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Yamaha 2008 Fazer FZ1-N, Service Manual

Introducing the Yamaha 2008 Fazer FZ1-N Service Manual, a comprehensive guide for maintaining and repairing this exceptional motorcycle model. Discover everything you need to know about your Fazer FZ1-N, from detailed instructions to essential tips, available for free download at 88.208.23.73:8080. Unlock the full potential of your bike with this invaluable manual.

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CHECKING THE CLUTCH PLATES.....................................................5-47
CHECKING THE CLUTCH SPRINGS ..................................................5-48
CHECKING THE CLUTCH HOUSING ................................................. 5-48
CHECKING THE CLUTCH BOSS ........................................................ 5-48
CHECKING THE PRESSURE PLATE ..................................................5-48
CHECKING THE PULL LEVER SHAFT AND PULL ROD....................5-49
INSTALLING THE CLUTCH.................................................................. 5-49

SHIFT SHAFT

.............................................................................................5-52

REMOVING THE SHIFT SHAFT .......................................................... 5-53
CHECKING THE SHIFT SHAFT .......................................................... 5-53
CHECKING THE STOPPER LEVER ....................................................5-53
INSTALLING THE SHIFT SHAFT ......................................................... 5-53

OIL PUMP

................................................................................................... 5-55

REMOVING THE OIL PAN ................................................................... 5-58
CHECKING THE SPROCKET AND CHAIN .........................................5-58
CHECKING THE OIL PUMP ................................................................5-58
CHECKING THE RELIEF VALVE ......................................................... 5-59
CHECKING THE OIL DELIVERY PIPES.............................................. 5-59
CHECKING THE OIL STRAINER......................................................... 5-59
CHECKING THE OIL NOZZLES .......................................................... 5-59
ASSEMBLING THE OIL PUMP ............................................................ 5-59
INSTALLING THE OIL/WATER PUMP ASSEMBLY..............................5-60
INSTALLING THE OIL PAN .................................................................. 5-61

CRANKCASE

.............................................................................................5-62

DISASSEMBLING THE CRANKCASE ................................................. 5-64
CHECKING THE CRANKCASE ........................................................... 5-64
CHECKING THE BEARING AND OIL SEALS ..................................... 5-64
ASSEMBLING THE CRANKCASE .......................................................5-64

CRANKSHAFT

........................................................................................... 5-66

REMOVING THE CONNECTING RODS AND PISTONS.....................5-68
REMOVING THE CRANKSHAFT ASSEMBLY ..................................... 5-68
CHECKING THE CYLINDER AND PISTON.........................................5-69
CHECKING THE PISTON RINGS ........................................................ 5-69
CHECKING THE PISTON PINS ........................................................... 5-70
CHECKING THE BIG END BEARINGS ............................................... 5-71
INSTALLING THE CONNECTING ROD AND PISTON ........................ 5-74
CHECKING THE CRANKSHAFT ......................................................... 5-77
CHECKING THE CRANKSHAFT DRIVE SPROCKET......................... 5-77
CHECKING THE CRANKSHAFT JOURNAL BEARINGS ....................5-77
INSTALLING THE CRANKSHAFT........................................................ 5-79

TRANSMISSION

......................................................................................... 5-81

REMOVING THE TRANSMISSION ......................................................5-86
CHECKING THE SHIFT FORKS .......................................................... 5-86
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-87
CHECKING THE TRANSMISSION ......................................................5-87

Summary of Contents for 2008 Fazer FZ1-N

Page 1: ...SERVICE MANUAL FZ1 N X FZ1 S X FZ1 SA FZ1 NA 2008 5D0 28197 E1 ...

Page 2: ...S X FZ1 SA FZ1 NA SERVICE MANUAL 2008 by Yamaha Motor Co Ltd First edition December 2007 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: ...id 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 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease G M E 9 10 11 12 B 13 LS 14 M 15 17 LT 18 New T R 1 2 3 4 5 6 7 8 16 BF 15 Molybdenum disulfide grease 16 Silicon grease 17 Apply locking agent LOCTITE 18 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: ...HE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 26 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 26 REPLACEMENT PARTS 1 26 GASKETS OIL SEALS AND O RINGS 1 26 LOCK WASHERS PLATES AND COTTER PINS 1 26 BEARINGS AND OIL SEALS 1 27 CIRCLIPS 1 27 CHECKING THE CONNECTIONS 1 28 SPECIAL TOOLS 1 29 ...

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: ...ance and cleaner exhaust gases increase 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 ...

Page 12: ...on 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 air temperature sensor coolant temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft posi tion sensor As a r...

Page 13: ...er and odometer tripmeter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachome ter needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit CAUTIO...

Page 14: ...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 fuel level decreases When only one segment...

Page 15: ...r system If any of the immobilizer system circuits are defective the immobilizer system indicator light will flash and then the display will indicate a two digit error code e g 51 52 53 NOTE If the display indicates error code 52 this could be caused by transponder interference If this error code appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there a...

Page 16: ...he ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle 3 The hydraulic unit which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout ABS The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles with a brake lever for operating the front brake and a bra...

Page 17: ...slippage and is defined by the following formula 0 There is no slipping between the wheel and the road surface The chassis speed is equal to the wheel speed 100 The wheel speed is 0 but the chassis 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 ...

Page 18: ...ncy to lock When the wheel slip and the wheel speed reduction rate exceed the preset values the ABS ECU determines that the wheel has a tendency to lock If the slip is large and the wheel has a tendency to lock point A in the following figure the ABS ECU reduces the brake fluid pressure in the brake caliper The ABS ECU increases the pressure of the brake fluid in the brake caliper when the tendenc...

Page 19: ...g of the vehicle cannot be pre vented if it is braked suddenly The ABS functions to prevent the tendency of the wheel to lock by controlling the brake fluid pres sure However if there is a tendency of the wheel to lock on a slippery road surface due to engine braking the ABS may not be able to prevent the wheel from locking WARNING EWA13870 The ABS controls only the tendency of the wheel to lock c...

Page 20: ...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 21: ...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 Hydraulic unit The hydraulic unit 1 is composed of three hydraulic control valves each with a solenoid valve and flow control valve two buffer chambers two hydraulic pumps and an ABS motor The hydraulic unit ...

Page 22: ...alve 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 decrease the brake fluid pressure the sole noid valve 2 closes and the brake fluid is pressurized again Pressurizing the brake fluid again while the ABS is activated limits ...

Page 23: ...operating ABS ECU electronic control unit The ABS ECU 1 controls the ABS and is installed inside the right cowling To protect the ABS ECU from water damage it is protected by a cover 2 1 Orifice 2 Solenoid valve 3 Spool 4 Flow control valve 1 Buffer chamber pressurized 2 Buffer chamber depressurized 3 Raised piston ...

Page 24: ... 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 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 war...

Page 25: ...of the ABS ECU for easy problem identification and troubleshooting NOTE Some types of 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 under the hydraulic unit bracket 1 Software operation flow 2 Main switch ON 3 Initialize 4 Self diagnosis when static 5 Self di...

Page 26: ... not been transmitted from the ABS ECU and port A 7 and port B 9 of the flow control valve are open Therefore when the brake lever is squeezed the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper via port A 7 and port B 9 At this time the inlet and outlet check valves of the pump close the lines and brake fluid is not sent As a result the b...

Page 27: ...ht 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 ...

Page 28: ...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 linked to the pump motor 1 Brake master...

Page 29: ...fice 10 and the brake fluid is sent to the brake calipers via port A 7 and port C 13 At this time the brake is pressurized 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 chamber B 21 of the flow control valve 9 Port B 10 Orifice 11 Port D 12 Solenoid valve 13 Port C...

Page 30: ...agnosis It is located 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 ...

Page 31: ...aking 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 8 105 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 32: ...ving the left inner panel front cowling When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flash ing 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 Come...

Page 33: ...osis mode for FI EAS5D01033 ABS WARNING LIGHT AND OPERATION ABS warning light When the main switch is turned to ON the ABS warning light comes on for 2 seconds then goes off If the ABS warning light comes on while riding stop the vehicle and then 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 The ABS operation i...

Page 34: ...rformance Depending on the road conditions the braking distance may be longer compared to that of vehi cles not equipped with ABS Therefore ride at a safe speed and keep a safe distance between yourself and other vehicles The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of t...

Page 35: ... 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 36: ...grease Oil bearings liberally when installing if appropriate 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 37: ...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 38: ...o avoid any 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 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 68 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 2 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 3...

Page 39: ... 67 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 67 Fork spring compressor 90890 01441 YM 01441 4 64 4 69 Fork seal driver 90890 01442 Adjust table fork seal driver 36 46 mm YM 01442 4 67 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 7 Compression gauge 90890 03081 Engine compression tester YU 33223 3 11 Tool name Tool No Illustration Refer...

Page 40: ...or adapter YM 04114 5 23 5 29 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 11 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 11 Universal clutch holder 90890 04086 YM 91042 5 46 5 50 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 25 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 25...

Page 41: ...er 4 0 mm YM 04113 5 25 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 25 Ignition checker 90890 06754 Opama pet 4000 spark checker YU 34487 8 148 Yamaha bond No 1215 Three Bond No 1215 90890 85505 5 64 6 11 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 7 8 7 9 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 5 7 Tool name Too...

Page 42: ... 145 8 146 8 147 8 148 8 149 8 150 8 151 8 152 8 153 8 154 8 155 8 156 8 157 Pressure gauge 90890 03153 YU 03153 3 14 7 7 Oil pressure gauge adapter 90890 03139 3 14 Vacuum pressure pump gauge set 90890 06756 7 7 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 5 Fuel pressure adapter 90890 03176 YM 03176 7 7 Tool name Tool No Illustration Reference pages ...

Page 43: ...SPECIAL TOOLS 1 34 Camshaft wrench 90890 04143 YM 04143 5 11 5 16 Test coupler adapter 90890 03149 1 23 4 54 4 55 Tool name Tool No Illustration Reference pages ...

Page 44: ...SPECIAL TOOLS 1 35 ...

Page 45: ...TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ENGINE 2 22 CHASSIS 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 37 CABLE ROUTING 2 41 ...

Page 46: ...UR ZAF FZ1 NA 22C4 FRA BEL FZ1 NA Dimensions Overall length 2140 mm 84 3 in Overall width 770 mm 30 3 in Overall height 1060 mm 41 7 in FZ1 N X FZ1 NA 1205 mm 47 4 in FZ1 S X FZ1 SA Seat height 815 mm 32 1 in Wheelbase 1460 mm 57 5 in Ground clearance 135 mm 5 31 in Minimum turning radius 3000 mm 118 1 in Weight With oil and fuel 214 0 kg 472 lb FZ1 N X 220 0 kg 485 lb FZ1 S X 221 0 kg 487 lb FZ1 ...

Page 47: ...ount 3 80 L 4 02 US qt 3 34 Imp qt Without oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt With oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 010 0 100 mm 0 0004 0 0039 in Limit 0 18 mm 0 0071 in Outer rotor to oil pump housing clearance 0 090 0 150 mm 0 0035 ...

Page 48: ...2 521 mm 0 8858 0 8867 in Camshaft journal diameter 22 459 22 472 mm 0 8842 0 8847 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Intake A 32 500 32 600 mm 1 2795 1 2835 in Limit 32 400 mm 1 2756 in Intake B 24 950 25 050 mm 0 9823 0 9862 in Limit 24 850 mm 0 9783 in Exhaust A 30 699 30 799 mm 1 2086 1 2126 in Limit 30 599 mm 1 2047 in Exhaus...

Page 49: ... 0197 0 0354 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 4 460 4 475 mm 0 1756 0 1762 in Limit 4 425 mm 0 1742 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1594 in Valve guide inside diameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Limit 4 550 mm 0 1791 in Valve stem to valve guide clea...

Page 50: ...ression spring force exhaust 133 00 153 00 N 29 90 34 39 lb 13 56 15 60 kgf Spring tilt intake 2 5 1 8 mm Spring tilt exhaust 2 5 1 8 mm Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 77 000 77 010 mm 3 0315 3 0319 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0...

Page 51: ...5 300 65 mm 11 76 11 84 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Journal oil clearance using plastigauge 0 014 0 037 mm 0 0006 0 0015 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 lever free play 10 0 15 0 mm 0 39 0 59 in Friction pla...

Page 52: ...ir filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 2D1 DENSO Maximum consumption amperage 4 3 A Output pressure 324 0 kPa 47 0 psi 3 24 kgf cm2 Fuel injection Model quantity 297500 0300 4 Manufacturer DENSO Throttle body Type quantity SE 45EIDW B41 1 Manufacturer MIKUNI ID mark 2D11 20 Throttle valve size 100 Throttle position sensor Resistance ...

Page 53: ... Rear tire Size 190 50 ZR17 M C 73W Manufacturer model MICHELIN Pilot Road D Manufacturer model DUNLOP D221G Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm2 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm2 2 90 bar Loading condition 90 196 kg 198 432 lb FZ1 N X 90 190 kg 198 419 lb FZ1 S X 90 189 kg 198 417 lb FZ...

Page 54: ...diameter 38 20 mm 1 50 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Lock to lock angle left 33 0 Lock to lock angle right 33 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 130 0 mm 5 12 in Fork spring free length 243 5 mm 9 59 in Collar length 100 0 mm 3 94 in Installed length 239 0 mm 9 41 in Spring rate K1 ...

Page 55: ...0 0 mm 0 00 2 36 in Optional spring available No Enclosed gas air pressure STD 1000 kPa 142 2 psi 10 0 kgf cm2 Drive chain Type manufacturer 50VA8 DAIDO Link quantity 122 Drive chain slack 25 0 35 0 mm 0 98 1 38 in 15 link length limit 239 3 mm 9 42 in ...

Page 56: ...MITSUBISHI FZ1 SA STATOR F074T85075 MITSUBISHI FZ1 NA Standard output 14 0 V 40 0 A at 6500 r min Stator coil resistance 0 144 0 176 Ω at 20 C 68 F FZ1 S X FZ1 N X FZ1 SA 0 153 0 187 Ω at 20 C 68 F FZ1 NA Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery M...

Page 57: ...021 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 manufacturer 2768109 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Ω at 20 C 68 F Horn Horn type Plane Quantity 1 pcs Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Ω at 20 C 68 F Performance 105 113 dB 2m Turn signal hazard relay Relay typ...

Page 58: ...r fan fuse 10 0 A 2 Fuel injection system fuse 15 0 A ABS motor fuse 30 0 A FZ1 SA FZ1 NA ABS control unit fuse 10 0 A FZ1 SA FZ1 NA Backup fuse 10 0 A Reserve fuse 30 0 A FZ1 SA FZ1 NA Reserve fuse 25 0 A FZ1 S X FZ1 SA Reserve fuse 15 0 A Reserve fuse 10 0 A ...

Page 59: ...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 60: ... lb Water pump inlet pipe bolt front side M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil water pump drive sprocket bolt M6 1 15 Nm 1 5 m kg 11 ft lb Water pump bolt M6 5 12 Nm 1 2 m kg 8 7 ft lb Thermostat cover nut M6 2 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil cooler bolt M20 1 63 Nm 6 3 m kg 46 ft lb Engine oil drain bolt M14 1 43 Nm 4 3 m kg 31 ft lb Oil pipe bol...

