZ6 N FZ6 NHG W FZ6 NAHG 7 Turn signal switch 8 Hazard switch 9 Clutch switch 10 Sidestand switch 11 Engine stop switch 12 Front brake light switch 13 Start switch 14 Oil level switch 15 Neutral switch 16 Rear brake light switch 17 Fuse 18 Left handlebar switch lead coupler FZ6 S FZ6 SA FZ6 SHG W FZ6 SAHG 19 Left handlebar switch lead coupler FZ6 N FZ6 NA FZ6 NHG W FZ6 NAHG ...

Page 484: ...k and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illus tration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE indicates a continuity of electricity between switch terminals i e a cl...

Page 485: ...he condition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid t...

Page 486: ... Check LED for proper operation Improper operation Replace a Disconnect the meter assembly coupler meter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown WARNING EWA4S81013 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produc...

Page 487: ... DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with...

Page 488: ...ly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of spark...

Page 489: ...tain the standard charging cur rent g Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charger and AMP meter to the battery and start charging c Make sure that the ...

Page 490: ...he relay operation Out of specification Replace Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity No continuity between 3 to 4 1 Positive battery termin...

Page 491: ...ing is Replace the ABS motor relay CAUTION ECA4S81022 Be sure to connect the pocket tester posi tive and negative probes correctly If the pocket tester probes are connected in reverse the diode of the ABS motor relay will be broken When connecting the ABS motor relay and battery terminals be careful not to short circuit the positive and negative battery terminals 1 Positive battery terminal 2 Nega...

Page 492: ...he solenoid valve rear terminal as shown 3 Check ABS motor continuity No continuity Replace the hydraulic unit a Connect the pocket tester Ω 1 to the ABS motor coupler terminal as shown Solenoid valve resistance 2 96 3 20 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe terminal 1 Negative tester probe terminal 2 Solenoid valve resistance 2 96 3 20 Ω a...

Page 493: ...pecification Replace a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown b Turn the main switch to ON c Measure the turn signal hazard relay out put voltage EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace Turn signal hazard relay input voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive te...

Page 494: ...ignition coils 1 Check Primary coil resistance Out of specification Replace Continuity Positive tester probe Sky blue 1 Negative tester probe Black Yellow 2 No continuity Positive tester probe Black Yellow 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Black Red 3 No continuity Positive tester probe Black Red 3 Negative tester probe Sky blue 1 ...

Page 495: ...ic spark tester 1 as shown c Set the main switch to ON d Measure the ignition spark gap a e Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Re...

Page 496: ...e lean angle sensor to 65 d Measure the lean angle sensor out put volt age EAS4S81036 CHECKING THE WHEEL SENSOR 1 Check Front wheel sensor output voltage Out of specification Replace a Connect the pocket tester DC20 V to the front wheel sensor coupler as shown Crankshaft position sensor 248 372 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Gray 1 Ne...

Page 497: ...the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation 2 Check Stator coil resistance Out of specification Replace the stator coil EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the stator...

Page 498: ...horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the specified horn sound is obtained EAS28190 CHECKING THE ENGINE OIL LEVEL GAUGE 1 Drain Engine oil 2 Remove Engine oil level gauge from the oil pan 3 Check Engine oil level gauge resistance Charging voltage above ...

Page 499: ...onnect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Engine oil level gauge Maximum level position resis tance 114 126 Ω at 20 C 68 F Minimum level position resis tance 484 536 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Maximum level position A Positive tester probe Connector white 1 Negative tester probe Body earth 2 Minimum level p...

Page 500: ...e sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor 1 as shown b Immerse the coolant temperature sensor in a container filled with coolant 2 NOTE Make sure the cool...

Page 501: ...ition sensor adjust its angle properly Refer to ADJUST ING THE THROTTLE POSITION SENSOR on page 7 6 EAS28350 CHECKING THE FUEL PUMP WARNING EWA13850 Gasoline is extremely flammable and under certain circumstances there can be a dan ger of an explosion or fire Be extremely careful and note the following points Stop the engine before refueling Do not smoke and keep away from open flames sparks or an...