Page 61: ... Breather cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Breather plate bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Plate bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover blind bolt M8 1 15 Nm 1 5 m kg 11 ft lb Generator rotor cover plug M20 1 8 Nm 0 8 m kg 5 8 ft lb Main gallery plug oil return M16 3 8 Nm 0 8 m kg 5 8 ft lb Main gallery plug M20 1 8 Nm 0 8 m kg 5 8 ft lb Oil return pipe bolt M6 2 10 Nm 1 0...

Page 62: ...er and then tighten them to 20 Nm 2 0 m kg 14 ft lb again 3 Retighten the bolts further to reach the specified angle 60 Shift rod locknut rear M6 1 7 Nm 0 7 m kg 5 1 ft lb Left thread Shift rod joint bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift arm bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Neutral switch M10 1 20 Nm 2 0 m kg 14 ft lb Sub throttle servo motor cover bolt M4 3 2 Nm 0 2 m kg 1 4 ft lb Coolant te...

Page 63: ...TIGHTENING TORQUES 2 18 ...

Page 64: ...3 ft lb Clutch lever holder pinch bolt M6 1 11 Nm 1 1 m kg 8 0 ft lb Right front engine mounting bolt 1 M10 1 45 Nm 4 5 m kg 33 ft lb Right front engine mounting bolt 2 M10 1 50 Nm 5 0 m kg 36 ft lb Left front engine mounting bolt M10 1 45 Nm 4 5 m kg 33 ft lb Upper self locking nut M10 1 51 Nm 5 1 m kg 37 ft lb Lower self locking nut M10 1 51 Nm 5 1 m kg 37 ft lb Engine mounting adjust bolt upper...

Page 65: ...b Coolant reservoir tank bolt M6 1 5 Nm 0 5 m kg 3 6 ft lb Front wheel axle shaft M18 1 72 Nm 7 2 m kg 52 ft lb Front wheel axle pinch bolt M8 1 23 Nm 2 3 m kg 17 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake disc screw M6 10 18 Nm 1 8 m kg 13 ft lb Brake caliper bleed screw M8 3 5 Nm 0 5 m kg 3 6 ft lb Rear wheel axle nut M24 1 150 Nm 15 0 m kg 108 ft lb Rear brake disc...

Page 66: ...Nm 0 7 m kg 5 1 ft lb Rear wheel sensor stay bolt FZ1 SA FZ1 NA M6 2 7 Nm 0 7 m kg 5 1 ft lb Hydraulic unit bracket 1 and hydraulic unit bracket 2 bolt FZ1 SA FZ1 NA M6 2 7 Nm 0 7 m kg 5 1 ft lb Hydraulic unit bracket 1 and hydraulic unit bracket 2 nut FZ1 SA FZ1 NA M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear wheel sensor rotor bolt FZ1 SA FZ1 NA M5 5 6 Nm 0 6 m kg 4 3 ft lb Hydraulic unit and brake hose un...

Page 67: ...Clutch pull rod Oil water pump drive sprocket and washer Clutch thrust plate 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 Crankcase mating surface Yamaha bond No 1215 C...

Page 68: ...sorber Seat lock assembly moving parts Sidestand pivoting point and metal to metal moving parts Sidestand switch contact point Sidestand hook and spring contact point Shift shaft joint rod moving parts Shift pedal pivoting parts Rear footrest ball and metal to metal moving parts Centerstand metal to metal moving parts FZ1 S X FZ1 SA Front wheel oil seal left and right Rear wheel oil seal Rear whee...

Page 69: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ...

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

Page 71: ...ner 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter 6 Main gallery 7 AC magneto drive gear shower 8 Shift fork upper 9 Main axle 10 Mission shower 11 Drive axle 12 Piston cooler 13 Piston cooler 14 Chain tensioner 15 Intake camshaft 16 Exhaust camshaft ...

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

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch ...

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

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump ...

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

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler ...

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

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Main axle 2 Oil delivery pipe 3 Drive axle ...

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

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Cylinder head 2 Crankshaft ...

Page 82: ...COOLING SYSTEM DIAGRAMS 2 37 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 83: ...COOLING SYSTEM DIAGRAMS 2 38 1 Water pump 2 Radiator 3 Radiator fan ...

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

Page 85: ...COOLING SYSTEM DIAGRAMS 2 40 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat ...

Page 86: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING ...

Page 87: ...ght switch lead above the throttle cable I Secure the brake hose to the front fork J Secure the horn lead to the front fork Cut the tip of the clamp head leaving 2 to 4 mm 0 08 to 0 16 in toward the outside of the vehicle K The center position of the clamp shall be within this numeric range 20 L Outside of the vehicle M Inside of the vehicle N Pass the brake hose in the space by the right side of ...

Page 88: ...CABLE ROUTING 2 43 MM NN OO FZ1 S X H M M N N O H O FZ1 N X FZ1 S X ...

Page 89: ...wire guide H To the EXUP I Pass the fuel tank breather hose and EXUP cable through the wire guide of the rear brake light switch stay J The clamp position shall be at the center of bending section of the brake fluid reservoir hose as shown in the illustration K Bind the two EXUP cables with the clamp For the clamping position a part of the clamp should be located within a range of 10 mm 0 39 in fr...

Page 90: ...CABLE ROUTING 2 45 ...

Page 91: ...e through the wire guide of the rear brake light switch stay G Clamping position should be placed by the inner side of the back stay tightening sec tion H Tighten the rear brake ground lead together with the hydraulic unit I Bind the two EXUP cables with the clamp For the clamping position a part of the clamp should be located within a range of 10 mm 0 39 in from the end of wire bend ing attachmen...

Page 92: ...CABLE ROUTING 2 47 ...

Page 93: ...tch stay H Clamping position should be above the wire guide of the rear brake light switch I Clamping position should be placed by the inner side of the back stay tightening sec tion J Tighten the rear brake ground lead together with the hydraulic unit Tighten the terminals so that the leads are routed through the shortest distance K Bind the two EXUP cables with the clamp A part of the clamp shou...

Page 94: ...CABLE ROUTING 2 49 KK LL PP FZ1 N X FF EE G Q P P C E E F F G K K Q FZ1 N X CC L C L FZ1 N X FZ1 S X ...

Page 95: ...hicle front side where the hose assembly 1 and water pump inlet pipe are routed K Pass the oil level switch lead to the vehicle front side of the water pump breather hose and water pipe L Route the AC magneto lead by the inside of the frame M There should be no exposure of bare con ductors due to the misalignment of tubes N Route the AC magneto lead by the inside of vehicle away from the water hos...

Page 96: ...CABLE ROUTING 2 51 ...

Page 97: ...switch lead by the vehicle front side where the water pump breather hose and water pump inlet pipe are routed K Pass the oil level switch lead to the vehicle front side of the water pump breather hose and water pipe L Route the AC magneto lead by the inside of the frame M There should be no exposure of bare con ductors due to the misalignment of tubes N Route the AC magneto lead by the inside of v...

Page 98: ...CABLE ROUTING 2 53 ...

Page 99: ...D Route the coolant reservoir tank drain hose so that it is positioned at the inner most part in hoses and leads AE The rear side of the vehicle AF The coolant reservoir tank drain hose shall cross with the speed sensor lead under the rear arm bracket The coolant reservoir tank drain hose shall be positioned above the vehicle AG Open to the air AH To the radiator ...

Page 100: ...CABLE ROUTING 2 55 ...

Page 101: ... Route the sidestand switch lead in front of the water pump breather hose and water pump inlet pipe K Route the oil level switch lead in front of the water pump breather hose and water pipe L Route the AC magneto lead by the inside of the frame M There should be no exposure of bare con ductors due to the misalignment of tubes N Route the AC magneto lead by the inner side of the water pump breather...

Page 102: ...CABLE ROUTING 2 57 RR TT UU DD JJ AA BB EE FF R R F F E E B B A U U A D J J D T T FZ1 N X FZ1 S X ...

Page 103: ...n signal light relay lead 58 Rear frame 59 Battery 60 Sidestand switch lead 61 Oil level switch lead 62 O2 sensor lead 63 Velcro 64 Protector 65 Mad guard 66 Fender 67 Fuel hose A Check that it is secured with the guide of the radiator stay B 10 30 mm 0 39 to 1 18 in C To the direct ignition coil lead D Make sure to install the air filter after checking that the leads are positioned out side of th...

Page 104: ...CABLE ROUTING 2 59 RR TT UU DD JJ AA BB EE FF R R F F E E B B A U U A D J J D T T FZ1 N X FZ1 S X ...

Page 105: ...e main switch lead immobilizer lead and left han dlebar switch lead The misalignment toler ance of ends is 0 to 5 mm 0 to 0 20 in AL Clamp each lead at the positioning taping section white and then insert it to the cover In random order AM Clamp each lead at the positioning taping section blue and then insert it to the cover For routing leads the wire harness shall be downside but others can be in...

Page 106: ...CABLE ROUTING 2 61 ...

Page 107: ...nsor lead 56 Sidestand switch lead 57 Speed sensor lead 58 Radiator fan motor lead Right 59 Rear frame 60 Battery box 61 Battery 62 Turn signal light relay lead 63 ABS fuse lead 64 Lean angle sensor lead 65 Mad guard 66 Fender 67 Tail brake light lead 68 Headlight leads 69 Rectifier regulator lead 70 AC magneto lead 71 Stay 72 Front upper body 73 Cap nut 74 Alarm lead 75 Ground lead A To the direc...

Page 108: ...CABLE ROUTING 2 63 ...

Page 109: ...d lead at 45 or less AH Point the ground lead to the direction in parallel to the bracket end face AI 15 20 mm 0 59 0 79 in shaded area AJ Installation procedure 1 Secure the main switch lead and immobilizer lead with Vel cro strap 2 Secure the left handlebar switch lead with Velcro strap The main switch lead and immobilizer lead shall not be twisted in the protector The installation position is w...

Page 110: ...CABLE ROUTING 2 65 PP HH AA XX JJ TT CC DD W YY BB RR H Y A X D J J D W T T X A B B Y H P R R P D J J D W T T Y X X A B B Y H H P R R P C C C C FZ1 NA ...

Page 111: ...ft 59 Oil level switch lead 60 O2 sensor lead 61 Sidestand switch lead 62 Rear frame 63 Battery box 64 Battery 65 Lean angle sensor lead 66 Turn signal light relay lead 67 ABS fuse lead 68 Mad guard 69 Fender 70 Turn signal light lead A To the direct ignition coil lead B 10 30 mm 0 39 1 18 in C Make sure to install the air cleaner after checking that the leads are positioned out side of the thrott...

Page 112: ...CABLE ROUTING 2 67 PP HH AA XX JJ TT CC DD W YY BB RR H Y A X D J J D W T T X A B B Y H P R R P D J J D W T T Y X X A B B Y H H P R R P C C C C FZ1 NA ...

Page 113: ... and front wheel sensor lead with the positioning tape end and pro tector end The misalignment tolerance of the end is 0 to 5 mm 0 to 0 20 in AI Clamp each lead at the positioning taping section white and then insert it into the cover 3 in random order AJ 15 20 mm 0 59 0 79 in shaded area AK Installation procedure 1 Secure the main switch lead and immobilizer lead with Vel cro strap 2 Secure the l...

Page 114: ...CABLE ROUTING 2 69 EE E E F F FF AA A A FZ1 S X ...

Page 115: ...oint the tip to the front side of the vehicle C Attach the clamp to the front upper cowl ing Clamp the turn signal light lead left and headlight lead D Pass the turn signal light lead left and tail brake light lead under the rear fender bracket E Pass the turn signal light lead left and tail brake light lead the route between the ribs of the battery box F Clamp each lead at the positioning taping ...

Page 116: ...CABLE ROUTING 2 71 ...

Page 117: ...t nut H Fit the orange double lock side to the pump side I Fit the black double lock side to the engine side J The fuel tank bracket shall not run on the tank flange as shown in the illustration K Fit the O ring with its lip pointed upward L Tightening sequence M Fuel piping connector attachment direc tions fuel pump side Always perform the connection disconnection works by hand Do not use tools N...

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

Page 119: ... CHECKING THE EXUP SERVO MOTOR 3 18 CHECKING THE COOLANT LEVEL 3 18 CHECKING THE COOLING SYSTEM 3 19 CHANGING THE COOLANT 3 19 CHASSIS 3 22 ADJUSTING THE FRONT DISC BRAKE 3 22 ADJUSTING THE REAR DISC BRAKE 3 22 CHECKING THE BRAKE FLUID LEVEL 3 23 CHECKING THE FRONT BRAKE PADS 3 23 CHECKING THE REAR BRAKE PADS 3 23 CHECKING THE FRONT BRAKE HOSES 3 24 CHECKING THE REAR BRAKE HOSE 3 24 ADJUSTING THE ...

Page 120: ...TERSTAND FZ1 S X FZ1 SA 3 35 LUBRICATING THE REAR SUSPENSION 3 35 ELECTRICAL SYSTEM 3 36 CHECKING AND CHARGING THE BATTERY 3 36 CHECKING THE FUSES 3 36 REPLACING THE HEADLIGHT BULBS 3 36 ADJUSTING THE HEADLIGHT BEAM 3 37 ...

Page 121: ......

Page 122: ... an asterisk should be performed by a Yamaha dealer 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 o...

Page 123: ...thium soap based grease 18 Sidestand FZ1 N X FZ1 NA Check operation Lubricate 19 Sidestand cen ter stand FZ1 S X FZ1 SA Check operation Lubricate 20 Sidestand switch Check operation 21 Front fork Check operation and for oil leakage 22 Shock absorber assembly Check operation and shock absorber for oil leakage 23 Rear suspen sion relay arm and connect ing arm pivot ing points Check operation 24 Fuel...

Page 124: ...d calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 29 Moving parts and cables Lubricate 30 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 31 Air induction system Check the air cut off valve reed valve and hose for damage Replace the ent...

Page 125: ... 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 9 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 the compres sion stroke align the TDC mark a on the pickup rotor with the crankcase mating sur face b N...

Page 126: ...he 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 Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 11 0 20 mm 0 004 0 008 in Measure valve clearance 0 25 mm 0 010 in 0 25 mm 0 010 in 0 20 mm 0 008 in 0 05 mm 0 002 in c Check the thic...

Page 127: ...fer to CAMSHAFTS on page 5 9 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshafts marks with the camshaft cap marks Turn the crankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifi cation repeat all of the valve clearance adjustment steps unt...

Page 128: ...zation a With throttle body 3 as standard adjust throttle bodies 1 2 and 4 using the air screw 1 NOTE After each step rev the engine two or three times each time for less than a 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 ECA5D01027 Do not use the throttle valve adjusting screws to adjust the...

Page 129: ...r more NOTE dI appears on the clock LCD 3 Press the SELECT button to select the CO adjustment mode Co 1 or the diag nostic mode dI 4 After selecting Co simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection NOTE The selected cylinder number appears on the clock LCD To decrease the selected cylinder number press the RESET button To increase the selected cyl...

Page 130: ... speed is obtained 5 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 9 EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted properly 1 Check Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play Handlebar side a Loosen the locknut 1...

Page 131: ...r 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plugs Ignition coils NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Install Radiator upper bolts Radiator lower bolt Refer to RADIAT...

Page 132: ... teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table 6 Install Spark plug 7 Install Ignition coils EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Start the engine warm it up for several minutes and then turn it off 3 Check Engine oil level The e...

Page 133: ...ttled 4 Start the engine warm it up for several minutes and then turn 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 d...

Page 134: ... it off 11 Check Engine for engine oil leaks 12 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 11 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a 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 ...

Page 135: ...1031 Be careful to tighten too much EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust Pressure gauge 90890 03153 YU 03153 Oil pressure adapter H 90890 03139 Engine oil pressure 230 kPa 2 3 kg cm2 2 3 bar 32 71 psi Engine speed Approx 5 000 r min Engine oil temperature 100 C 212 F Engine oil pressure Possible causes Below specification Faulty...

Page 136: ... Tighten the locknuts EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Remove Air filter case cover 1 3 Check Air filter element 1 Damage Replace NOTE Replace the air filter element every 40000 km 2400 mi of operation The air filter needs more frequent service if you are riding in unusually w...

Page 137: ...on page 7 4 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Throttle bodies Refer to THROTTLE BODIES on page 7 4 EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel vacuum and breather hoses 1 Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Check Fuel hose 1 Vacuum hose 2 Breather hose 3 C...

Page 138: ... gaskets 1 Check Exhaust pipe 1 Muffler 2 Cracks damage Replace Gaskets 3 Exhaust gas leaks Replace 2 Check Tightening torque Exhaust pipe nut 4 Exhaust pipe and exhaust pipe bracket bolt 5 Exhaust pipe and muffler bolt 6 Muffler and rear footrest bracket bolt 7 NOTE When installing the EXUP cables make sure they are parallel and not twisted Upper cable White metal section 8 Lower cable Black meta...

Page 139: ...ve is seized Disconnect the EXUP cable and check that the EXUP valve is moved smoothly by hand When the valve is not moved smoothly repair or replace it Refer to ADJUSTING THE EXUP CABLES on page 3 17 b When the EXUP valve is moved smoothly replace the EXUP servo motor c Perform the self diagnosis mode and check the operation of EXUP valve by visual inspection Code No 53 The operation should be ca...

Page 140: ... be used 3 Start the engine warm it up for several minutes and then turn it off 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Check Radiator 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 inlet hose 8 Water p...

Page 141: ...ap and turn it counterclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers 6 Remove Coolant drain bolts 1 along with the copper washers 7 Drain Coolant from the water pump inlet pipe and outlet pipe 8 Check Copper washers 1 9 Install Coolant drain bolts 2 10 Install Coolant reservoir tank 11 Connect Coolant reservoir hose 12 Fill Cooling system w...

Page 142: ...if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 13 Install Radiator cap 14 Fill Coolant reservoir tank with the recommended coolant to the maximum level mark a 15 I...

Page 143: ...90 After adjusting the brake lever position make sure there is no brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d...

Page 144: ...ficantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following proce...

Page 145: ...right 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 38 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brak...

Page 146: ...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 several times f Fully pull the brake lever or fully press down the brake pedal and hold it in...

Page 147: ...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 148: ...ied 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 several times and find the tightest position of drive chain 3 Check Drive chain slack a Out of specification Adjust 4 Adjust Drive chain slack a Loosen the wh...

Page 149: ...RNING 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 Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 71 4 Adjust Steering head a Remove the ...

Page 150: ...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 the oppo site handlebar f If the steering head te...

Page 151: ...sting bolt the right front fork leg is equipped with a rebound damping force adjusting screw and left front fork leg with a compression damping force adjusting screw WARNING EWA13150 Always adjust both front fork legs evenly Uneven adjustment can result in poor handling and loss of stability Securely support the vehicle so that there is no danger of it falling over Spring preload CAUTION ECA13570 ...

Page 152: ...wo kinds of forks for the rebound side and for the compression side 1 Adjust Compression damping a Turn the adjusting screw 1 in direction a or b Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Rebound damping adjusting positions Minimum 26 clicks in direction b Standard 15 clicks in direction b Maximum 1 ...

Page 153: ...d 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 Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping Direction a Spring preload is increased suspension is harder Direction b Spring preload...

Page 154: ...r Direction b Rebound damping is decreased suspension is softer Rebound damping adjusting position Minimum 12 clicks in direction b Standard 6 clicks in direction b Maximum 1 clicks in direction b With the adjusting screw fully turned in direction a Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 5 kg cm2 2 5 bar 36 psi Rear 290 kPa 2 9 kg cm2 2 9 bar 42...

Page 155: ...90 After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufac turer and of the 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 ...

Page 156: ... end upright and pour a few drops of lubricant into the 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...

Page 157: ...o ELECTRICAL COMPONENTS on page 8 131 EAS21780 REPLACING THE HEADLIGHT BULBS 1 Remove Headlight side cover bolts 1 FZ1 N X FZ1 NA 2 Disconnect Headlight sub wire harness coupler 2 FZ1 N X FZ1 NA 3 Disconnect Headlight coupler 1 4 Remove Headlight bulb cover 1 FZ1 S X FZ1 SA 5 Remove Headlight bulb holder 1 A FZ1 N X FZ1 NA B FZ1 S X FZ1 SA A FZ1 N X FZ1 NA B FZ1 S X FZ1 SA ...

Page 158: ...bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 8 Install Headlight bulb holder 9 Install Headlight bulb cover 10 Connect Headlight coupler 11 Connect Headlight assembly coupler 12 Install Headlight assembly bolts EAS21800 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight b...

Page 159: ...ELECTRICAL SYSTEM 3 38 A FZ1 N X FZ1 NA B FZ1 S X FZ1 SA ...

Page 160: ...ELECTRICAL SYSTEM 3 39 ...

Page 161: ... 4 31 REPLACING THE FRONT BRAKE PADS 4 32 REMOVING THE FRONT BRAKE CALIPERS 4 33 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 33 CHECKING THE FRONT BRAKE CALIPERS 4 34 ASSEMBLING THE FRONT BRAKE CALIPERS 4 34 INSTALLING THE FRONT BRAKE CALIPERS 4 34 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 35 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 36 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 36 INSTALLING THE...

Page 162: ...HE LOWER BRACKET 4 73 CHECKING THE STEERING HEAD 4 73 INSTALLING THE STEERING HEAD 4 74 REAR SHOCK ABSORBER ASSEMBLY 4 75 HANDLING THE REAR SHOCK ABSORBER 4 76 DISPOSING OF A REAR SHOCK ABSORBER 4 76 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 76 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 76 CHECKING THE CONNECTING ARM AND RELAY ARM 4 77 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 77 SWINGARM 4...

Page 163: ......

Page 164: ...he seat and battery Order Job Parts to remove Q ty Remarks 1 Passenger seat 1 2 Rider seat 1 3 Battery band 1 4 Battery cover 1 5 Battery negative lead 1 6 Battery positive lead 1 7 Battery 1 8 Battery seat 1 For installation reverse the removal proce dure ...

Page 165: ...ide cover bolt left and right 4 2 Headlight coupler 1 Disconnect 3 Headlight sub wire harness coupler 1 Disconnect 4 Headlight assembly 1 5 Headlight bracket 2 6 Headlight side cover left and right 2 7 Meter cover 1 8 Meter coupler 1 9 Meter assembly 1 10 Headlight and meter stay 1 For installation reverse the removal proce dure ...

Page 166: ...Job Parts to remove Q ty Remarks 1 Inner panel 2 2 Headlight assembly coupler 1 Disconnect 3 Meter coupler 1 Disconnect 4 Front cowling assembly 1 5 Rear view mirror 2 6 Cowling stay 1 7 Meter assembly 1 8 Headlight unit 1 For installation reverse the removal proce dure ...

Page 167: ...moving the under cowling FZ1 NA Order Job Parts to remove Q ty Remarks 1 Under cowling 1 2 Rectifier regulator 1 3 Right under cowling bracket 1 4 Left under cowling bracket 1 For installation reverse the removal proce dure ...

Page 168: ...t Refer to GENERAL CHASSIS on page 4 1 1 Licence plate light lead coupler 1 Disconnect 2 Turn signal light lead coupler 1 Disconnect 3 Mud guard assembly 1 4 Rear fender 1 5 Tail brake light lead coupler 1 Disconnect 6 Tail cover 1 7 Rear fender bracket 1 8 Tail brake light 1 For installation reverse the removal proce dure ...

Page 169: ...4 1 1 Licence plate light lead coupler 1 Disconnect 2 Turn signal light lead coupler 1 Disconnect 3 Mud guard assembly 1 4 Rear fender 1 5 Tail brake light lead coupler 1 Disconnect 6 Tail brake light cover 1 7 Rear fender side cover left and right 2 8 Rear fender bracket 1 9 Tail brake light 1 10 Tail cover 1 For installation reverse the removal proce dure ...

Page 170: ... CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Intake air temperature sensor lead coupler 1 Disconnect 2 Intake air temperature sensor 1 3 Air filter case cover 1 4 Air filter 1 5 Funnel 2 6 Air filter case 1 7 Air induction system hose 1 8 Crankcase breather hose 1 For installation reverse the removal proce dure ...

Page 171: ...th a screwdriver then pull the fastener out EAS21850 INSTALLING THE COVER 1 Install Rear fender Tail cover NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cover and push the pin a in with screwdriver Make sure that the pin is flush with the fastener s head ...

Page 172: ...e discs FZ1 N X FZ1 S X Order Job Parts to remove Q ty Remarks 1 Brake hose holder 2 2 Front brake caliper 2 3 Front wheel axle pinch bolt 1 4 Front wheel axle 1 5 Collar 2 6 Dust cover 2 7 Front wheel 1 8 Front brake disc 2 For installation reverse the removal proce dure ...

Page 173: ... Job Parts to remove Q ty Remarks 1 Brake hose holder 2 2 Front brake caliper 2 3 Front wheel sensor 1 4 Front wheel axle pinch bolt 1 5 Front wheel axle 1 6 Collar 1 7 Sensor housing 1 8 Dust cover 2 9 Front wheel 1 10 Front brake disc 2 For installation reverse the removal proce dure ...

Page 174: ...FRONT WHEEL 4 11 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 175: ...NG 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 33 and CHECKING THE WHEELS on page 3 35 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel...

Page 176: ...ve 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 sensor elec trode to any...

Page 177: ...heel sensor lead for twists and the sensor electrode for foreign materials CAUTION ECA14480 To route the front wheel sensor lead refer to CABLE ROUTING on page 2 41 3 Check Front wheel sensor installation Check if the wheel sensor housing is installed properly Refer to D 3 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 13 EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE Aft...

Page 178: ...heel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain station ary at all of the positions rebalance it EAS22000 INSTALLING TH...

Page 179: ...r several times and check if the front fork rebounds smoothly 6 Install Brake caliper WARNING EWA13490 Make sure the brake cable is routed prop erly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs Wheel axle nut 72 Nm 7 2 m kg 52 ft lb Wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb Brake caliper bolt 40 Nm 4 0 m kg 29 ft lb...

Page 180: ...Parts to remove Q ty Remarks 1 Rear brake caliper 1 2 Locknut 2 Loosen 3 Adjusting bolt 2 Loosen 4 Wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Adjusting block left 1 8 Adjusting block right 1 9 Rear wheel 1 10 Brake caliper bracket 1 For installation reverse the removal proce dure ...

Page 181: ...tor 1 2 Rear wheel sensor 1 3 Rear wheel sensor lead stay 1 4 Rear brake caliper 1 5 Lock nut 2 Loosen 6 Adjusting nut 2 Loosen 7 Wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Adjusting block left 1 11 Adjusting block right 1 12 Rear wheel 1 13 Rear brake caliper bracket 1 14 Sensor rotor 1 For installation reverse the removal proce dure ...

Page 182: ...rder Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar left and right 2 4 Dust cover 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal proce dure ...

Page 183: ...REAR WHEEL 4 20 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 184: ...Push the rear 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 FRONT WHEEL on page 4 9 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS...

Page 185: ...el sprocket 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 ECA5D01002 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...

Page 186: ...e 4 24 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 3 Install Rear wheel sensor 2 Rear wheel sensor protector Rear wheel sensor lead stay 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 rout...

Page 187: ...ng is installed properly EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 14 EAS22160 INSTALLING THE REAR WHEEL 1 Lubric...

Page 188: ...le nut Brake caliper bolts WARNING EWA13500 Make sure the brake hose is routed prop erly Wheel axle nut 150 Nm 15 m kg 108 ft lb Brake caliper bolt front 27 Nm 2 7 m kg 20 ft lb Brake caliper bolt rear 22 Nm 2 2 m kg 16 ft lb ...

Page 189: ...ing the front brake pads Order Job Parts to remove Q ty Remarks 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Bleed screw 1 For installation reverse the removal proce dure ...

Page 190: ... mirror FZ1 N X FZ1 NA 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir diaphragm holder 1 4 Brake master cylinder diaphragm 1 5 Brake lever 1 6 Front brake light switch lead coupler 1 Disconnect 7 Front brake light switch 1 8 Union bolt 1 9 Copper washer 2 10 Master cylinder bracket 1 11 Master cylinder assembly 1 For assembly reverse the disassembly pro cedure ...

Page 191: ...T BRAKE 4 28 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 192: ...ke calipers Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 193: ...ve 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 dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 For assembly reverse the disassembly pro cedure 3 1 2 7 5 4 6 5 5 6 7 7 6 6 7 BF BF BF ...

Page 194: ...AS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 9 2 Check Brake disc Damage galling Replace 3 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 f...

Page 195: ...e brake hose or disas semble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pads Brake pad spring NOTE Always install new brake pads 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 cal...

Page 196: ... of the brake calipers NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 B...

Page 197: ...ore installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals EAS22440 INSTALLING THE FRONT BRAKE CALI PERS The following procedure applies to both of the brake cali...

Page 198: ...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 damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 6 Check Brake fluid level Below the min...

Page 199: ...NG THE FRONT BRAKE MAS TER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder bracket 2 NOTE Install the brake master cylinder holder with the UP mark a fa...

Page 200: ...ake 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 master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may...

Page 201: ...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 Bleed screw 1 7 Brake pad spring 1 For installation reverse the removal proce dure ...

Page 202: ...DRAULIC BRAKE SYSTEM on page 3 25 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir tank 1 5 Brake fluid reservoir hose 1 6 Hose joint 1 7 Bushing 1 8 Union bolt 1 9 Copper washer 2 10 Brake hose 1 11 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 203: ...RAULIC BRAKE SYSTEM on page 3 25 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir tank 1 5 Brake fluid reservoir hose 1 6 Hose joint 1 7 Bushing 1 8 Union bolt 1 9 Copper washer 2 10 Brake hose 1 11 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 204: ...isassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Hose joint 1 3 Bushing 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 205: ...REAR BRAKE 4 42 Removing the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal proce dure ...

Page 206: ...rts 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 dust seal 1 8 Brake caliper piston seal 1 9 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 207: ...asure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 4 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 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAK...

Page 208: ... to CHECKING THE BRAKE FLUID LEVEL on page 3 23 5 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 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 NOTE Put the end of the brake ...

Page 209: ... the brake caliper assembly Brake 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 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 an...

Page 210: ...er 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 cause vap...

Page 211: ...lace 3 Check Brake fluid reservoir Cracks damage Replace Brake fluid reservoir diaphragm Cracks damage Replace 4 Check Brake hose Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components EAS22740 INST...

Page 212: ...could cause vapor lock CAUTION ECA5D01025 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23...

Page 213: ...on page 7 1 EXUP servo motor Refer to ENGINE REMOVAL on page 5 1 Brake fluid reservoir tank Refer to REAR BRAKE on page 4 38 ABS motor relay Refer to ABS ECU AND ABS MOTOR RELAY on page 8 101 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Side cover 2 2 Under cover 1 3 Union bolt 1 4 Copper washer 2 5 Brake hose front brake master cylinder to hydraulic unit 1 6 Union...

Page 214: ...e hose rear brake master cylinder to hydraulic unit 1 15 ABS motor coupler 1 16 Hydraulic unit solenoid coupler 1 17 Brake hose holder 1 18 Ground lead 1 19 Hydraulic unit bracket 1 1 20 Hydraulic unit bracket 2 1 21 Hydraulic unit 1 For installation reverse the removal proce dure Removing the hydraulic unit FZ1 SA FZ1 NA Order Job Parts to remove Q ty Remarks ...

Page 215: ...ately 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 mas ter cylinder Brake hose 2 to the front brake caliper Brake hose 3 to the...

Page 216: ...f 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 41 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 UNIT OPERATION TEST on page 4 53 CAUTION ECA...

Page 217: ...4 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 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 bra...

Page 218: ...s are connected cor rectly to the hydraulic unit If the operation of the hydraulic unit is normal delete all of the malfunction codes Hydraulic unit operation test 2 WARNING EWA13120 Securely support 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...

Page 219: ...inue to operate the brake lever and brake pedal even after the pulsat ing action has stopped 10 After the pulsating action has stopped in the brake lever it is generated in the brake pedal 2 0 5 second after and continues for approximately 1 second NOTE Be sure to continue to operate the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopp...

Page 220: ...orrectly to the hydraulic unit 12 Set the main switch to OFF 13 Remove the test coupler adaptor from the test coupler 14 Set the main switch to ON 15 Set the engine stop switch to EAS22820 D 6 5 TRIAL RUN After all checks and services are completed always ensure the scooter has no problems by performing the trial running at a speed of faster than 10 km h ...

Page 221: ... switch connector 2 Disconnect 3 Front master cylinder bracket 1 4 Front brake master cylinder assembly 1 5 Right handlebar switch 1 6 Throttle cable housing 1 7 Throttle cable 2 8 Grip end 2 9 Throttle grip 1 10 Clutch cable 1 11 Handlebar grip 1 12 Left handlebar switch 1 13 Clutch lever holder 1 14 Upper handlebar holder 1 15 Handlebar 1 16 Lower handlebar holder 2 For installation reverse the ...

Page 222: ...as this may dangerously weaken it EAS22930 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders 1 NOTE Temporarily tighten the nuts 2 3 Install Handlebar 1 Upper handlebar holder 2 CAUTION ECA14250 First tighten the bolts on the front side of the handlebar holder...

Page 223: ...he handlebar b Side the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA5D01009 Do not touch the handlebar grip until the rubber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clearance a between the handlebar grip and the grip end 8 Install Throttle grip 1 Throttle cable housing 2 Throttle cables Grip end 3 ...

Page 224: ...l Front brake master cylinder assembly Front brake master cylinder holder 1 CAUTION ECA5D01032 Install the brake master cylinder bracket with the UP mark facing up First tighten the upper bolt then the lower bolt NOTE Align the end of the brake master cylinder holder with the punch mark a on the handle bar 11 Adjust Throttle cable free play Front brake master cylinder bracket bolt 10 Nm 1 0 m kg 7...

Page 225: ...y Remarks Front wheel Front brake calipers Refer to CHECKING THE TIRES on page 3 33 and CHECKING THE WHEELS on page 3 35 1 Front fender 1 2 Cap bolt 1 Loosen 3 Upper bracket pinch bolt 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 For installation reverse the removal proce dure ...

Page 226: ...lt 1 2 O ring 1 3 Damper adjusting rod 1 4 Nut 1 5 Washer 1 6 Spacer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14 Damper rod assembly 1 15 Inner tube 1 16 Outer tube 1 For assembly reverse the disassembly pro cedure ...

Page 227: ...wer bracket pinch bolts 3 WARNING EWA13640 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper adjusting rod Spacers 2 Nut 3 a Press down on the spacer with the fork spring compressor 4 b Install the ro...

Page 228: ...our holes of oil path unlike the right side NOTE While holding the damper rod with the damper rod holder 1 loosen the damper rod assem bly bolt EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously we...

Page 229: ...t seal Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 Damper rod assembly bolt Copper washer CAUTION ECA5D01026 For the damper rod assembly the right side is used for the rebound operation and left side for the compression Pay attention not to mistake the right and left NOTE The left side for the compression damper rod as...

Page 230: ...ng installation 5 Install Oil seal 1 with the fork seal driver 2 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 2 8 Install Rod puller 1 Rod puller attachment M 10 2 onto the damper rod 3 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442...

Page 231: ...ecause the fork oil may spurt out 11 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any resid ual air 12 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 13 Install Nut 1 Fork sp...

Page 232: ...nut to specification k Remove the rod holder and fork spring compressor WARNING EWA5D01005 The fork spring is compressed Always use a new cap bolt O ring EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTE Each front fork leg is equipped with a spring preload adjusting bolt the right fork leg is equipped with a rebound damping force adjusting...

Page 233: ... 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE FRONT FORK LEGS on page 3 30 Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb Cap bolt 23 Nm 2 3 m kg 17 ft lb Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb ...

Page 234: ...AL CHASSIS on page 4 1 Headlight and meter assembly FZ1 N X FZ1 NA Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 58 Front fork legs Refer to FRONT FORK on page 4 62 1 Main switch connector 2 Disconnect 2 Steering stem nut 1 3 Upper bracket 1 4 Front brake hose joint 1 5 Front brake hose joint bracket 1 6 Horn 1 7 Horn bracket 1 8 Lock washer 1 9 Upper ring nut 1 10 Ru...

Page 235: ...ring dust seal 1 15 Lower bearing inner race 1 16 Bearing cover 1 17 Upper bearing inner race 1 18 Upper bearing 1 19 Bearing outer race 2 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks ...

Page 236: ...ash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace 3 Replace Bearings Bearing races a Remove the bearing races from the steer ing head pipe with a long rod 1 and ham mer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber seal and new bearing races CAUTION ECA14270 If the bearing race is not installed properly t...

Page 237: ...3 Lock washer 4 Refer to INSTALLING THE STEERING HEAD on page 4 74 3 Install Front brake hose joint bracket Front brake hose joint 4 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 62 NOTE Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut Recommended lubricant Lithiu...

Page 238: ...t Refer to GENERAL CHASSIS on page 4 1 Brake fluid reservoir tank bolt Refer to REAR BRAKE on page 4 38 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 4 Self locking nut bolt collar 1 1 1 5 Rear shock absorber assembly 1 6 Oil seal bearing collar 6 3 3 7 Collar self locking nut bolt 1 1 1 8 Connecting arm 2 9 Oil seal bearing collar 2 1 1 10 Relay arm 1 For ins...

Page 239: ...k absorber To release the gas pressure drill a 2 3 mm 0 079 0 118 in hole through the rear shock absorber at a point 15 20 mm 0 59 0 79 in 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 the...

Page 240: ...als Damage pitting Replace 3 Check Collar Damage scratches Replace EAS23300 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacers Bearings 2 Install Rear shock absorber assembly NOTE When installing the rear shock absorber assembly lift up the swingarm 3 Tighten Rear shock absorber assembly upper nut Rear shock absorber assembly lower nut Relay arm to swingarm nut Recommended lubricant L...

Page 241: ...absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 75 Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Rear fender cover 1 2 Drive chain guard 1 3 Brake hose holder 1 4 Drive chain adjusting bolt locknut 2 2 5 Pivot shaft nut washer 1 1 6 Pivot shaft 1 7 Swingarm 1 8 Drive chain 1 9 Dust cover 2 10 Drive chain guide 1 11 Spacer 1 12 Bearing 2 For installation reverse the removal proce du...

Page 242: ...by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the 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 washers and dust cov ers EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks...

Page 243: ...ings Spacers Dust covers Pivot shaft 2 Install Swingarm Pivot shaft 1 Pivot shaft nut 2 3 Install Rear shock absorber assembly Rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 77 and INSTALLING THE REAR WHEEL on page 4 24 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 27 Recommended lubricant Lithium soap based grease Drive chain slack 25 0 3...

Page 244: ...AS23400 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain guard 1 2 Drive chain 1 For installation reverse the removal proce dure ...

Page 245: ... link section push down on the drive 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...

Page 246: ...et 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 22 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 21 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE R...

Page 247: ... AND VALVE GUIDES 5 24 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 27 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 GENERATOR 5 30 REMOVING THE GENERATOR 5 32 INSTALLING THE GENERATOR 5 32 STARTER CLUTCH 5 34 REMOVING THE STARTER CLUTCH 5 35 CHECKING THE DAMPER 5 35 CHECKING THE STARTER CLUTCH 5 35 INSTALLING THE STARTER CLUTCH 5 36 CRANKSHAFT POSITION SENSOR 5 37 REMOV...

Page 248: ...LING THE OIL PUMP 5 59 INSTALLING THE OIL WATER PUMP ASSEMBLY 5 60 INSTALLING THE OIL PAN 5 61 CRANKCASE 5 62 DISASSEMBLING THE CRANKCASE 5 64 CHECKING THE CRANKCASE 5 64 CHECKING THE BEARING AND OIL SEALS 5 64 ASSEMBLING THE CRANKCASE 5 64 CRANKSHAFT 5 66 REMOVING THE CONNECTING RODS AND PISTONS 5 68 REMOVING THE CRANKSHAFT ASSEMBLY 5 68 CHECKING THE CYLINDER AND PISTON 5 69 CHECKING THE PISTON R...

Page 249: ...INSTALLING THE TRANSMISSION 5 88 ...

Page 250: ...emoving the drive sprocket Order Job Parts to remove Q ty Remarks 1 Locknut 2 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 8 Plate 1 For installation reverse the removal proce dure ...

Page 251: ...t Refer to GENERAL CHASSIS on page 4 1 1 EXUP pulley cover 1 2 EXUP servo motor cover 1 3 EXUP cables 2 4 EXUP servo motor 1 5 O2 sensor 1 6 Exhaust pipe assembly 1 7 Exhaust pipe gasket 4 8 Muffler 1 9 Muffler gasket 1 10 Muffler cover 1 11 Muffler end cover 1 For installation reverse the removal proce dure ...

Page 252: ...ENGINE REMOVAL 5 3 Disassembling the exhaust valve pipe Order Job Parts to remove Q ty Remarks 1 Nut 1 2 Pulley 1 3 Spring 1 4 Spring seat 1 For assembly reverse the disassembly pro cedure ...

Page 253: ...il cooler Refer to OIL COOLER on page 6 3 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 12 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Battery negative lead 1 2 Battery positive lead 1 3 Clutch cable 1 4 Ground lead 2 5 Stator coil assembly coupler 1 Disconnect 6 Crankshaft position sensor lead coupler 1 Disconnect 7 Oil level switch connector 1 Disconnect 8 Neutral switch c...

Page 254: ...ENGINE REMOVAL 5 5 For assembly reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks ...

Page 255: ... 1 Right front engine mounting bolt 1 1 2 Left front engine mounting bolt 1 3 Upper self locking nut 1 4 Upper engine mounting bolt 1 5 Lower self locking nut 1 6 Lower engine mounting bolt 1 7 Engine mounting adjust bolt 2 8 Engine 1 For assembly reverse the removal proce dure ...

Page 256: ...ng nuts NOTE Do not fully tighten the bolts and nuts 6 Install Left front engine mounting bolt 1 temporarily tighten Right front engine mounting bolt 1 2 temporarily tighten 7 Tighten Engine mounting adjust bolts NOTE Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mounting adjust bolts Right front engine mounting bolt 2 50 Nm 5 0 m kg 36 ft lb Engine mounting a...

Page 257: ... then tighten the upper self locking nut 9 Tighten Left front engine mounting bolt 1 Right front engine mounting bolt 1 2 Upper self locking nut 51 Nm 5 1 m kg 37 ft lb Lower self locking nut 51 Nm 5 1 m kg 37 ft lb Left front engine mounting bolt 45 Nm 4 5 m kg 33 ft lb Right front engine mounting bolt 1 45 Nm 4 5 m kg 33 ft lb ...

Page 258: ...ssembly Refer to THROTTLE BODIES on page 7 4 Radiator assembly Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 12 1 Ignition coil 4 2 Spark plug 4 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Timing chain guide top side 1 6 Cylinder identification sensor 1 7 O ring 1 For assembly reverse the removal proce dure ...

Page 259: ...sprocket bolt 4 Loosen 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 3 5 Dowel pin 6 Refer to REMOVING THE CAMSHAFTS on page 5 11 6 Exhaust camshaft cap 3 7 Dowel pin 6 Refer to REMOVING THE CAMSHAFTS on page 5 11 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Camshaft sprocket 2 For assembly reverse the removal proce dure ...

Page 260: ... TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Remove Timing chain tensioner 1 Gasket 5 Remove 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 cross pattern working from the outside in 6 Remove...

Page 261: ...ft caps NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 Camshaft lobe dimension limit Intake camshaft a 32 50 32 60 mm 1 280 1 284 in Limit 32 40 mm 1 276 in...

Page 262: ...h wear a Replace the camshaft sprockets and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing chain guide exhaust side 1 Timing chain guide intake side 2 Timing chain guide top side 3 Damage wear Replace the defective part s EAS23960 CHECKING THE TIMING CHAIN TEN SIONER 1 Remov...

Page 263: ...hain tensioner spring and timing chain tensioner rod 1 b Squeeze the timing chain tensioner clip 2 and push the timing chain tensioner rod 3 NOTE When the timing chain tensioner rod 3 is pushed while holding the grip of the timing chain tensioner clip 2 make sure not to release the timing chain tensioner rod 3 before releasing the timing chain tensioner clip 2 Otherwise the timing chain tensioner ...

Page 264: ...ed NOTE Make sure the punch mark a on each cam shaft faces up 4 Install Dowel pins Intake camshaft caps Exhaust camshaft caps NOTE Make sure each camshaft cap is installed in its original place Refer to the identification marks as follows I Intake side camshaft cap mark E Exhaust side camshaft cap mark L Left side camshaft cap mark R Right side camshaft cap mark Make sure the arrow mark a on each ...