Page 502: ...ake air pressure sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the intake air pressure sensor coupler wire harness side as shown b Set the main switch to ON Fuel pump resistance 0 2 3 0 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red blue 1 Negative tester probe Black 2 Air induction system solenoid resi...

Page 503: ...temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the intake air temperature sensor terminal as shown b Measure the intake air temperature sensor resistance Intake air pressure sensor resistance 2 2 2 7 kΩ at 20 C 68 F Pocket tester 90890 0...

Page 504: ...ELECTRICAL COMPONENTS 8 131 ...

Page 505: ...EDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 ...

Page 506: ...2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty sp...

Page 507: ...ft forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmis...

Page 508: ...ake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper ro...

Page 509: ... signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal rela...

Page 510: ... sec onds Voltage drop Less than 10 V Battery Rectifier regulator AC magneto Strong radio waves or static electricity Test coupler adapter is connected to test coupler ABS Warning light continues to come on Defective connection of the wheel sensor front or rear circuit Wheel sensor lead front or rear coupler has come off Wheel sensor lead front or rear or the IC internal circuit is disconnected Se...

Page 511: ...TROUBLESHOOTING 9 6 ...

Page 512: ... stop switch 46 Start switch 47 Radiator fan motor fuse 48 Radiator fan motor relay 49 Radiator fan motor 50 Signal fuse 51 Headlight fuse 52 Ignition fuse 53 Tail fuse 54 Turn signal relay 55 Rear brake light switch 56 License plate light 57 Tail brake light 58 Left handlebar switch 59 Clutch switch 60 Pass switch 61 Dimmer switch 62 Hazard switch 63 Turn signal switch 64 Horn switch 65 Horn 66 H...

Page 513: ... brake light switch 51 Engine stop switch 52 Start switch 53 Radiator fan motor fuse 54 Radiator fan motor relay 55 Radiator fan motor 56 ABS fuse 57 Signal fuse 58 Headlight fuse 59 Ignition fuse 60 Tail fuse 61 Turn signal relay 62 Rear brake light switch 63 License plate light 64 Tail brake light 65 Left handlebar switch 66 Clutch switch 67 Pass switch 68 Dimmer switch 69 Hazard switch 70 Turn ...

Page 514: ...48 Front brake light switch 49 Engine stop switch 50 Start switch 51 Radiator fan motor fuse 52 Radiator fan motor relay 53 Radiator fan motor 54 Signal fuse 55 Headlight fuse 56 Ignition fuse 57 Tail fuse 58 Turn signal relay 59 Rear brake light switch 60 License plate light 61 Tail brake light 62 Left handlebar switch 63 Clutch switch 64 Pass switch 65 Dimmer switch 66 Hazard switch 67 Turn sign...

Page 515: ...l level switch 53 Anti theft alarm 54 Right handlebar switch 55 Front brake light switch 56 Engine stop switch 57 Start switch 58 Radiator fan motor fuse 59 Radiator fan motor relay 60 Radiator fan motor 61 ABS fuse 62 Signal fuse 63 Headlight fuse 64 Ignition fuse 65 Tail fuse 66 Turn signal relay 67 Rear brake light switch 68 License plate light 69 Tail brake light 70 Left handlebar switch 71 Cl...

Page 516: ...h 47 Radiator fan motor fuse 48 Radiator fan motor relay 49 Radiator fan motor 50 Signal fuse 51 Headlight fuse 52 Ignition fuse 53 Tail fuse 54 Turn signal relay 55 Rear brake light switch 56 License plate light 57 Tail brake light 58 Left handlebar switch 59 Clutch switch 60 Pass switch 61 Dimmer switch 62 Hazard switch 63 Turn signal switch 64 Horn switch 65 Horn 66 Headlight relay 67 Auxiliary...