Page 265: ...cap arrow mark b 8 Install Gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 CAUTION ECA5D01011 The arrow mark a on the timing chain ten sioner should face up WARNING EWA5D01008 Always use a new gasket 9 Turn Crankshaft several turns clockwise 10 Check T mark a Make sure the T mark on the pickup rotor is aligned with the crankcase mating surface b Camshaft punch mark c Make sure the p...

Page 266: ...CAMSHAFTS 5 17 11 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 12 Install Pickup coil rotor cover CRANKSHAFT POSITION SENSOR on page 5 37 ...

Page 267: ...r to ENGINE REMOVAL on page 5 1 Intake camshaft Refer to CAMSHAFTS on page 5 9 Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 4 Coolant pipe 1 5 O ring 1 6 Thermo wax outlet hose 1 7 Right front engine mounting bolt 2 1 For assembly reverse the removal proce dure ...

Page 268: ...age scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder 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 th...

Page 269: ... 14 ft lb with a torque wrench and then tighten the 67 Nm 6 7 m kg 48 ft lb Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages 5 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAM SHAFTS on page 5 15 Cylinder head nut 1st 19 Nm 1 9 m kg 14 ft lb Cylinder head nut 2nd 67 Nm 6 7 m ...

Page 270: ...3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve stem seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve stem seal 8 16 Exhaust valve lower spring seat 8 17 ...

Page 271: ...VALVES AND VALVE SPRINGS 5 22 For installation reverse the removal proce dure Removing the valves and valve springs Order Job Parts to remove Q ty Remarks ...

Page 272: ...SEATS on page 5 25 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 spring with the valve spring compressor 2 and the valve spring compressor attach ment 3 4 Remove Upper spring seat 1 Valve spring 2 Valve stem seal 3 Lo...

Page 273: ...Remove the valve guide with the valve guide 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 ...

Page 274: ...300 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate 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 cylin der head Intake Valve guide remover ø4 90890 04111 YM 04111 Exhaust Valve guide remover ø4 5 90890 04116 YM 04116...

Page 275: ...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 the valve seat while rotating the valve back and forth b...

Page 276: ...ce the valve spring 2 Measure Compressed valve spring force a Out of specification Replace the valve spring 3 Measure Valve spring tilt a Out of specification Replace the valve spring Valve spring free length Intake valve spring 40 5 mm 1 60 in Limit 38 5 mm 1 47 in Exhaust valve spring 40 5 mm 1 60 in Limit 38 5 mm 1 47 in Compressed valve spring force installed Intake valve spring 127 4 144 6 N ...

Page 277: ... recommended lubricant 3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Refer to the following embossed marks Right and left intake valve s 5VY Middle intake valve s 5VY Exhaust valve s 5VY Install the valve springs with the larger pitch a facing up 4 Install Valve cotters...

Page 278: ...r 2 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 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter YM 04114 Valve spring compressor attachment 90890 04108...

Page 279: ...EL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Stator coil assembly lead coupler 1 Disconnect 2 Plug 1 3 Generator rotor cover 1 4 Gasket 1 5 Dowel pin 2 6 Generator rotor assembly 1 7 Stator coil assembly 1 8 Dowel pin 2 9 Bearing housing 1 10 Collar 1 11 Bearing 1 12 Stator coil assembly lead holder 1 13 Idler gear 1 14 Idler gear shaft 1 ...

Page 280: ...GENERATOR 5 31 15 Washer 1 16 Bearing 1 For assembly reverse the removal proce dure Removing the generator Order Job Parts to remove Q ty Remarks ...

Page 281: ...er all of the bolts are fully loosened remove them 2 Remove Generator rotor and starter clutch assem bly 1 3 Remove Idle gear shaft bolt 1 Idle shaft Idle gear 2 EAS24500 INSTALLING THE GENERATOR 1 Install Idle gear shaft Idle gear 1 Washer Idle gear shaft bolt 2 2 Install Generator rotor and starter clutch assem bly 1 3 Install Generator rotor cover gasket Generator rotor cover 1 Idle gear shaft ...

Page 282: ...en the M8 bolts and then tighten the M6 bolts Tighten the generator rotor cover bolts in stages and in a crisscross pattern Generator rotor cover bolt M6 12 Nm 1 2 m kg 8 7 ft lb Generator rotor cover bolt M8 22 Nm 2 2 m kg 16 ft lb ...

Page 283: ...H Removing the starter clutch Order Job Parts to remove Q ty Remarks 1 Generator rotor 1 2 Damper 3 3 Driven gear 1 4 Washer 1 5 Starter clutch drive gear 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 O ring 1 For assembly reverse the removal proce dure ...

Page 284: ...e wear Replace EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Install the starter clutch drive gear 1...

Page 285: ...kwise B it should turn freely other wise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Generator rotor 1 Damper 2 Driven gear 3 NOTE The hole side of the damper is installed to the generator side Lubricate the engine oil 4 2 Install Starter clutch drive gear 1 Collar 2 Washer 3 Refer to CHECKING THE STARTER CLUTCH on page 5 35 3 Install Washer 1...

Page 286: ...ider and passenger seat 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 12 1 Crankshaft position sensor lead coupler 1 Disconnect 2 Crankshaft position sensor 1 3 O ring 1 4 Pickup rotor cover 1 5 Gasket 1 6 Cover 1 For assembly reverse the removal proce dure ...

Page 287: ... each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Gasket Pickup rotor cover 1 O ring Crankshaft position sensor 2 Connect Crankshaft position sensor lead coupler Pickup rotor cover 12 Nm 1 2 m kg 8 7 ft lb Crankshaft position sensor bolt 10 Nm 1 0 m kg 7 2 ft lb...

Page 288: ... Job Parts to remove Q ty Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 2 Starter motor 1 For assembly reverse the removal proce dure ...

Page 289: ...r Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 O ring 2 8 Starter motor lead 2 9 Brush holder 1 10 Rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 290: ...d 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 Commutator wear limit 27 0 mm 1 06 in Mica...

Page 291: ... 3 Install Starter motor yoke 1 O rings 2 Starter motor rear cover 3 Starter motor assembling bolts NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor bolts 2 2 Connect Starter motor lead 3 Starter motor assembling bolt 5 Nm 0 5 m kg 3 6 ft lb New Star...

Page 292: ...h cover Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Clutch cable 1 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 For installation reverse the removal proce dure ...

Page 293: ... Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal proce dure ...

Page 294: ...ng 1 5 Friction plate 1 1 6 Clutch plate 1 7 7 Friction plate 2 7 8 Wire circlip 1 9 Clutch plate 2 1 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Clutch boss nut 1 14 Washer 1 15 Clutch boss assembly 1 16 Thrust plate 1 17 Clutch housing 1 18 Bearing 1 For assembly reverse the removal proce dure ...

Page 295: ...emove Compression spring bolts 1 Compression springs Pressure plate 2 Pull rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 5 Straighten the clutch boss nut rib 1 6 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut 7 Remove Clutch boss nut Washer Clutch boss assembly Universal clutch holder 90890...

Page 296: ...the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric tion plates as a set NOTE Measure the friction plate at four places EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measur...

Page 297: ...rr 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 housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause erratic clutch operation EAS25170 CHECKING...

Page 298: ... 1 Install Clutch damper spring seat 1 Clutch damper spring 2 2 Install Friction plate 3 1 Clutch plate 2 2 NOTE Lubricate the engine oil 3 Install Wire circlip 1 4 Install Clutch housing 1 NOTE Align the projection of clutch housing a and hollow of the oil pump drive gear b 5 Install Thrust plate Clutch boss assembly 1 Washer Clutch boss nut 2 NOTE Install the washer on the main axle with the OUT...

Page 299: ...lates Clutch plates with the recommended lubricant 7 Install Friction plate 2 Clutch plate 1 1 8 Install Friction plate 1 1 NOTE Install the last friction plate shifting half phase 9 Install Bearing Pull rod 1 Pressure plate 2 Clutch springs Clutch spring bolts 3 NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern Universal clutch holder 90890 04086 YM 91042 Recommended lubr...

Page 300: ...sh 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 lever shaft pinion gear are engaged Tighten the clutch cover bolts in stages and in a crisscross pattern 12 Tighten Clutch cover bolts 1 Clutch cover bolt 2 NOTE Tighten the clutch cover bolts in a stages and in a crisscross pattern 13 Adjust Clu...

Page 301: ...y Refer to CLUTCH on page 5 43 Shift arm and shift rod Refer to ENGINE REMOVAL on page 5 1 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Collar 1 5 Shift shaft spring 1 6 Washer 1 7 Stopper screw 1 8 Stopper lever 1 9 Washer 1 10 Oil seal 1 11 Bearing 1 12 Bearing 1 13 Stopper lever spring 1 For installation reverse the removal proce dure ...

Page 302: ...lar Washer 5 Remove Stopper lever spring 1 Stopper screw 2 Stopper lever 3 Washer EAS25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift shaft spring 2 Collar 3 Damage wear Replace EAS25430 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Bends damage Replace Roller turns roughly Replace the stop per lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Washer Stop...

Page 303: ... with the shift drum segment assembly Lubricate the oil seal lips with lithium soap base grease Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install Washer 1 Circlip 2 4 Install Shift rod Shift arm Refer to ENGINE REMOVAL on page 5 1 5 Install Clutch assembly Refer to CLUTCH on page 5 43 New ...

Page 304: ... page 5 1 Muffler Refer to ENGINE REMOVAL on page 5 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Clutch assembly Refer to CLUTCH on page 5 43 Water pump inlet pipe Refer to OIL COOLER on page 6 3 Water pump outlet pipe Refer to OIL COOLER on page 6 3 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 Do...

Page 305: ...y drive chain guide 1 13 Collar 1 14 Oil water pump assembly drive sprocket 1 15 Washer 1 16 Oil water pump assembly drive chain 1 17 Dowel pin 1 18 Oil water pump assembly 1 For assembly reverse the removal proce dure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 306: ... pump Order Job Parts to remove Q ty Remarks 1 Oil water pump driven sprocket 1 2 Collar 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For assembly reverse the disassembly pro cedure ...

Page 307: ...assembly drive chain and oil water pump assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Oil pump rotor housing 2 Oil pump cover Cracks damage wear Replace the defective part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clear ance b 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the d...

Page 308: ...RAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent EAS25600 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Oil nozzle 1 Damage wear Replace the oil nozzles 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 w...

Page 309: ...mp assembly drive chain 1 Oil water pump assembly drive sprocket 2 Collar NOTE Install the oil water pump assembly drive chain 1 onto the oil water pump assembly drive sprocket 2 CAUTION ECA5D01016 After installing the oil water pump assem bly drive chain and drive sprocket make sure the oil water pump turns smoothly 3 Install Oil water pump assembly drive chain guide 1 NOTE UP mark of the oil wat...

Page 310: ...rain bolt 3 WARNING EWA12820 Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil Oil delivery pipe bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE Oil strainer bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE New New New New Oil pan bolt 12 Nm 1 2 m kg 8 7 ft lb Oil level switch bolt 10 Nm 1 0 m kg 7 2 ft lb Engine oil...

Page 311: ...EAD on page 5 18 Generator Refer to GENERATOR on page 5 30 Starter clutch Refer to STARTER CLUTCH on page 5 34 Shift shaft Refer to SHIFT SHAFT on page 5 52 Crankshaft position sensor Refer to CRANKSHAFT POSITION SEN SOR on page 5 37 Clutch Refer to CLUTCH on page 5 43 Oil pump Refer to OIL PUMP on page 5 55 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Timing chain 1 2 Timing chain guide...

Page 312: ...CRANKCASE 5 63 7 Lower crankcase 1 8 Dowel pin 3 9 Damper 1 For assembly reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 313: ...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 gasket surfaces and crankcase ...

Page 314: ... 22 Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase M9 x 105 mm 4 1 in bolts 1 10 M8 x 60 mm 2 4 in bolt 11 LOCTITE M8 x 60 mm 2 4 in bolts 12 16 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 65 mm 2 5 in bolts 17 18 M6 x 60 mm 2 4 in bolt and washer 22 M6 x 60 mm 2 4 in bolts 24 25 M6 x 50 mm 2 0 in bolts 20 26 M8 x 50 mm 2 0 in bolts 13 15 Following the tightening order l...

Page 315: ...rks Lower crankcase Refer to CRANKCASE on page 5 62 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 11 Cylinder 1 12 Cylinder gasket 1 For installation reverse the removal proce dure ...

Page 316: ...SE on page 5 62 Connecting rod and connecting rod caps Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 68 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Washer 1 5 Crankshaft drive gear 1 6 Pin 1 7 Pickup rotor 1 For assembly reverse the disassembly pro cedure ...

Page 317: ...n 3 CAUTION ECA5D01020 Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are debarred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 4 Remove Top ring 2nd ring Oil ...

Page 318: ...ecification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with 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 cl...

Page 319: ...n grooves Replace the piston pin and then check the lubrica tion 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 pis ton Piston ring side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 mm 0 0045 in ...

Page 320: ...ing 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 with molybdenum disulfide greas...

Page 321: ...chined face a Thrusting faces 4 places at front and rear 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 ...

Page 322: ... 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 68 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 crank s...

Page 323: ...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 Connecting rod big end inner surface with the recom...

Page 324: ...rod bolts c After installing the big end bearing assem ble the connecting rod and connecting rod cap once using a single unit of the connect ing rod d Tighten 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 o...

Page 325: ...ning angle method a Clean the connecting rod bolts b Tighten the connecting rod bolts c Put a mark 1 on the connecting rod bolt 2 and the connecting rod cap 3 d Tighten the bolt further to reach the speci fied angle 150 e After the installation check that the section shown a is flush with each other by touch ing the surface WARNING EWA13990 When the bolt is tightened more than the specified angle ...

Page 326: ...OURNAL BEARINGS 1 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA5D01021 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must be installed in their original positio...

Page 327: ...2 16 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 65 mm 2 5 in bolts 17 18 M6 x 60 mm 2 4 in bolt and washer 22 M6 x 60 mm 2 4 in bolts 24 25 M6 x 50 mm 2 0 in bolts 20 26 M8 x 50 mm 2 0 in bolts 13 15 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque NOTE Lubricate the crankcase bolt threads with engine oil Refer to CRANKCASE on page 5 62 g Remove the...

Page 328: ...ngs 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 then the bearing size for J1 is EAS26200 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bearings 1 into the upper crankcase 2 Lubricate Crankshaft journal upper bearings with the recommended lubric...

Page 329: ...ith the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 3 Install Crankshaft 4 Install Crankcase lower Refer to CRANKCASE on page 5 62 5 Install Pin Pickup rotor 1 Drive sprocket 2 Drive sprocket bolt 60 Nm 6 0 m kg 43 ft lb ...

Page 330: ... Separate Refer to CRANKCASE on page 5 62 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Washer 1 6 Shift fork guide bar retainer 2 7 Spring 2 8 Shift fork guide bar 2 9 Shift fork L 1 10 Shift fork R 1 11 Shift drum assembly 1 12 Shift fork C 1 13 Main axle retainer 1 14 Main axle assembly 1 15 Oil pipe 1 16 O ring 2 17 Oil baffle plate 1 ...

Page 331: ...TRANSMISSION 5 82 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks ...

Page 332: ...d pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 333: ... Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 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 Collar 1 19 2nd wheel gear 1 20 Collar 1 21 Oil seal 1 22 Bearing 1 23 Drive axle 1 ...

Page 334: ...TRANSMISSION 5 85 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks ...

Page 335: ... Tighten the bolts until they contact the crankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil pipe 1 Bearing 2 EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork g...

Page 336: ... 3 Damage pitting Replace the shift drum assembly EAS26280 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure Drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Tra...

Page 337: ...ft forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle 3 Install Shift fork L 1 and R 2 Drive axle assembly 3 Shift fork guide bar Shift fork guide bar retainer 4 NOTE Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive a...

Page 338: ...TRANSMISSION 5 89 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly ...

Page 339: ...ER 6 3 CHECKING THE OIL COOLER 6 4 INSTALLING THE OIL COOLER 6 4 THERMOSTAT 6 5 CHECKING THE THERMOSTAT 6 7 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 10 ...

Page 340: ...r case Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Radiator side covers 2 2 Coolant reservoir hose 1 3 Radiator front cover 1 4 Radiator 1 5 Radiator fan motor 2 6 Radiator inlet hose 1 7 Oil cooler outlet hose 1 8 Water pump breather hose 1 9 Radiator outlet hose 1 10 Water pump inlet pipe 1 11 O ring 1 For installation reverse the removal proce...

Page 341: ...d make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to RADIATOR on page 6 1 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 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure Below the...

Page 342: ...l Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 3 Washer 1 4 Oil cooler 1 5 O ring 1 6 Water pump outlet pipe 1 7 O ring 1 8 Water jacket joint inlet hose 1 9 O ring 1 10 Water jacket joint 1 11 Stay 1 12 O ring 1 For assembly reverse the removal proce dure ...

Page 343: ...d O ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the crankcase 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 12 4 Check Co...

Page 344: ...er 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 19 1 Thermostat assembly outlet hose 1 2 Thermostat assembly 1 3 Thermostat assembly inlet hose 1 4 Band 2 For installation reverse the removal proce dure ...

Page 345: ...AT 6 6 Disassembling the thermostat assembly Order Job Parts to remove Q ty Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 4 O ring 1 For assembly reverse the disassembly pro cedure ...

Page 346: ...use seri ous overheating or over cooling 2 Check Thermostat housing cover 1 Thermostat housing 2 Cracks damage Replace EAS26460 ASSEMBLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 NOTE Install the thermostat with its breather hole a facing up EAS26480 INSTALLING THE THERMOSTAT ASSEM BLY 1 Fill Cooling system with the specified amount ...

Page 347: ...THERMOSTAT 6 8 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 ...

Page 348: ...Remarks Oil water pump assembly Refer to OIL PUMP on page 5 55 Oil pump rotor Refer to OIL PUMP on page 5 55 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8 O ring 1 For installation reverse the removal proce dure ...

Page 349: ...lat head screwdriver NOTE Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller 3 Rubber damper 4 Rubber damper holder 5 Water pump seals Oil seal Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil se...

Page 350: ...ore 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 Mechanical seal installer 4 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 5 90890 04058 Bearing driver 40 mm ...

Page 351: ... THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 7 CHECKING THE THROTTLE BODIES 7 7 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 ADJUSTING THE SUB THROTTLE POSITION SENSOR 7 8 CHECKING THE SUB THROTTLE SERVO MOTOR 7 10 CHECKING THE THERMO WAX 7 10 ADJUSTING THE THERMO WAX 7 10 AIR INDUCTION SYSTEM 7 12 CHECKING THE AIR INDUCTION SYSTEM 7 13 INSTALLING THE AIR INDUCTION SY...

Page 352: ...enger seat Refer to GENERAL CHASSIS on page 4 1 1 Fuel hose 1 Disconnect 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank breather hose 1 Disconnect 6 Fuel tank 1 7 Fuel tank cover 1 8 Fuel pump 1 For installation reverse the removal proce dure ...

Page 353: ...ectly under the 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 fa...

Page 354: ...properly installed 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 whi...

Page 355: ...lter case Refer to GENERAL CHASSIS on page 4 1 1 Sub wire harness coupler 2 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Thermo wax inlet hose 1 Disconnect 4 Thermo wax outlet hose 1 Disconnect 5 Idle adjust screw wire 1 6 Throttle body joint clamp 4 Loosen 7 Throttle bodies 1 8 Throttle cables 2 Disconnect 9 Throttle body joint 4 10 Fuel hose 1 Disconnect For installation revers...

Page 356: ...isconnect 5 Cylinder 1 injector coupler 1 Disconnect 6 Cylinder 2 injector coupler 1 Disconnect 7 Cylinder 3 injector coupler 1 Disconnect 8 Cylinder 4 injector coupler 1 Disconnect 9 Sub wire harness 1 10 Negative pressure hose 1 Disconnect 11 Intake air pressure sensor 1 12 Fuel distributor 1 13 Injector 4 14 Spring 1 15 Thermo wax assembly 1 16 Idle adjust screw wire 1 17 Link cover 1 Loosen 18...

Page 357: ...THROTTLE BODIES 7 6 22 Throttle position sensor 1 23 Throttle body assembly 1 For installation reverse the removal proce dure Removing the injectors Order Job Parts to remove Q ty Remarks ...

Page 358: ...l hose fuel tank to pri mary injector fuel rail 1 from the primary injector fuel rail WARNING EWA5D01002 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 2 and adapter 3 to the fuel hose fuel tank to pri mary injector fuel rail d Start the engine e Measure the fue...

Page 359: ...ockwise until it con tacts with the full open stopper b When the dimension of a sections of the throttle bodies 3 and 4 is measured with a micrometer caliper adjust with the adjuster 2 of the output shaft section of the sub throttle servo motor so that the dimension is in a range from 24 2 to 24 6 mm 0 95 to 0 97 in c After adjusting the dimension of a sec tions of the throttle bodies 3 and 4 mea ...

Page 360: ...voltage tighten the sub throttle position sensor screws NOTE After setting up the sub throttle position sen sor check that the sub throttle position sen sor output voltage is 0 4 V or more with the nut of worm shaft turned to the full close side until it stops When the sub throttle position sensor output voltage is 0 4 V or more check that the sub throttle position sensor output voltage is 4 6 V o...

Page 361: ...he seizure of sub throttle valve body itself When it moved smoothly at Step 1 and 2 replace the sub throttle servo motor b Perform the self diagnosis mode and check the operation of sub throttle valve by visual inspection Code No 56 The operation should be carried out as 5 second drive in the full open direction 2 second stop and 5 second drive in the full close direction EAS5D01012 CHECKING THE T...

Page 362: ...the coolant tem perature around 60 C 140 F by idling If the first idling is not released around 60 C 140 F make sure to set it again When the coolant temperature is low adjust the dis tance between the end faces longer or adjust it shorter when the coolant temperature is high In case of turning the adjusting bolt two third turn the temperature varies about 10 C 50 F ...

Page 363: ... Job Parts to remove Q ty Remarks 1 Air cut off valve coupler 1 Disconnect 2 Air cut off valve hose 1 1 Disconnect 3 Air cut off valve hose 2 1 Disconnect 4 Air cut off valve hose 3 1 Disconnect 5 Air cut off valve 1 6 Reed valve cap 2 7 Reed valve assembly 2 8 Plate 4 For assembly reverse the removal proce dure ...

Page 364: ...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 valve stopper Reed valve seat Cracks damage Replace...

Page 365: ...ation Replace EAS27070 INSTALLING THE AIR INDUCTION SYSTEM 1 Install Plate Reed valve assembly Reed valve cap 2 Install Air cut off valve Air cut off valve hose 1 Air cut off valve hose 2 Air cut off valve hose 3 Air cut off valve coupler Air induction system solenoid resistance 18 22Ω at 20 C 68 F ...

Page 366: ...AIR INDUCTION SYSTEM 7 15 ...

Page 367: ...1 CIRCUIT DIAGRAM 8 21 TROUBLESHOOTING 8 23 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 TROUBLESHOOTING 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 37 SELF DIAGNOSTIC FUNCTION TABLE 8 38 TROUBLESHOOTING METHOD 8 41 DIAGNOSTIC MODE 8 42 TROUBLESHOOTING DETAILS 8 50 FUEL PUMP SYSTEM 8 75 CIRCUIT DIAGRAM 8 75 TROUBLESHOOTING 8 77 IMMOBILIZER S...

Page 368: ...NCTION TEST 8 129 D 6 FINAL CHECK 8 130 ELECTRICAL COMPONENTS 8 131 CHECKING THE SWITCHES 8 135 CHECKING THE BULBS AND BULB SOCKETS 8 138 CHECKING THE FUSES 8 139 CHECKING AND CHARGING THE BATTERY 8 140 CHECKING THE RELAYS 8 142 CHECKING THE ABS MOTOR RELAY 8 144 CHECKING THE SOLENOID VALVES AND MOTOR 8 145 CHECKING THE TURN SIGNAL HAZARD RELAY 8 146 CHECKING THE RELAY UNIT DIODE 8 146 CHECKING TH...

Page 369: ...CHECKING THE INTAKE AIR PRESSURE SENSOR 8 156 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 156 ...

Page 370: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 371: ...circuit cut off relay 14 Neutral switch 15 Sidestand switch 17 Crankshaft position sensor 21 Lean angle sensor 23 ECU engine control unit 24 Ignition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 Ignition coil 4 28 Spark plug 56 Engine stop switch 60 Clutch switch 78 Ignition fuse ...

Page 372: ... 140 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 10 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 147 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 147 Replace the ignition coils 6 Check the cranksh...

Page 373: ...WITCHES on page 8 135 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the clutch switch 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 142 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 149 Replace the lean angle sensor 14 Check the entire igniti...

Page 374: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 375: ...6 1 Main switch 6 Main fuse 7 Battery 9 Starter relay 10 Starter motor 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Sidestand switch 56 Engine stop switch 57 Start switch 60 Clutch switch 78 Ignition fuse ...

Page 376: ...sed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay 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 h...

Page 377: ...SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor ...

Page 378: ... 8 140 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 150 Replace the starter motor 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 41 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 142 Rep...

Page 379: ... SWITCHES on page 8 135 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the right handlebar switch 14 Check the entire starting system s wir...

Page 380: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 381: ...CHARGING SYSTEM 8 12 2 Rectifier regulator 3 AC magneto 6 Main fuse 7 Battery ...

Page 382: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 140 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 150 Replace the stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 150 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT D...

Page 383: ...CHARGING SYSTEM 8 14 ...

Page 384: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM FZ1 N X ...

Page 385: ...7 Battery 23 ECU engine control unit 49 High beam indicator light 52 Meter light 61 Pass switch 62 Dimmer switch 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight relay on off 77 Taillight fuse 81 Headlight fuse ...

Page 386: ...LIGHTING SYSTEM 8 17 EAS5D01027 CIRCUIT DIAGRAM FZ1 S X ...

Page 387: ...ECU engine control unit 49 High beam indicator light 52 Meter light 61 Pass switch 62 Dimmer switch 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight relay on off 77 Headlight relay dimmer 78 Taillight fuse 82 Headlight fuse ...

Page 388: ... Refer to CHECKING THE FUSES on page 8 139 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 140 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the immobilizer kit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 135 The dimmer switch is faulty Repla...

Page 389: ...2 Replace the headlight relay 9 Check the headlight relay dimmer FZ1 S W FZ1 SA Refer to CHECKING THE RELAYS on page 8 142 Replace the headlight relay 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM FZ1 N X on page 8 15 Properly connect or repair the lighting system s wiring This circuit is OK ...

Page 390: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 391: ...Coolant temperature indicator light 50 Left turn signal indicator light 51 Right turn signal indicator light 53 Oil level switch 55 Front brake light switch 58 Rear brake light switch 63 Hazard switch 64 Turn signal switch 65 Horn switch 66 Horn 67 Turn signal hazard relay 68 Front left turn signal light 69 Front right turn signal light 70 Rear left turn signal light 71 Rear right turn signal ligh...

Page 392: ...to CHECKING THE FUSES on page 8 139 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 140 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the immobilizer kit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair t...

Page 393: ...brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the rear brake light switch 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system ...

Page 394: ...turn signal hazard relay 5 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the neutral switch 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair the si...

Page 395: ...ender Refer to CHECKING THE FUEL SENDER on page 8 151 Replace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 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 8 152 Replace the speed sensor 2 Check the entire signaling system s wiring Refer to CI...

Page 396: ...COOLING SYSTEM 8 27 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 397: ...in fuse 7 Battery 23 ECU engine control unit 38 Coolant temperature sensor 78 Ignition fuse 82 Radiator fan motor relay 83 Left radiator fan motor fuse 84 Right radiator fan motor fuse 85 Left radiator fan motor 86 Right radiator fan motor ...

Page 398: ...heck the main switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the immobilizer kit 4 Check the radiator fan motor left and right Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 152 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 142 Replace the radiator fan motor relay 6 Check the coolant temperature R...

Page 399: ...COOLING SYSTEM 8 30 ...

Page 400: ...FUEL INJECTION SYSTEM 8 31 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 401: ...sor 19 Speed sensor 20 Atmospheric pressure sensor 21 Lean angle sensor 22 O2 sensor 23 ECU engine control unit 24 Ignition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 Ignition coil 4 28 Spark plug 29 Injector 1 30 Injector 2 31 Injector 3 32 Injector 4 34 Sub throttle position sensor 35 EXUP servo motor 36 Intake air pressure sensor 37 Throttle position sensor 38 Coolant temperature sensor 39...

Page 402: ...RGING THE BATTERY on page 8 140 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 10 Re gap or replace the spark plugs 4 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 147 Replace the ignition coils 5 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITION SEN SOR on page...

Page 403: ... SWITCHES on page 8 135 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 142 Replace the relay unit 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 149 Replace the lean angle sensor 15 Check the ...

Page 404: ... the throttle position sensor 20 Check the sub throttle position sensor Refer to CHECKING THE SUB THROTTLE POSITION SENSOR on page 8 154 Replace the sub throttle position sen sor 21 Check the intake air pressure sen sor Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 156 Replace the intake air pressure sensor 22 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERA...

Page 405: ...FUEL INJECTION SYSTEM 8 36 NG OK 24 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition system s wiring Replace the ECU ...

Page 406: ... tripmeter fuel reserve tripmeter LCD Once a fault code has been 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 the engine trouble warning light The engine trouble warning light comes on fo...

Page 407: ...ing driven Unable Able 12 Crankshaft position sensor No normal signals are received from the crankshaft position sensor 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 hose line piping system Intake air pressure sensor faulty intake air pressure sensor system Able Able 15 Throttle po...

Page 408: ...1 ignition coil open circuit detected Able depend ing on the num ber of faulty cylin ders Able depend ing on the num ber of faulty cylin ders 34 Cylinder 2 ignition coil open circuit Primary lead of the cylinder 2 ignition coil open circuit detected Able depend ing on the num ber of faulty cylin ders Able depend ing on the num ber of faulty cylin ders 35 Cylinder 3 ignition coil open circuit Prima...

Page 409: ...ring voltage Power supply to the fuel injection system is not normal Able Able 47 Sub throttle servo motor potention open or short circuit sub throttle servo motor potention open or short circuit detected Able Able 48 Sub throttle servo motor lock A lock of the sub throttle servo motor is detected Able Able 50 ECU internal malfunc tion memory check error ECU memory is faulty When this mal function...

Page 410: ...ng sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation table Er 2 ECU internal malfunc tion output signal error No signals are received from the ECU within the specified duration Unable Unable Er 3 ECU internal malfunc tion output signal error Data from the ECU cannot be received correctly Unable Unable Er 4 ECU internal malfunc tion input signal err...

Page 411: ... tripmeter LCD 4 Press the SELECT button to select the diagnostic mode dI 5 After selecting dI simultaneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode The diagnostic code number d01 appears on the clock LCD 6 Set the engine stop switch to 7 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET butto...

Page 412: ...n ECU 13 Intake air pressure sensor open or short circuit detected Open or short circuit in wire harness Open or short circuit in sub wire harness Defective intake air pressure sensor Malfunction in ECU 03 14 Intake air pressure sensor faulty intake air pressure sensor system Intake air pressure sensor hose is detached clogged kinked or pinched Malfunction in ECU 03 15 Throttle position sensor ope...

Page 413: ...ire harness Defective atmospheric pressure sensor Improperly installed atmospheric pressure sensor Malfunction in ECU 02 24 No normal signal is received from the O2 sen sor Open or short circuit in wire harness Defective O2 sensor Improperly installed O2 sensor Malfunction in ECU 30 No normal signal is received from the lean angle sensor Vehicle has overturned Defective lean angle sensor Improperl...

Page 414: ...e harness Malfunction in ECU 09 44 An error is detected while reading or writing on EEPROM CO adjustment value Malfunction in ECU The CO adjustment value is not properly written on or read from the internal memory 60 46 Power supply to the fuel injection system relay is not normal Malfunction in the charging system Refer to CHARGING SYSTEM on page 8 11 47 Sub throttle servo motor potention circuit...

Page 415: ...c pressure Compare the actually mea sured atmospheric pres sure with the meter display value 03 Intake air pressure Displays the cylinder 1 intake air pressure Set the engine stop switch to then operate the throttle while pushing the start switch If the dis play value changes the performance is OK 05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured air tem...

Page 416: ...e the display changes every two seconds to show all the detected cyl inder numbers When all cylinder numbers are shown the display repeats 61 Malfunction history code No history 00 History exists Fault codes 11 50 If more than one code number is detected the dis play changes every two seconds to show all the detected code numbers When all code numbers are shown the display repeats 62 Malfunction h...

Page 417: ...nd intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 32 Cylinder 3 ignition coil Actuates the cylinder 3 igni tion coil five times at one sec ond intervals Illuminates the engine trou ble warning light Check the spark five times Connect an ignition checker 33 Cylinder 4 ignition coil Actuates the cylinder 4 igni tion coil five times at o...

Page 418: ... trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel injection system relay five times 51 Radiator fan motor relay Actuates the radiator fan motor relay five times at one second intervals ON 2 sec onds OFF 3 seconds Illuminates the engine trou ble warning light Che...

Page 419: ... Fault code No 11 Symptom No normal signals are received from the cylinder identi fication sensor when the engine is started or while the vehicle is being driven Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of cylinder identifi cation sensor Check for looseness or pinching Starting the engine and operate it at idle ...

Page 420: ...rankshaft position sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may have pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft posi tion sensor coupler and ECU coupler Gray Gr...

Page 421: ...Blue Blue 3 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 156 Fault code No 14 Symptom Intake air pressure sensor faulty intake air pressure sensor system Diagnostic code No 03 Intake air pressure sensor Order Item components and probable cause Check or maintenance job Reinstatement method...

Page 422: ...ed out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler Black Blue Black Blue Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open circuit output voltage check Check for o...

Page 423: ...ction Fault code No 17 Symptom EXUP servo motor circuit open or short circuit detected Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EXUP servo motor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfu...

Page 424: ...ERVO MOTOR on page 3 18 4 Defective EXUP valve pulley and cables Replace if defective Fault code No 19 Symptom Open circuit is detected in the input line of ECU No 24 ter minal is defected when the start switch is pressed Diagnostic code No 20 Sidestand switch Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Execute ...

Page 425: ...tom 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 Reinstatement method 1 Connections Coolant temperature sensor coupler Main wire harness ECU coupler Sub wire harness coupler Check the coupler for any pins that may be pulled out Check the locking condition of the couplers ...

Page 426: ...k the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler Brown White Brown White Black Blue Black Blue 3 ...

Page 427: ... Refer to CHECKING THE ATMOSPHERIC PRESSURE SENSOR on page 8 155 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 Reinstatement method 1 Installed state of O2 sensor Check for looseness or pinching Start and warm up the engine until the cool ant tempera ture rises over 60 C when accelerat i...

Page 428: ...defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 149 Fault code No 33 Symptom Open circuit detected in the primary lead of the cylinder 1 ignition coil Diagnostic code No 30 Cylinder 1 ignition coil Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 1 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler...

Page 429: ... that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 2 ignition coil coupler and ECU coupler Red Black Red Black Gray Red Gray Red 3 ...

Page 430: ...t may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler Red Black Red Black Orange Green Orange Gree...

Page 431: ...hat may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 4 ignition coil coupler and ECU coupler Red Black Red Black Gray Green Gray Green ...

Page 432: ...out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Start the engine and operating it at idle 2 Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between primary injector cou pler and ECU coupler Red Blue Red Blue 1 Red Black Red Black 2 Green Black Green Black 3 Blue...

Page 433: ... for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in lead Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler Blue Blue Yellow Green Yellow Green Black Blue Black Blue 3 Defective lean angle se...

Page 434: ...peed signals by operating the vehicle at a 20 to 30 km h A 2 Connections Speed sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely A 3 Open or short circuit in lead Repair or replace if there is an open or short circuit Between speed senso...

Page 435: ...tral switch coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely B 3 Open circuit in neutral switch lead Repair or replace if there is an open or short circuit Between neutral switch coupler and relay unit coupler Sky blue Sky blue Between relay u...

Page 436: ...ion of the couplers If there is a malfunction repair it and connect it securely Starting the engine and operating it at idle 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler Blue Yellow Blue Yellow Red Blue Red Blue Between relay unit coupler and battery terminal Red Red Between relay unit coupler and engine s...

Page 437: ...e Code No 60 to check the faulty cylinder number If multiple cylin ders are defective the numbers of the faulty cylin ders are displayed alter nately at 2 second intervals 2 Execute the CO adjust ment 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 VOL...

Page 438: ...r If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Faulty battery Replace or change the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 140 3 Malfunction in rectifier regulator 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 sh...

Page 439: ...ons Sub throttle position sensor coupler Main wire harness ECU coupler Sub wire harness coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sub throttle position sensor coup...

Page 440: ...t in wire harness Repair or replace if there is an open or short circuit Between sub throttle servo motor coupler and ECU coupler Yellow Red Yellow Red Yellow White Yellow White 3 Defective sub throttle servo motor Execute the diagnostic mode Code No 56 Replace if defective Refer to CHECKING THE SUB THROTTLE SERVO MOTOR on page 7 10 Fault code No 50 Symptom Faulty ECU memory When this malfunction ...

Page 441: ...lue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Sub wire harnes...

Page 442: ...lue Yellow Blue 3 Malfunction in meter assembly Replace the meter assembly 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 Reinstatement method 1 Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Sub wire harness ...

Page 443: ...FUEL INJECTION SYSTEM 8 74 ...

Page 444: ...FUEL PUMP SYSTEM 8 75 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 445: ...L PUMP SYSTEM 8 76 1 Main switch 6 Main fuse 7 Battery 8 Fuel injection system fuse 13 Fuel pump relay 16 Fuel pump 23 ECU engine control unit 46 Multi function meter 56 Engine stop switch 78 Ignition fuse ...

Page 446: ...8 140 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the immobilizer kit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 8 142 Replace the relay unit 6 Check the fuel pump...

Page 447: ...FUEL PUMP SYSTEM 8 78 ...

Page 448: ...IMMOBILIZER SYSTEM 8 79 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 449: ...IMMOBILIZER SYSTEM 8 80 1 Main switch 4 Backup fuse 5 Immobilizer unit 6 Main fuse 7 Battery 23 ECU engine control unit 41 Immobilizer indicator 46 Multi function meter 78 Ignition fuse ...

Page 450: ... NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key 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 i e 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 a...

Page 451: ...he immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration requirement Main switch immo bilizer unit Standard key ECU Acces sory loc...

Page 452: ...istration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 seconds insert the second standard key to be registered into the main switch NOTE If the immobilizer system indicator light stops flashing 5 seconds after the first standard ke...

Page 453: ... the memory thus dis abling the lost standard key To re register refer to Standard key registration Standard key code voiding method a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first stan dard key is registered the second ...

Page 454: ...Refer to CHECKING AND CHARGING THE BATTERY on page 8 140 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 135 Replace the immobilizer kit 4 Check the entire immobilizer sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 79 Properly connect or repair the immobi lizer system s wiring Check the condition of the each immobili...

Page 455: ...Unregistered sub key was used 1 Place the immo bilizer unit away more than 50 mm from the transponder of other vehicle 2 Register the standard key 53 IMMOBILIZER UNIT Cannot transmit code between the ECU and immobi lizer unit Noise interference or dis connected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnec tion of the communi cation harness 3 Immobilizer unit fail ure 4 ECU...

Page 456: ...to continu ously two times register Prepare the new standard key and register it 56 ECU Undefinition code is received Noise interference or dis connected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnec tion of the communi cation harness 3 Immobilizer unit fail ure 4 ECU failure 1 Check the wire harness and con nector 2 Replace the immobilizer unit 3 Replace the ECU Error code...

Page 457: ...IMMOBILIZER SYSTEM 8 88 ...

Page 458: ...ABS ANTI LOCK BRAKE SYSTEM 8 89 EAS28790 ABS ANTI LOCK BRAKE SYSTEM EAS27730 CIRCUIT DIAGRAM FZ1 SA ...

Page 459: ...relay 14 Neutral switch 46 Multi function meter 53 ABS warning light 56 Front brake light switch 57 Engine stop switch 58 Start switch 59 Rear brake light switch 76 Tail brake light 82 Signal fuse 84 ABS fuse 90 ABS ECU 91 ABS test coupler 92 Front wheel sensor 93 Rear wheel sensor 94 ABS motor relay 95 Hydraulic unit 96 ABS motor fuse ...

Page 460: ...W R B L B R R W Sb W Sb W W L Y B L W Y L B L Br Y B B B B4 B L B L B L L L L Br W Br W L B L B L R B B B B B2 B1 B2 B1 B B4 B B3 B B1 B B2 W W Lg Lg R G R G R G B L B L Sb Sb B Gy2 Y B2 Y L R Y B Gy B B L Gy Br R Br G B B1 W R R L W R W R R B B3 B B2 R G Y L Lg R W R B B L Y G L B L W L W G B G B R W B Y R W R R W R W W W R B B B B Br Br R W3 R W3 B G W B R L Y Y B B R R B L W R L B R B G B B G B...

Page 461: ...relay 14 Neutral switch 46 Multi function meter 53 ABS warning light 56 Front brake light switch 57 Engine stop switch 58 Start switch 59 Rear brake light switch 76 Tail brake light 81 Signal fuse 83 ABS fuse 89 ABS ECU 90 ABS test coupler 91 Front wheel sensor 92 Rear wheel sensor 93 ABS motor relay 94 Hydraulic unit 95 ABS motor fuse ...

Page 462: ...ABS ANTI LOCK BRAKE SYSTEM 8 93 EAS27740 ABS COMPONENTS CHART FZ1 SA ...

Page 463: ...I LOCK BRAKE SYSTEM 8 94 FZ1 SA 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 464: ...ABS ANTI LOCK BRAKE SYSTEM 8 95 FZ1 NA ...

Page 465: ...I LOCK BRAKE SYSTEM 8 96 FZ1 NA 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 466: ...ABS ANTI LOCK BRAKE SYSTEM 8 97 EAS27750 ABS CONNECTOR LOCATION CHART FZ1 SA ...

Page 467: ...ABS ANTI LOCK BRAKE SYSTEM 8 98 FZ1 SA 1 ABS ECU coupler 2 Front wheel sensor coupler 3 Rear wheel sensor coupler 4 Hydraulic unit coupler 5 ABS motor relay 6 ABS test coupler 7 Multi function coupler ...

Page 468: ...ABS ANTI LOCK BRAKE SYSTEM 8 99 FZ1 NA ...

Page 469: ...ABS ANTI LOCK BRAKE SYSTEM 8 100 FZ1 NA 1 Front wheel sensor coupler 2 Rear wheel sensor coupler 3 Hydraulic unit coupler 4 ABS ECU coupler 5 ABS motor relay 6 ABS test coupler 7 Multi function coupler ...

Page 470: ...r Job Parts to remove Q ty Remarks Right front cowling inner panel Refer to GENERAL CHASSIS on page 4 1 Under cover Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 50 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 471: ...ks Right front cowling inner panel Refer to GENERAL CHASSIS on page 4 1 Under cover Refer to ABS ANTI LOCK BRAKE SYS TEM on page 4 50 1 Rear fender lower cover 1 2 ABS motor relay 1 3 ABS motor relay coupler 1 Disconnect 4 ABS ECU 1 5 ABS ECU coupler 1 Disconnect For installation reverse the removal proce dure 3 4 2 1 ...

Page 472: ...NOTE Do not pull the ABS ECU leads to remove the ABS ECU couplers Always press on the locks 3 to disconnect the ABS ECU couplers from the ABS ECU Checking the ABS ECU 1 Check Terminals 1 of the ABS ECU Cracks damages Replace ABS ECU Terminals 2 of the ABS ECU coupler Connection defective contaminated come off Correct or clean NOTE If the ABS ECU couplers are clogged with mud or dirt clean with com...

Page 473: ... OF THE ABS MOTOR RELAY Removing the ABS motor relay 1 Remove ABS motor relay 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 ...

Page 474: ...g on extremely uneven roads Other defective Self diagnosis and services The ABS ECU has a self diagnostic function By utilizing this function quick and secure services are possible Previously occurred error phenomenon can be checked since it also installs the memory for storing malfunction history In case malfunctions are detected It is disabled to call the malfunction code by using the multi func...

Page 475: ...LESHOOTING WARNING EWA14030 Execute the troubleshooting on each malfunction from A to D in sequence Use the sufficiently charged regular batteries only A Malfunction check by the ABS warning light B Detail check of malfunction Results by self diagnosis are displayed by the multi function display or a pocket tester according to the ECU s operation C Supposing the malfunction cause and position Find...

Page 476: ...ABS ANTI LOCK BRAKE SYSTEM 8 107 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...

Page 477: ...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 478: ...nction diagnostic mode when the 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 suffic...

Page 479: ...ht comes on EAS27870 B 5 MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS PRESENT MALFUNCTION NOTE Before proceeding to read the part of Arrangement and the function of test coupler Remove the side cowling left and check the location of test coupler Connect the test coupler adapter with the test coupler in order to ground the T C terminal sky blue Figure A Set the range of pocket tester to DC 20 V Conn...

Page 480: ... 10 digits 1 digit pattern of tester reading is shown below 1 ABS test coupler 2 Lock plate 3 Protective cap 4 Grounding 5 T C terminal 6 T F terminal 7 ABS warning light terminal White Red 8 Test coupler adapter 9 Light green 10 Black 11 White Red ...

Page 481: ...ng 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 the power supply system 1 Check that the battery is connected correctly 2 Check the battery voltage Refer to CHECKING AND CHARGING THE BATTERY on page 8 1...

Page 482: ...lace or adjust EAS4S81025 C 4 ABS WARNING LIGHT FLASHES EVERY 0 5 SECOND If the ABS warning 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...

Page 483: ...perly Installation of the rear wheel sen sor Rear wheel sensor lead and cou pler ABS wire harness circuit Rear wheel sensor rotor Malfunction code 12 13 front 14 rear Incorrect signal is detected by the front 13 or rear 14 wheel sen sor Wheel sensor installation Wheel sensor housings Wheel sensor rotors Malfunction codes 13 front wheel and 14 rear wheel 15 front 16 rear No continuity in the front ...

Page 484: ...nd 27 rear 28 Other malfunctions Malfunction of the memory in ABS ECU Replace the ABS ECU Malfunction 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...

Page 485: ...te 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 volta...

Page 486: ...operly D 3 Front wheel 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 FZ1 SA on page 8 89 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...

Page 487: ...Check if there is looseness rear brake caliper bracket and the rear wheel D 3 4 2 Installation 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 def...

Page 488: ...l replace the wheel sensor 5 Replace the ABS ECU if the condition 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 sole...

Page 489: ...vity of the wire harness and repair or replace the failure part 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 repai...

Page 490: ...alfunction code 31 Disconnection is detected between the battery and the ABS ECU sys tem NOTE Check following the steps in sequence 1 ABS motor fuse blown Replace the ABS motor fuse 2 Coupler joint between the battery 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 a...

Page 491: ...1 to 2 are normal replace the ABS ECU Malfunction code 33 Defective operation of the ABS motor is detected ABS motor stops and will not rotate NOTE Check following the steps in sequence 1 ABS motor fuse Check if the ABS motor fuse beside the battery is blown 2 ABS motor relay Check if the ABS motor relay operates correctly D 2 3 Wire harness Remove the ABS motor relay and the ABS motor fuse and th...

Page 492: ...motor relay and check for continuity between the red white terminal of the ABS motor coupler of the wire harness ABS and the positive battery terminal 3 ABS motor relay Check if the ABS motor relay operates correctly D 2 Malfunction code 35 Disconnection is detected between the ABS ECU and solenoid system Downstream side of the solenoid relay 1 Disconnected coupler between the ABS ECU and HU solen...

Page 493: ...reversed Front brake hose 1 inlet from the front brake master cylinder Front brake hose 2 outlet to the front brake caliper NOTE If the front brake hose inlet and outlet connections are reversed on the hydraulic unit the brake lever is pulled to full stroke without responding and will be pushed back slowly without pulsating when the final check in D 6 is performed If the front and rear brake hose ...

Page 494: ...nd the rear brake caliper WARNING EWA4S81011 Only use genuine Yamaha parts Using other brake pipes hoses and union bolts may close the brake hose lines Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the rear brake caliper from the hydraulic unit are correct WARNING EWA4S81012 The rear brake will not function properly if the connection...

Page 495: ... 3 Brake fluid Refer to Malfunction code 41 4 Brake hose lines Refer to Malfunction code 41 5 Hydraulic unit solenoid coupler terminals Refer 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 t...

Page 496: ...BS ECU coupler and wheel sensor coupler and check the conductivity between the wire harness and GND If short circuit is detected replace the wire 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 th...

Page 497: ...3 Turn the engine stop switch off CAUTION ECA4S81019 If the starter switch is pushed without turning the engine stop switch off it may damage the starting motor gears or other parts therefore be sure to turn it off 4 Push the starter switch more than 10 times in 4 seconds to delete the malfunction codes NOTE If the malfunction codes cannot be cleared the disconnection of the starter switch monitor...

Page 498: ...te the malfunction code when the service work is finished EAS5D01006 D 6 6 DELETE FUNCTION TEST 1 Place the vehicle on the sidestand 2 Set the main switch to OFF 3 Connect the test coupler adapter to the test coupler 4 Set the main switch to ON 5 Check ECU voltage Connect the pocket tester DC 20 V to the ECU coupler Tester positive probe Brown White 1 Tester negative probe Black White 2 Lower than...

Page 499: ...ioned check are within specification replace the ECU EAS5D01007 D 6 FINAL CHECK Checking procedures 1 Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 2 Check the wheel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL on page 4 15 and INSTALLING THE REAR WHE...

Page 500: ...ELECTRICAL COMPONENTS 8 131 EAS27970 ELECTRICAL COMPONENTS ...

Page 501: ...132 1 Main switch immobilizer unit 2 Front brake light switch 3 Battery 4 Fuse box 5 Starter relay 6 Rear brake light switch 7 Neutral switch 8 Sidestand switch 9 Oil level switch 10 Ignition coil 11 Radiator fan motor 12 Horn ...

Page 502: ...ELECTRICAL COMPONENTS 8 133 ...

Page 503: ...motor relay 7 Lean angle sensor 8 Starting circuit cut off relay 9 Turn signal relay 10 Rear wheel sensor FZ1 SA FZ1 NA 11 Rectifier regulator 12 ABS motor relay FZ1 SA FZ1 NA 13 Hydraulic unit FZ1 SA FZ1 NA 14 Coolant temperature sensor 15 Intake air pressure sensor 16 Throttle position sensor 17 Front wheel sensor FZ1 SA FZ1 NA 18 Sub throttle position sensor ...

Page 504: ...ELECTRICAL COMPONENTS 8 135 EAS27980 CHECKING THE SWITCHES ...

Page 505: ...FZ1 NA 6 Pass switch FZ1 S X FZ1 SA 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 box 18 Left handlebar switch lead FZ1 N X FZ1 NA 19 Left handlebar switch lead FZ1 S X FZ1 SA ...

Page 506: ...o 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a ...

Page 507: ...b 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 touching the glass part of the head light bulb to keep it free from oil other wise the tran...

Page 508: ...ac ing a fuse 1 Remove Rider and passenger seat 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If t...

Page 509: ...d with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION ECA13660 This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batter ies The MF battery should ...

Page 510: ...ger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age Charging method using a variable current voltage charger a Measure the open circu...

Page 511: ...minutes 6 Install Battery 7 Connect Battery leads to the battery terminals CAUTION ECA13630 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals 10 Install Rider and passenger seat EAS28040 CHECKING THE RELAYS Check each switch for continuity with the poc...

Page 512: ...3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 1 P...

Page 513: ... reading is Replace the ABS motor relay CAUTION ECA5D01006 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...

Page 514: ...e 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 at...

Page 515: ...er 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 NOTE The pocket tester and the analog pocket tester readings are shown in the following table Turn signal hazard relay input voltage DC 12 V Pocket tester 90890 0...

Page 516: ... tester probe Yel low Black 2 FZ1 N X FZ1 S X FZ1 NA Black Yellow 2 FZ1 SA No continuity Positive tester probe Yel low Black 2 FZ1 N X FZ1 S X FZ1 NA Black Yellow 2 FZ1 SA Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue Yellow 3 No continuity Positive tester probe Blue Yellow 3 Negative tester probe Sky blue 1 Continuity Positive tester probe...

Page 517: ... switch and gradually increase the spark gap until a misfire occurs EAS28110 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor Positive tester probe Ignition coil terminal Negative tester probe Ignition coil terminal Secondary coil r...

Page 518: ...fication Replace a Connect the pocket tester DC20 V to the front wheel sensor coupler as shown b Turn the main switch to ON c Elevate the front wheel and slowly rotate it d Measure the voltage with each full rotation of the front wheel the voltage reading should cycle from Lo 0 5 0 9 V to Hi 1 1 1 7 V to Lo to Hi Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Gray ...

Page 519: ...resistance Out of specification Replace the starter coil EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stater coil resistance Out of specification Replace the stator coil a Connect the pocket tester Ω 1 to the stator coil coupler as shown b Measure the stator coil resistance EAS28170 CHECKING THE RECTIFIER REGULATOR 1 Check Charging voltage Out of...

Page 520: ...esistance 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 EAS28230 CHECKING THE FUEL SENDER 1 Remove Fuel tank 2 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 3 Remove Fuel pump from the fuel tank 4 Check Fuel sender resistance Pocket tester 9089...

Page 521: ... fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it Fu...

Page 522: ...tion sensor from the throttle body 2 Check Throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor as shown b Check the throttle position sensor maxi mum resistance Out of specification Replace the throttle position sensor c Connect the pocket tester Ω 1k to the throttle position sensor as shown Coolant temperature sensor resistance 0 C 32 F 5 21 6 37 kΩ 80 C 176 ...

Page 523: ...nsor as shown e Check the throttle position sensor maxi mum resistance Out of specification Replace the throttle position sensor f Connect the pocket tester Ω 1k to the throttle position sensor as shown g While slowly opening the sub throttle worm nut check that the sub throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace t...

Page 524: ...nduction system solenoid resistance EAS28380 CHECKING THE ATMOSPHERIC PRES SURE SENSOR 1 Check Atmospheric pressure sensor output volt age Out of specification Replace a Connect the pocket tester DC 20 V to the atmospheric pressure sensor coupler wire harness side as shown b Set the main switch to ON c Measure the atmospheric pressure sensor output voltage Air induction system solenoid resistance ...

Page 525: ...witch to ON c Measure the intake air pressure sensor output voltage EAS28420 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake ...

Page 526: ...rminal as shown b Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown White 1 Negative tester probe Black Blue 2 Intake air temperature sensor bolt 1 2 Nm 0 12 m kg 0 87 ft lb ...

Page 527: ...DIUM 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 OVER COOLING 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 528: ...valve hose Deteriorated or contaminated fuel 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 ...

Page 529: ...m 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 Transmission Worn gear dog EAS28560 FAULTY CLU...

Page 530: ...ake 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 rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Da...

Page 531: ...perly 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 relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb Horn does not sound Impro...

Page 532: ...aves 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 Sensor circuit of the ABS harness is discon nected ABS ECU coupler terminal has come off ...

Page 533: ...TROUBLESHOOTING 9 6 ...

Page 534: ... switch 56 Engine stop switch 57 Start switch 58 Rear brake light switch 59 Left handlebar switch 60 Clutch switch 61 Pass switch 62 Dimmer switch 63 Hazard switch 64 Turn signal switch 65 Horn switch 66 Horn 67 Turn signal relay 68 Front left turn signal light 69 Front right turn signal light 70 Rear left turn signal light 71 Rear right turn signal light 72 Auxiliary light 73 Headlight 74 License...

Page 535: ...stop switch 57 Start switch 58 Rear brake light switch 59 Left handlebar switch 60 Clutch switch 61 Pass switch 62 Dimmer switch 63 Hazard switch 64 Turn signal switch 65 Horn switch 66 Horn 67 Turn signal relay 68 Front left turn signal light 69 Front right turn signal light 70 Rear left turn signal light 71 Rear right turn signal light 72 Auxiliary light 73 Headlight 74 License plate light 75 Ta...

Page 536: ...witch 61 Clutch switch 62 Pass switch 63 Dimmer switch 64 Hazard switch 65 Turn signal switch 66 Horn switch 67 Horn 68 Turn signal relay 69 Front left turn signal light 70 Front right turn signal light 71 Rear left turn signal light 72 Rear right turn signal light 73 Auxiliary light 74 Headlight 75 License plate light 76 Tail brake light 77 Headlight relay on off 78 Headlight relay dimmer 79 Tail...

Page 537: ...t handlebar switch 61 Clutch switch 62 Pass switch 63 Dimmer switch 64 Hazard switch 65 Turn signal switch 66 Horn switch 67 Horn 68 Turn signal relay 69 Front left turn signal light 70 Front right turn signal light 71 Rear left turn signal light 72 Rear right turn signal light 73 Auxiliary light 74 Headlight 75 License plate light 76 Tail brake light 77 Headlight relay on off 78 Taillight fuse 79...

Page 538: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 539: ...FZ1 N X 2008 WIRING DIAGRAM FZ1 N X 2008 SCHEMA DE CABLAGE FZ1 N X 2008 SCHALTPLAN FZ1 N X 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 N X 2008 ...

Page 540: ...FZ1 S X 2008 WIRING DIAGRAM FZ1 S X 2008 SCHEMA DE CABLAGE FZ1 S X 2008 SCHALTPLAN FZ1 S X 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 S X 2008 ...

Page 541: ...FZ1 SA 2008 WIRING DIAGRAM FZ1 SA 2008 SCHEMA DE CABLAGE FZ1 SA 2008 SCHALTPLAN FZ1 SA 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 SA 2008 ...

Page 542: ...B B2 B1 B2 B1 B B4 B B3 B B1 B B2 W W Lg Lg R G R G R G B L B L Sb Sb B Gy2 Y B2 Y L R Y B Gy B B L Gy Br R Br G B B1 W R R L W R W R R B B3 B B2 R G Y L Lg R W R B B L Y G L B L W L W G B G B R W B Y R W R R W R W W W R B B B B Br Br R W3 R W3 B G W B R L Y Y B B R R B L W R L B R B G B B G B G B Y B Y B R Br L Br R R R Br G Gy2 R W B B L B B Br R G Y B B2 R G Y L Lg R W R Br Br Br G Br G B B Gy ...

Page 543: ...FZ1 N X 2008 WIRING DIAGRAM FZ1 N X 2008 SCHEMA DE CABLAGE FZ1 N X 2008 SCHALTPLAN FZ1 N X 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 N X 2008 ...

Page 544: ...FZ1 S X 2008 WIRING DIAGRAM FZ1 S X 2008 SCHEMA DE CABLAGE FZ1 S X 2008 SCHALTPLAN FZ1 S X 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 S X 2008 ...

Page 545: ...FZ1 SA 2008 WIRING DIAGRAM FZ1 SA 2008 SCHEMA DE CABLAGE FZ1 SA 2008 SCHALTPLAN FZ1 SA 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 SA 2008 ...

Page 546: ...FZ1 NA 2008 WIRING DIAGRAM FZ1 NA 2008 SCHEMA DE CABLAGE FZ1 NA 2008 SCHALTPLAN FZ1 NA 2008 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 NA 2008 ...

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