Page 517: ...tch 51 Engine stop switch 52 Start switch 53 Radiator fan motor fuse 54 Radiator fan motor relay 55 Radiator fan motor 56 ABS fuse 57 Signal fuse 58 Headlight fuse 59 Ignition fuse 60 Tail fuse 61 Turn signal relay 62 Rear brake light switch 63 License plate light 64 Tail brake light 65 Left handlebar switch 66 Clutch switch 67 Pass switch 68 Dimmer switch 69 Hazard switch 70 Turn signal switch 71...

Page 518: ...ight switch 49 Engine stop switch 50 Start switch 51 Radiator fan motor fuse 52 Radiator fan motor relay 53 Radiator fan motor 54 Signal fuse 55 Headlight fuse 56 Ignition fuse 57 Tail fuse 58 Turn signal relay 59 Rear brake light switch 60 License plate light 61 Tail brake light 62 Left handlebar switch 63 Clutch switch 64 Pass switch 65 Dimmer switch 66 Hazard switch 67 Turn signal switch 68 Hor...

Page 519: ... Anti theft alarm 54 Right handlebar switch 55 Front brake light switch 56 Engine stop switch 57 Start switch 58 Radiator fan motor fuse 59 Radiator fan motor relay 60 Radiator fan motor 61 ABS fuser 62 Signal fuse 63 Headlight fuse 64 Ignition fuse 65 Tail fuse 66 Turn signal relay 67 Rear brake light switch 68 License plate light 69 Tail brake light 70 Left handlebar switch 71 Clutch switch 72 P...

Page 520: ......

Page 521: ......

Page 522: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 523: ...Br G Y R R L W L W R B B B Y B Y B B L G B B R B R R Y R Y Ch B R G Dg B Br W Br G Br G Br G Br W Br W Ch P Ch Dg Dg B E B B E B Ch Dg B G W R W B R L G B B L Y B Y Dg B W Br B R W Sb Sb R L R L R L W L R B L W R Lg B Y Sb B R L G R W L Y L W Br R W B R B L Y Sb Sb B B L W G W Lg Ch B Ch B B Dg B Dg B Dg Ch B R R R Br B Br B W W W W W W R W W W W W W R Br L R G Br L B B B B Br B L G Y R W Br R B R...

Page 524: ...FZ6 NA 2007 WIRING DIAGRAM FZ6 NA 2007 SCHEMA DE CABLAGE FZ6 NA 2007 SCHALTPLAN FZ6 NA 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 NA 2007 ...

Page 525: ... L Y L R B B Y Br R Y G Y B R Y R Y Dg P G Br W R Y Ch B R L R B B Y Br B B Br Y Br G Y R R L W L W R B B B Y B Y B B L G B 65 B R B R R Y R Y Ch B R G Dg B Br W Br G Br G Br G Br W Br W Ch P Ch Dg Dg B E B B E B Ch Dg B G W R W B R L G B B L Y B Y Dg B W Br B R W Sb Sb R L R L R L W L R B L W R Lg B Y Sb B R L G R W L Y L W Br R W B R B L Y Sb Sb B B L W G W Lg Ch B Ch B B Dg B Dg B Dg Ch B R R R...

Page 526: ...FZ6 NAHG 2007 WIRING DIAGRAM FZ6 NAHG 2007 SCHEMA DE CABLAGE FZ6 NAHG 2007 SCHALTPLAN FZ6 NAHG 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 NAHG 2007 ...

Page 527: ... B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br B B Br Y Br G Y B R R L W L W R B B B Y B Y B B L G B 63 B R B R R Y R Y Ch B R Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L G G B B L Y B Y Dg B W Br B R W Sb Sb R L R L L R R L W L R B L W R Lg B Y Sb B R L G R W L Y L W Br R W B R B L Y Sb Sb R W B B L W W G W G W G L Lg Lg Ch B Ch B B B B B L R Dg B Dg ...

Page 528: ...FZ6 SA 2007 WIRING DIAGRAM FZ6 SA 2007 SCHEMA DE CABLAGE FZ6 SA 2007 SCHALTPLAN FZ6 SA 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 SA 2007 ...

Page 529: ... L OFF ON ON Y Y B Dg Y L B Br W R Y Ch L Y G B B Y Br R Y G Y B R Y R Y Dg Y L B Br W R Y Ch B R B B Y Br B B Br Y Br G Y B R R L W L W R B B B Y B Y B B L G B B R B R R Y R Y Ch B R Y Y L B Dg B Br W Br G Br G Br G Br W Br W Ch Ch Dg Dg Ch Dg B G W R W B R L G G B B L Y B Y Dg B W Br B R W Sb Sb R L R L L R R L W L R B L W R Lg B Y Sb B R L G R W L Y L W Br R W B R B L Y Sb Sb R W B B L W W G W ...

Page 530: ...FZ6 SAHG 2007 WIRING DIAGRAM FZ6 SAHG 2007 SCHEMA DE CABLAGE FZ6 SAHG 2007 SCHALTPLAN FZ6 SAHG 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 SAHG 2007 ...

Page 531: ...FZ6 N 2007 WIRING DIAGRAM FZ6 N 2007 SCHEMA DE CABLAGE FZ6 N 2007 SCHALTPLAN FZ6 N 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 N 2007 ...

Page 532: ...FZ6 NA 2007 WIRING DIAGRAM FZ6 NA 2007 SCHEMA DE CABLAGE FZ6 NA 2007 SCHALTPLAN FZ6 NA 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 NA 2007 ...

Page 533: ...FZ6 NHG W 2007 WIRING DIAGRAM FZ6 NHG W 2007 SCHEMA DE CABLAGE FZ6 NHG W 2007 SCHALTPLAN FZ6 NHG W 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 NHG W 2007 ...

Page 534: ...FZ6 NAHG 2007 WIRING DIAGRAM FZ6 NAHG 2007 SCHEMA DE CABLAGE FZ6 NAHG 2007 SCHALTPLAN FZ6 NAHG 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 NAHG 2007 ...

Page 535: ...FZ6 S 2007 WIRING DIAGRAM FZ6 S 2007 SCHEMA DE CABLAGE FZ6 S 2007 SCHALTPLAN FZ6 S 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 S 2007 ...

Page 536: ...FZ6 SA 2007 WIRING DIAGRAM FZ6 SA 2007 SCHEMA DE CABLAGE FZ6 SA 2007 SCHALTPLAN FZ6 SA 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 SA 2007 ...

Page 537: ...FZ6 SHG W 2007 WIRING DIAGRAM FZ6 SHG W 2007 SCHEMA DE CABLAGE FZ6 SHG W 2007 SCHALTPLAN FZ6 SHG W 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 SHG W 2007 ...

Page 538: ...FZ6 SAHG 2007 WIRING DIAGRAM FZ6 SAHG 2007 SCHEMA DE CABLAGE FZ6 SAHG 2007 SCHALTPLAN FZ6 SAHG 2007 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ6 SAHG 2007 ...

Reviews:

No comments

Related manuals for 2007 FZ6-NA

Brand: KYMCO Pages: 58

Brand: CB Sabbiatrici Pages: 43

Brand: ACERBIS Pages: 72

Brand: GAS GAS Pages: 74

MD-052-2 Series

Brand: Acewell Pages: 2

Brand: KSR Moto Pages: 51

Brand: Cellularline Pages: 2

Brand: Suzuki Pages: 522

Brand: Honda Pages: 161

Krauser 630.2516

Brand: hepco & becker Pages: 6

Brand: Sachs Bikes Pages: 84

Brand: Twiins Pages: 40

Brand: tucanourbano Pages: 4

Brand: Memphis Shades Pages: 2

Brand: Memphis Shades Pages: 2

Brand: Memphis Shades Pages: 2

Brand: Wunderlich Pages: 2

Brand: Cagiva Pages: 230

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands