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Yamaha 2006 FZ1-N, Service Manual

The Yamaha 2006 FZ1-N Service Manual is a comprehensive guide that allows users to properly maintain and repair their motorcycle. With step-by-step instructions and detailed illustrations, this manual is a valuable resource for any FZ1-N owner. Download it for free at manualshive.com and unlock the full potential of your bike.

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3

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

......................................................................... 3-1

INTRODUCTION .................................................................................... 3-1

ENGINE

......................................................................................................... 3-4

ADJUSTING THE VALVE CLEARANCE ................................................ 3-4
SYNCHRONIZING THE THROTTLE BODIES ....................................... 3-6
ADJUSTING THE EXHAUST GAS VOLUME......................................... 3-8
ADJUSTING THE ENGINE IDLING SPEED .......................................... 3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-9
CHECKING THE SPARK PLUGS......................................................... 3-10
MEASURING THE COMPRESSION PRESSURE ............................... 3-10
CHECKING THE ENGINE OIL LEVEL................................................. 3-11
CHANGING THE ENGINE OIL............................................................. 3-12
MEASURING THE ENGINE OIL PRESSURE ..................................... 3-13
ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-14
REPLACING THE AIR FILTER ELEMENT ........................................... 3-15
CHECKING THE THROTTLE BODY JOINTS ...................................... 3-16
CHECKING THE FUEL LINE ............................................................... 3-16
CHECKING THE CRANKCASE BREATHER HOSE ............................ 3-16
CHECKING THE EXHAUST SYSTEM ................................................. 3-17
ADJUSTING THE EXUP CABLES ....................................................... 3-17
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 REAR BRAKE LIGHT SWITCH .............................. 3-24
BLEEDING THE HYDRAULIC BRAKE SYSTEM................................. 3-25
ADJUSTING THE SHIFT PEDAL ......................................................... 3-26
ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-26
LUBRICATING THE DRIVE CHAIN...................................................... 3-27
CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-27
CHECKING THE FRONT FORK .......................................................... 3-28
ADJUSTING THE FRONT FORK LEGS .............................................. 3-29
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................ 3-31
CHECKING THE TIRES ....................................................................... 3-32
CHECKING THE WHEELS .................................................................. 3-34
CHECKING AND LUBRICATING THE CABLES .................................. 3-34
LUBRICATING THE LEVERS............................................................... 3-34
LUBRICATING THE PEDAL ................................................................. 3-34
LUBRICATING THE SIDESTAND......................................................... 3-34

Summary of Contents for 2006 FZ1-N

Page 1: ...2006 2D1 28197 E0 FZ1 N V FZ1 S V SERVICE MANUAL ...

Page 2: ... V FZ1 S V SERVICE MANUAL 2005 by Yamaha Motor Co Ltd First edition December 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

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

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

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

Page 6: ......

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

Page 8: ......

Page 9: ...S 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 CHECKING THE CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

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: ...nd 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 regula...

Page 12: ...n 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 re...

Page 13: ...dometer 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 C...

Page 14: ... 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 is left near E refuel as...

Page 15: ... 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 are no other immobilizer keys close to the main switch and do not keep more than one immobilizer key on the same key ri...

Page 16: ...ECT button 3 Turn the key to ON and then release the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to confirm the selected brightness level The display will return to the odometer or tripmeter mode ...

Page 17: ...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 a...

Page 18: ...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 19: ...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 20: ...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 71 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 3...

Page 21: ...ng rod bleeding tool set YM A8703 4 54 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 54 Fork spring compressor 90890 01441 YM 01441 4 50 4 55 Fork seal driver 90890 01442 Adjust table fork seal driver 36 46 mm YM 01442 4 53 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 7 Tool name Tool No Illustration Reference pages ...

Page 22: ...compressor adapter 22 mm YM 04108 5 23 5 29 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter YM 04114 5 23 5 29 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 12 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 12 Universal clutch holder 90890 04086 YM 91042 5 47 5 51 Tool name Tool No Illustration Reference ...

Page 23: ...90 04112 Valve guide installer 4 0 mm YM 04112 5 25 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 25 Valve guide reamer ø4 90890 04113 Valve guide reamer 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 8 104 Tool name Tool No Illustration Reference pa...

Page 24: ...890 01518 Frame spanner socket YM 01518 5 7 Pivot shaft wrench adapter 90890 01476 5 7 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 10 5 41 8 95 8 96 8 97 8 100 8 102 8 103 8 104 8 105 8 106 8 107 8 108 8 109 8 110 8 111 8 112 Oil pressure gauge 90890 03153 Pressure gauge YU 03153 3 14 Oil pressure gauge adapter 90890 03139 3 14 Tool name Tool No Illustration Reference pages ...

Page 25: ...90 06756 7 8 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 5 Fuel pressure adapter 90890 03176 YM 03176 7 8 Pressure gauge 90890 03153 YU 03153 3 14 7 8 Camshaft wrench 90890 04143 YM 04143 5 11 5 16 Tool name Tool No Illustration Reference pages ...

Page 26: ...SPECIAL TOOLS 1 17 ...

Page 27: ...TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 39 ...

Page 28: ...ement Forward inclined parallel 4 cylinder Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 11 50 1 Standard compression pressure at sea level 1480 kPa 350 r min 210 5 psi 350 r min 14 8 kgf cm 350 r min Starting system Electric starter Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 18 0 L 4 76 US gal 3 96 Imp gal Fuel reserve amount 3 4 L 0 90 US gal 0 75 Imp gal E...

Page 29: ...adiator core Width 222 6 mm 8 76 in Height 360 0 mm 14 17 in Depth 22 0 mm 0 87 in Water pump Water pump type Single suction centrifugal pump Reduction ratio 65 43 25 32 1 181 Max impeller shaft tilt limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK CR9EK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cylinder head Volume 12 20 13 00 cm 0 74 0 79 cu in Warpage limit 0 10 mm 0 0039 in Camshaft ...

Page 30: ...ead diameter A exhaust 24 90 25 10 mm 0 9803 0 9882 in Valve face width B intake 1 760 2 900 mm 0 0693 0 1142 in Valve face width B exhaust 1 760 2 900 mm 0 0693 0 1142 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Valve margin thickness D intake 0 50 0 90 mm 0 0197 0 0354 in Valve margin thickness D exhaust 0 50 0 90 mm 0 0197 ...

Page 31: ...in Installed length intake 32 66 mm 1 29 in Installed length exhaust 33 88 mm 1 33 in Spring rate K1 intake 17 53 N mm 100 10 lb in 1 79 kgf mm Spring rate K2 intake 22 86 N mm 130 53 lb in 2 33 kgf mm Spring rate K1 exhaust 21 52 N mm 122 88 lb in 2 19 kgf mm Spring rate K2 exhaust 27 99 N mm 159 82 lb in 2 85 kgf mm Installed compression spring force intake 127 40 144 60 N 28 64 32 51 lb 12 99 1...

Page 32: ...0026 in 2nd ring Ring type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 0118 0 0177 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Oil ring Dimensions B T 1 50 2 25 mm 0 06 0 09 in End gap installed 0 10 0 40 mm 0 0039 0 0157 in Connecting rod Oil clearance using plastigauge 0 034 0 058 mm 0 0013 0 0023 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green...

Page 33: ...condary reduction system Chain drive Secondary reduction ratio 45 17 2 647 Operation Left foot operation Gear ratio 1st 38 15 2 533 2nd 33 16 2 063 3rd 37 21 1 762 4th 35 23 1 522 5th 27 20 1 350 6th 29 24 1 208 Main axle runout limit 0 08 mm 0 0032 in Drive axle runout limit 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0 100 mm 0 0039 in S...

Page 34: ...ing condition Engine idling speed 1100 1300 r min Intake vacuum 30 0 kPa 8 9 inHg 225 mmHg Water temperature 95 0 105 0 C 203 00 221 00 F Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 35: ...LIN Pilot Road D Manufacturer model DUNLOP D221G Wear limit rear 0 8 mm 0 03 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar Loading condition 90 196 kg 198 432 lb FZ1 N 90 190 kg 198 419 lb FZ1 S Front 250 kPa 36 psi 2 50 kgf cm 2 50 bar Rear 290 kPa 42 psi 2 90 kgf cm 2 90 bar High s...

Page 36: ...scopic 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 9 32 N mm 53 22 lb in 0 95 kgf mm Spring stroke K1 0 0 130 0 mm 0 00 5 12 in Inner tube outer diameter 43 0 mm 1 69 in Inner tube bending limit 0 2 mm 0 01 in Optional spring availab...

Page 37: ... r min Stator coil resistance 0 14 0 18 Ω at 20 C 68 F Voltage regulator 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 Model YTZ14S Voltage capacity 12 V 11 2 Ah Specific gravity 1 310 Manufacturer GYM Ten hour rate amperage 1 12 A Headlight Bulb type ...

Page 38: ...0 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 type Full transistor Model manufacturer FE218BH DENSO Built in self canceling device No Turn signal blinking frequency 75 0 95 0 cycles min Wattage 10 W 2 0 3 4 W Oi...

Page 39: ...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 40: ...g 7 2 ft lb Water pump inlet pipe bolt water pump side M6 1 10 Nm 1 0 m kg 7 2 ft 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...

Page 41: ...ket cover bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Crankcase cover screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Clutch cover bolt M6 7 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt M6 1 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt M6 6 12 Nm 1 2 m kg 8 7 ft lb 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...

Page 42: ...kg 7 2 ft lb Use a lock washer Drive sprocket nut M22 1 85 Nm 8 5 m kg 61 ft lb Bearing plate bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Shift fork stopper plate bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Stopper screw M8 1 22 Nm 2 2 m kg 16 ft lb Shift rod locknut front M6 1 7 Nm 0 7 m kg 5 1 ft lb 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 ...

Page 43: ...TIGHTENING TORQUES 2 16 ...

Page 44: ...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 M11 1 7 Nm 0 7 m kg 5 1 ft lb Engine mounting adj...

Page 45: ...nch 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 screw M8 5 30 Nm 3 0 m kg 22 ft lb Rear brake caliper bolt front M12 1 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt rear M8 1 2...

Page 46: ...to approximately 52 Nm 5 2 m kg 38 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut 18 Nm 1 8 m kg 13 ft lb Clutch cable adjust nut M8 1 7 Nm 0 7 m kg 5 1 ft lb Item Thread size Q ty Tightening torque Remarks ...

Page 47: ...s inner and outer Oil pump housing Oil strainer 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 121...

Page 48: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 21 Pickup rotor cover Yamaha bond No 1215 Lubrication point Lubricant ...

Page 49: ...ear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber 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...

Page 50: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 51: ...er 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 AC magneto axle 13 Piston cooler 14 Chain tensioner 15 Intake camshaft 16 Exhaust camshaft ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20410 LUBRICATION DIAGRAMS ...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Main axle 2 Oil delivery pipe 3 Drive axle ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Cylinder head 2 Crankshaft ...

Page 62: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 63: ...COOLING SYSTEM DIAGRAMS 2 36 1 Water pump 2 Radiator 3 Radiator fan ...

Page 64: ...COOLING SYSTEM DIAGRAMS 2 37 ...

Page 65: ...COOLING SYSTEM DIAGRAMS 2 38 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat ...

Page 66: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING ...

Page 67: ...icle body and cut the tip to be between 2 to 4mm 0 08 to 0 16in F Clamp the wire harness at the place of the white tape and insert it to the stay assem bly Point the clamp opening to the outside of the vehicle G Lay on the front brake light switch lead above the throttle cables H Secure the brake hose to the front fork I Secure the horn lead to the front fork Cut the tip of the clamp head leaving ...

Page 68: ...CABLE ROUTING 2 41 ...

Page 69: ...ank breather hose and EXUP cable through the wire guide of the rear brake light switch stay H The clamp position shall be at the center of bending section of the brake fluid reservoir hose as shown in the illustration 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 attachment Any...

Page 70: ...CABLE ROUTING 2 43 ...

Page 71: ... illustration I More than 10 mm 0 39 in J Route the sidestand switch lead by the vehicle 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...

Page 72: ...CABLE ROUTING 2 45 ...

Page 73: ...CABLE ROUTING 2 46 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 ...

Page 74: ...CABLE ROUTING 2 47 ...

Page 75: ...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 To the direct ignition coil lead C Make sure to install the air filter after checking that the leads are positioned out side of the vehicle from the throttle body side cover D To the eng...

Page 76: ...CABLE ROUTING 2 49 ...

Page 77: ...Positioning tape shaded area AI Fit the protector by aligning the positioning tape end and protector end for the main switch lead immobilizer lead and left han dlebar switch lead The misalignment toler ance of ends is 5 mm 0 20 in AJ Clamp each lead at the positioning taping section white and then insert it to the cover In random order AK Clamp each lead at the positioning taping section blue and ...

Page 78: ...CABLE ROUTING 2 51 ...

Page 79: ...int 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 the route between the ribs of the battery box and tail brake light lead F Clamp each lead at the positioning taping s...

Page 80: ...CABLE ROUTING 2 53 ...

Page 81: ...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 82: ...CABLE ROUTING 2 55 ...

Page 83: ... 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 84: ...E CENTERSTAND FZ1 S 3 34 LUBRICATING THE REAR SUSPENSION 3 34 ELECTRICAL SYSTEM 3 35 CHECKING AND CHARGING THE BATTERY 3 35 CHECKING THE FUSES 3 35 REPLACING THE HEADLIGHT BULBS 3 35 ADJUSTING THE HEADLIGHT BEAM 3 36 ...

Page 85: ......

Page 86: ... 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 87: ...kage 19 Shock absorber assembly Check operation and shock absorber for oil leakage 20 Rear suspen sion relay arm and connect ing arm pivot ing points Check operation 21 Fuel injection Adjust engine idling speed and syn chronization 22 Engine oil Change Check oil level and vehicle for oil leakage 23 Engine oil filter cartridge Replace 24 Cooling system Check coolant level and vehicle for coolant le...

Page 88: ...brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 28 Air induction system Check the air cut off valve reed valve and hose for damage Replace the entire air induction sys tem if necessary 29 Muffler and exhaust pipe Check the screw clamp for loose ...

Page 89: ...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 10 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 90: ...ing into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b 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 Chec...

Page 91: ...ge 5 10 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 until the specified clea...

Page 92: ...st 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 EC2D1080 Do not use the throttle valve adjusting screws to adjust the throttle body synchro nization NOTE The differe...

Page 93: ... 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 cylinder number press the SELECT...

Page 94: ...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 95: ... 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 RADIATO...

Page 96: ...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 en...

Page 97: ...e 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 drain bolt 2 alon...

Page 98: ...ngine warm it up for several minutes and then turn 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 CAUTIO...

Page 99: ...re 6 Install Oil gallery bolt 1 CAUTION ECS2D1001 Be careful to tighten too much ET2D1004 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 pressu...

Page 100: ... 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 101: ... THROTTLE BODIES 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 ...

Page 102: ...haust pipes and 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 c...

Page 103: ...s 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 carrie...

Page 104: ...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 pump ...

Page 105: ...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 with the spec...

Page 106: ...orrect 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 max imum level mark a 15 Install Coolan...

Page 107: ...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 108: ...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 109: ...Brake hose clamp 2 Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to REAR BRAKE on page 4 32 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 ...

Page 110: ... 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 i...

Page 111: ...chain slack within the speci fied limits 1 Stand the vehicle on a level surface WARNING EW2D1005 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 Dri...

Page 112: ...n a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket Refer to STEERING HEAD on page 4 57 4 Adjust Steerin...

Page 113: ...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 114: ...sting bolt the right front fork leg is equipped with a reboumd 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 115: ... 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 cl...

Page 116: ... the stopper 2 Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting screw 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 1 Standard 3 Maximum 7 Direction a Rebound damping i...

Page 117: ...EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check Tire surfaces Damage wear Replace the tire Tire air pressure measured on cold tires Basic weight with oil and a full fuel tank FZ1 N 214kg 472lb FZ1 S 220kg 485lb 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 ...

Page 118: ...me 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 road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE ...

Page 119: ...ble sheath or use a suitable lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21730 LUBRICATING THE CE...

Page 120: ... THE FUSES Refer to ELECTRICAL COMPONENTS on page 8 89 EAS21780 REPLACING THE HEADLIGHT BULBS 1 Remove Headlight side cover bolts 1 FZ1 N 2 Disconnect Headlight sub wire harness coupler 2 FZ1 N 3 Disconnect Headlight coupler 1 4 Remove Headlight bulb cover 1 FZ1 S 5 Remove Headlight bulb holder 1 6 Remove Headlight bulb 1 A FZ1 N B FZ1 S A FZ1 N B FZ1 S ...

Page 121: ...dlight 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 Head...

Page 122: ...ELECTRICAL SYSTEM 3 37 A FZ1 N B FZ1 S ...

Page 123: ...EMBLING THE FRONT BRAKE CALIPERS 4 27 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 28 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 29 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 30 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 30 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 30 REAR BRAKE 4 32 INTRODUCTION 4 37 CHECKING THE REAR B...

Page 124: ...K ABSORBER ASSEMBLY 4 61 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK ABSORBER 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE CONNECTING ARM AND RELAY ARM 4 64 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 SWINGARM 4 65 REMOVING THE SWINGARM 4 67 CHECKING THE SWINGARM 4 67 INSTALLING THE SWINGARM 4 68 CHAIN DRIV...

Page 125: ......

Page 126: ...the 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 procedure ...

Page 127: ...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 procedure ...

Page 128: ...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 procedure ...

Page 129: ...fer 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 procedure ...

Page 130: ...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 procedure ...

Page 131: ... CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Intake air temperature sensor lead cou pler 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 procedure ...

Page 132: ...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 133: ...s to remove Q ty Remarks 1 Brake hose holder left and right 2 2 Front brake caliper left and right 2 3 Front wheel axle pinch bolt 1 4 Front wheel axle 1 5 Collar left and right 2 6 Dust cover 2 7 Front wheel 1 8 Front brake disc left and right 2 For installation reverse the removal procedure ...

Page 134: ...RONT WHEEL 4 9 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassem bly procedure ...

Page 135: ...ECKING 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 32 and CHECKING THE WHEELS on page 3 34 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front w...

Page 136: ...heel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the...

Page 137: ...2000 INSTALLING THE FRONT WHEEL DISC The following procedure applies to both of the brake discs 1 Lubricate Wheel axle Oil seal lips 2 Lift the wheel up between the fork legs 3 Insert the wheel axle NOTE Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation 4 Lower the front wheel so that it is on the ground 5 Tighten Wheel axle Wheel axle pinch bolt CAUTION ECA141...

Page 138: ...RONT WHEEL 4 13 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 ...

Page 139: ...emarks 1 Rear brake caliper 1 2 Locknut left and right 2 Loosen 3 Adjusting bolt left and right 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 procedure ...

Page 140: ...rder Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Coller 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 procedure ...

Page 141: ...REAR WHEEL 4 16 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Coller 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassem bly procedure ...

Page 142: ...r wheel NOTE 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 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKI...

Page 143: ...el 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 11 EAS22160 INSTALLING THE REAR WHEEL DISC 1 Lubricate Wheel axle Wheel bearings Oil seal lips 2 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CH...

Page 144: ...REAR WHEEL 4 19 WARNING EWA13500 Make sure the brake hose is routed prop erly ...

Page 145: ...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 procedure ...

Page 146: ...view mirror FZ1 N 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir dia phragm 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 disassem bly procedure ...

Page 147: ...T BRAKE 4 22 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 disassem bly procedure ...

Page 148: ...ke calipers Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAU LIC 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 procedure ...

Page 149: ...rake calipers Order Job Parts to remove Q ty Remarks 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassem bly procedure ...

Page 150: ...EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 8 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 ...

Page 151: ...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 152: ...both 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...

Page 153: ...leaned 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 calipers 1 Install Brake caliper 1 temporarily Copper washers B...

Page 154: ...rvoir 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 minimum level mark a Add the recommended brake fl...

Page 155: ...MBLING 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 ...

Page 156: ...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 master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid m...

Page 157: ...emoving 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 procedure ...

Page 158: ... 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 procedure ...

Page 159: ...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 disassem bly procedure ...

Page 160: ...REAR BRAKE 4 35 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 Barke caliper 1 For installation reverse the removal procedure ...

Page 161: ...iper Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassem bly procedure ...

Page 162: ...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 25 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 25 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAK...

Page 163: ...roper level Refer 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 ...

Page 164: ...ce the brake cali per 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...

Page 165: ...rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause...

Page 166: ...ear Replace 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 ET2D10...

Page 167: ...the brake fluid and could cause vapor lock CAUTION EC2D1010 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 ...

Page 168: ...ew mirror FZ1 N 2 2 Front brake light 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 ...

Page 169: ...HANDLEBAR 4 44 15 Handlebar 1 16 Lower handlebar holder 2 For installation reverse the removal procedure Removing the handlebar Order Job Parts to remove Q ty Remarks ...

Page 170: ...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 171: ...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 EW2D1007 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 hoousing 2 Throttle cables Grip end 3 N...

Page 172: ...ll Front brake master cylinder assembly Front brake master cylinder holder 1 CAUTION ECS2D1010 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 173: ...y Remarks Front wheel Front brake calipers Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 34 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 procedure ...

Page 174: ...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 disassem bly procedure ...

Page 175: ...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 176: ...ur 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 wea...

Page 177: ...Dust 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 EC2D1080 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 a...

Page 178: ...er the top of the front fork leg with a plastic bag to protect the oil seal during 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 ...

Page 179: ...NOTE Be sure to stroke the damper rod slowly because 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 ...

Page 180: ...marked B f Remove the rod puller and the rod puller attachment g Install the nut 1 and position it as speci fied b h Set the cap bolt distance c to specifica tion i Inatall the damper adjusting rod and cap bolt and then finger tighten the cap bolt j Hold the cap bolt and tighten the damper adjusting rod locknut to specification k Remove the rod holder and fork spring compressor Fork spring compres...

Page 181: ...e adjusting screw Pay attension not to mistake the right and left 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring preload Rebou...

Page 182: ...calipers Refer to FRONT BRAKE on page 4 20 Front cowling FZ1 S Refer to GENERAL CHASSIS on page 4 1 Headlight and meter assembly FZ1 N Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 43 Front fork legs Refer to FRONT FORK on page 4 48 1 Main switch connector 2 Disconnect 2 Steering stem nut 1 3 Upper bracket 1 4 Front brake hose joint 1 ...

Page 183: ...sher 1 11 Lower ring nut 1 12 Lower bracket 1 13 Lower bearing 1 14 Lower bearing 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 procedure Removing the lower bracket Order Job Parts to remove Q ty Remarks ...

Page 184: ...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 185: ...3 Lock washer 4 Refer to INSTALLING THE STEERING HEAD on page 4 60 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 48 NOTE Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut Recommended lubricant Lithiu...

Page 186: ...Side cover left and right Refer to GENERAL CHASSIS on page 4 1 Brake fluid reservoir tank bolt Refer to REAR BRAKE on page 4 32 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 ...

Page 187: ...REAR SHOCK ABSORBER ASSEMBLY 4 62 For installation reverse the removal procedure Removing the rear shock absorber assembly Order Job Parts to remove Q ty Remarks ...

Page 188: ...r To release the gas pressure drill a 2 3mm 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 there is no d...

Page 189: ... pitting Replace 3 Check Coller 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 Lithium soa...

Page 190: ...Rear brake caliper Refer to REAR BRAKE on page 4 32 Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 61 Drive sprocket Refer to ENGINE REMOVAL on page 5 2 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 ...

Page 191: ...SWINGARM 4 66 8 Drive chain 1 9 Dust cover 2 10 Drive chain guide 1 11 Spacer 1 12 Bearing 2 For installation reverse the removal procedure Removing the swingarm Order Job Parts to remove Q ty Remarks ...

Page 192: ...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 193: ...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 64 and INSTALLING THE REAR WHEEL DISC on page 4 18 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 Recommended lubricant Lithium soap based grease Drive chain slack 2...

Page 194: ...AS23400 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 2 1 Drive chain guard 1 2 Drive chain 1 For installation reverse the removal procedure ...

Page 195: ... 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 196: ... set Bent teeth Replace the drive chain sprockets as a set EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 18 ET2D1031 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 17 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain 2 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE...

Page 197: ...ECKING THE VALVES AND VALVE GUIDES 5 25 CHECKING THE VALVE SEATS 5 26 CHECKING THE VALVE SPRINGS 5 28 CHECKING THE VALVE LIFTERS 5 29 INSTALLING THE VALVES 5 29 GENERATOR 5 31 REMOVING THE GENERATOR 5 33 INSTALLING THE GENERATOR 5 33 STARTER CLUTCH 5 35 REMOVING THE STARTER CLUTCH 5 36 CHECKING THE DAMPER 5 36 CHECKING THE STARTER CLUTCH 5 36 INSTALLING THE STARTER CLUTCH 5 37 CRANKSHAFT POSITION ...

Page 198: ...KING THE OIL NOZZLES 5 63 ASSEMBLING THE OIL PUMP 5 63 INSTALLING THE OIL WATER PUMP ASSEMBLY 5 64 INSTALLING THE OIL PAN 5 65 CRANKCASE 5 66 DISASSEMBLING THE CRANKCASE 5 68 CHECKING THE CRANKCASE 5 68 CHECKING THE BEARING AND OIL SEALS 5 68 ASSEMBLING THE CRANKCASE 5 68 CRANKSHAFT 5 70 REMOVING THE CONNECTING RODS AND PISTONS 5 72 REMOVING THE CRANKSHAFT ASSEMBLY 5 72 CHECKING THE CYLINDER AND P...

Page 199: ...CHECKING THE TRANSMISSION 5 91 INSTALLING THE TRANSMISSION 5 92 ...

Page 200: ...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 procedure ...

Page 201: ...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 procedure ...

Page 202: ...ENGINE REMOVAL 5 4 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 disassem bly procedure ...

Page 203: ...dy assembly Refer to THROTTLE BODIES on page 7 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 Oil cooler Refer to OIL COOLER on page 6 4 Air cut off valve Refer to AIR INDUCTION SYS TEM on page 7 13 Starter motor Refer to ELECTRIC STARTER on page 5 40 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 ...

Page 204: ...level switch connector 1 Disconnect 8 Neutral switch connector 1 Disconnect 9 Cylinder identification sensor coupler 1 Disconnect 10 Speed sensor coupler 1 Disconnect For assembly reverse the removal procedure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks ...

Page 205: ...s 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 procedure ...

Page 206: ...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 207: ... 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 208: ...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 SYS TEM on page 7 13 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 procedure ...

Page 209: ...procket 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 CAM SHAFTS on page 5 12 6 Exhaust camshaft cap 3 7 Dowel pin 6 Refer to REMOVING THE CAM SHAFTS on page 5 12 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Camshaft sprocket 2 For assembly reverse the removal procedure ...

Page 210: ... NOTE 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 R...

Page 211: ...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 212: ... 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 Remove Timing chain t...

Page 213: ...pring 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 rod 3 may run of...

Page 214: ...ned 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 215: ...e camshaft cap arrow mark b 8 Install Gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 CAUTION EC2D1003 The arrow mark a on the timing chain ten sioner should face up WARNING EW2D1006 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 sur face b Camshaft punch mark c Make su...

Page 216: ...CAMSHAFTS 5 18 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 38 ...

Page 217: ... to ENGINE REMOVAL on page 5 2 Intake camshaft Refer to CAMSHAFTS on page 5 10 Exhaust camshaft Refer to CAMSHAFTS on page 5 10 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 procedure ...

Page 218: ...ratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cyli...

Page 219: ... 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 CAMSHAFTS on page 5 16 Cylinder head nut 1st 19 Nm 1 9 m kg 14 ft lb Cylinder head nut 2nd 67 Nm 6 7 m kg 4...

Page 220: ...e valve lifter 12 2 Intake valve pad 12 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 ...

Page 221: ... SPRINGS 5 23 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 For installation reverse the removal procedure Removing the valves and valve springs Order Job Parts to remove Q ty Remarks ...

Page 222: ...S on page 5 26 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 Lower ...

Page 223: ...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 224: ...4300 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 cylinder head Intake Valve guide remover ø4 90890 04111 YM 04111 Exhaust Valve guide remover ø4 5 90890 04116 YM 04116...

Page 225: ...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 226: ...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 227: ... 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 228: ...tall Valve pad 1 Valve lifter 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 Intake Valve spring compressor attachment 90890 04114 YM 04114 Exhaust Valve spring compressor attachment ...

Page 229: ...RAL 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 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 ...

Page 230: ...1 Bearing 1 12 Stator coil assembly lead holder 1 13 Idler gear 1 14 Idler gear shaft 1 15 Washer 1 16 Bearing 1 For assembly reverse the removal procedure Removing the generator Order Job Parts to remove Q ty Remarks ...

Page 231: ...fter 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 shaf...

Page 232: ...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 233: ...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 procedure ...

Page 234: ...r 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 onto the starter clutch 2 and hold the starter clutch b When turn...

Page 235: ...aulty 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 36 3 Install Washer 1 O ring 2 Spacer 3 NOTE Lubricate the engine oil to O ring ...

Page 236: ...Rider 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 procedure ...

Page 237: ...osen 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 posision 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 f...

Page 238: ...r 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 procedure ...

Page 239: ...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 disassem bly procedure ...

Page 240: ...nd 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 Mic...

Page 241: ... 1 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 Starte...

Page 242: ...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 procedure ...

Page 243: ...5 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 procedure ...

Page 244: ...1 3 Pull rod 1 4 Bearing 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 ...

Page 245: ...CLUTCH 5 47 For assembly reverse the removal procedure Removing the clutch Order Job Parts to remove Q ty Remarks ...

Page 246: ...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 247: ...f 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 friction 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 Measu...

Page 248: ...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 THE PRESSURE PLATE 1 Check Pr...

Page 249: ...ing 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 mark facing away from the v...

Page 250: ...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 251: ...push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull 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 C...

Page 252: ...y Remarks Clutch assembly Refer to CLUTCH on page 5 44 Shift arm and shift rod Refer to ENGINE REMOVAL on page 5 2 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 ...

Page 253: ...SHIFT SHAFT 5 55 For installation reverse the removal procedure Removing the shift shaft and stopper lever Order Job Parts to remove Q ty Remarks ...

Page 254: ...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 stopper lever EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Washer Stopp...

Page 255: ...er 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 2 5 Install Clutch assembly Refer to CLUTCH on page 5 44 ...

Page 256: ...Refer to ENGINE REMOVAL on page 5 2 O2 sensor Refer to ENGINE REMOVAL on page 5 2 Muffler Refer to ENGINE REMOVAL on page 5 2 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 2 Clutch assembly Refer to CLUTCH on page 5 44 Water pump inlet pipe Refer to OIL COOLER on page 6 4 Water pump outlet pipe Refer to OIL COOLER on page 6 4 1 Oil level switch lead coupler 1 Disconnect ...

Page 257: ... 1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Relief valve assembly 1 12 Oil water pump assembly 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 Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 258: ...OIL PUMP 5 60 18 Oil water pump assembly 1 For assembly reverse the removal procedure Removing the oil pan and oil pump Order Job Parts to remove Q ty Remarks ...

Page 259: ... 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 roter 1 7 Oil pump inner roter 1 8 Pin 1 For assembly reverse the disassem bly procedure ...

Page 260: ...p 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 clearance b 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the ...

Page 261: ...RAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent ET2D1013 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 262: ... pump 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 EC2D1008 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 wa...

Page 263: ...gine oil drain 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 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 drain...

Page 264: ...er to THROTTLE BODIES on page 7 4 Engine Refer to ENGINE REMOVAL on page 5 2 Cylinder head Refer to CYLINDER HEAD on page 5 19 Generator Refer to GENERATOR on page 5 31 Starter clutch Refer to STARTER CLUTCH on page 5 35 Shift shaft Refer to SHIFT SHAFT on page 5 54 Crankshaft position sensor Refer to CRANKSHAFT POSITION SENSOR on page 5 38 Clutch Refer to CLUTCH on page 5 44 ...

Page 265: ...ER on page 5 40 1 Timing chain 1 2 Timing chain guide intake side 1 3 Pin 2 4 Timing chain guide exhaust side 1 5 Left side cover 1 6 O ring 1 7 Lower crankcase 1 8 Dowel pin 3 9 Damper 1 For assembly reverse the removal procedure Separating the crankcase Order Job Parts to remove Q ty Remarks ...

Page 266: ... 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 267: ... 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 268: ...rks Lower crankcase Refer to CRANKCASE on page 5 66 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 procedure ...

Page 269: ...E on page 5 66 Connecting rod and connecting rod caps Refer to REMOVING THE CON NECTING RODS AND PISTONS on page 5 72 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 disassem bly procedure ...

Page 270: ...on 3 CAUTION EC2D1006 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 r...

Page 271: ...cification 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 ET2D1015 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 cle...

Page 272: ...on grooves Replace the piston pin and then check the lubrication system 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston 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 P...

Page 273: ...ng 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 Pleastigauge 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 274: ...achined 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 275: ...ntil 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 72 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 sha...

Page 276: ...hat 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 r...

Page 277: ...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 278: ...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 279: ...URNAL BEARINGS 1 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION EC2D1008 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 positions ...

Page 280: ...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 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 66 g Remove th...

Page 281: ...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 ET2D1021 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 282: ...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 66 5 Install Pin Pickup rotor 1 Drive sprocket 2 Drive sprocket bolt 60 Nm 6 0 m kg 43 ft lb ...

Page 283: ... remove Q ty Remarks Crankcase lower Separate Refer to CRANKCASE on page 5 66 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 ...

Page 284: ...14 Main axle assembly 1 15 Oil pipe 1 16 O ring 2 17 Oil baffle plate 1 For installation reverse the removal procedure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks ...

Page 285: ...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 disassem bly procedure ...

Page 286: ... 2 1st wheel gear 1 3 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 ...

Page 287: ...TRANSMISSION 5 89 21 Oil seal 1 22 Bearing 1 23 Drive axle 1 For assembly reverse the disassem bly procedure Disassembling the drive axle assenbly Order Job Parts to remove Q ty Remarks ...

Page 288: ... 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 289: ... 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 290: ...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 291: ...TRANSMISSION 5 93 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly ...

Page 292: ...R 6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 8 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 ...

Page 293: ...nk 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 COOL ANT 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 ...

Page 294: ...RADIATOR 6 2 10 Water pump inlet pipe 1 11 O ring 1 For installation reverse the removal procedure Removing the radiator Order Job Parts to remove Q ty Remarks ...

Page 295: ...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 296: ...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 procedure ...

Page 297: ...t and 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 Chec...

Page 298: ...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 COOL ANT 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 procedure ...

Page 299: ...AT 6 7 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 disassem bly procedure ...

Page 300: ...eating or overcooling 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 of the recom mended...

Page 301: ...THERMOSTAT 6 9 Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 302: ... Remarks Oil water pump assembly Refer to OIL PUMP on page 5 58 Oil pump roter Refer to OIL PUMP on page 5 58 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 procedure ...

Page 303: ... flat head screwdriver NOTE Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 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 ...

Page 304: ...TE Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 4 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 5 90890 04058 Bearing driver ...

Page 305: ...WATER PUMP 6 13 ...

Page 306: ... THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 8 CHECKING THE THROTTLE BODIES 7 8 CHECKING THE FUEL PRESSURE 7 8 ADJUSTING THE THROTTLE POSITION SENSOR 7 8 ADJUSTING THE SUB THROTTLE POSITION SENSOR 7 9 CHECKING THE SUB THROTTLE SERVO MOTOR 7 10 CHECKING THE THERMO WAX 7 11 ADJUSTING THE THERMO WAX 7 11 AIR INDUCTION SYSTEM 7 13 CHECKING THE AIR INDUCTION SYSTEM 7 14 INSTALLING THE AIR INDUCTION SY...

Page 307: ...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 procedure ...

Page 308: ...ctly 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 fat...

Page 309: ...roperly 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 whit...

Page 310: ... TANK on page 7 1 Air filter 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 inret 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...

Page 311: ...THROTTLE BODIES 7 5 For installation reverse the removal procedure Removing the throttle bodies Order Job Parts to remove Q ty Remarks ...

Page 312: ...air pressure sensor coupler 1 Disconnect 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 w...

Page 313: ...Washer 2 20 Link 1 21 Sub throttle servo motor assembly 1 22 Throttle position sensor 1 23 Throttle body assembly 1 For installation reverse the removal procedure Removing the injectors Order Job Parts to remove Q ty Remarks ...

Page 314: ...l hose fuel tank to pri mary injector fuel rail 1 from the primary injector fuel rail WARNING EW2C01008 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 fuel...

Page 315: ...sub throttle counterclockwise 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 thrott...

Page 316: ...b 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 or less with the nut of...

Page 317: ...6 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 EAT2D1004 CHECKING THE THERMO WAX 1 Check Thermo wax 1 Damage Replace the thermo wax assembly ET2D1025 ADJUSTING THE THERMO WAX 1 Adjust Thermo wax the end face distance a a Before adjusting the distance push the rod b in order to be fitted in several time...

Page 318: ...THROTTLE BODIES 7 12 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 319: ... 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 procedure ...

Page 320: ...olled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes h...

Page 321: ...ls as shown c Measure the air induction system solenoid resistance d Out of specification 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 Reed valve bending limit 0 4 mm 0 016 in Positive tester probe Brown terminal...

Page 322: ... SYSTEM 8 21 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 IM...

Page 323: ...TOR MOTOR OPERATION 8 105 CHECKING THE STARTOR COIL 8 106 CHECKING THE RECTIFIER REGULATOR 8 106 CHECKING THE HORN 8 106 CHECKING THE FUEL SENDER 8 107 CHECKING THE SPEED SENSOR 8 107 CHECKING THE RADIATOR FAN MOTOR 8 108 CHECKING THE COOLANT TEMPERATURE SENSOR 8 108 CHECKING THE THROTTLE POSITION SENSOR 8 109 CHECKING THE SUB THROTTLE POSITION SENSOR 8 110 CHECKING THE AIR INDUCTION SYSTEM SOLENO...

Page 324: ......

Page 325: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 326: ... Starting circuit cut off relay 14 Neutral switch 15 Sidestand switch 17 Crankshaft position sensor 21 Lean angle sensor 23 ECU 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 Fuse ignition ...

Page 327: ... 97 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 8 103 Ignition system is OK 5 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 103 Replace the ignition coils 6 Check the cranksha...

Page 328: ...WITCHES on page 8 93 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the clutch switch 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 100 Replace the relay unit 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 105 Replace the lean angle sensor 14 Check the entire ignition...

Page 329: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 330: ...6 1 Main switch 6 Fuse main 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 Fuse ignition ...

Page 331: ...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 332: ...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 333: ... 8 97 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STAR TOR MOTOR OPERATION on page 8 105 Replace the starter motor 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on page 5 42 Repair or replace the starter motor 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 100 Rep...

Page 334: ...E SWITCHES on page 8 93 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the right handlebar switch 14 Check the entire starting system s wiring...

Page 335: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 336: ...CHARGING SYSTEM 8 12 2 Rectifier regulator 3 A C magneto 6 Fuse main 7 Battery ...

Page 337: ...efer to CHECKING AND CHARGING THE BATTERY on page 8 97 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 106 Replace the startor assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 106 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT DI...

Page 338: ...CHARGING SYSTEM 8 14 ...

Page 339: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM FZ1 N ...

Page 340: ...use main 7 Battery 23 ECU 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 Fuse tail light 81 Fuse headlight ...

Page 341: ...LIGHTING SYSTEM 8 17 ET2D1026 CIRCUIT DIAGRAM FZ1 S ...

Page 342: ...ttery 23 ECU 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 Fuse tail light 82 Fuse headlight ...

Page 343: ...ht Refer to CHECKING THE FUSES on page 8 97 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the immobilizer kit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on page 8 93 The dimmer switch is faulty Replace...

Page 344: ...e 8 100 Replace the headlight relay 9 Check the headlight relay dimmer FZ1 S Refer to CHECKING THE RELAYS on page 8 100 Replace the headlight relay 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM FZ1 N on page 8 15 Properly connect or repair the lighting system s wiring This circuit is OK ...

Page 345: ...SIGNALING SYSTEM 8 21 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 346: ...rature indicator light 50 Turn signal indicator light left 51 Turn signal indicator light right 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 turn signal light left 69 Front turn signal light right 70 Rear turn signal light left 71 Rear turn signal light right 75 Tail bra...

Page 347: ...r to CHECKING THE FUSES on page 8 97 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the immobilizer kit 4 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Properly connect or repair th...

Page 348: ...l brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 93 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 349: ... 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 93 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 signal ing system s wiring This circuit is OK 1 Check th...

Page 350: ...gnaling 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 8 107 Replace the speed sensor 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 Replace the meter ass...

Page 351: ...COOLING SYSTEM 8 27 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 352: ...witch 6 Fuse main 7 Battery 23 ECU 38 Coolant temperature sensor 78 Fuse ignition 82 Radiator fan motor relay 83 Fuse radiator fan motor left 84 Fuse radiator fan motor right 85 Radiator fan motor left 86 Radiator fan motor right ...

Page 353: ...heck the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the immobilizer kit 4 Check the radiator fan motor left and right Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 108 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 100 Replace the radiator fan motor relay 6 Check the coolant temperature Re...

Page 354: ...COOLING SYSTEM 8 30 ...

Page 355: ...FUEL INJECTION SYSTEM 8 31 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 356: ...on sensor 19 Speed sensor 20 Atmospheric pressure sensor 21 Lean angle sensor 22 O2 sensor 23 ECU 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 Air temperatu...

Page 357: ...ARGING THE BATTERY on page 8 97 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 8 103 Replace the ignition coils 5 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITION SEN SOR on page...

Page 358: ...SWITCHES on page 8 93 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 100 Replace the relay unit 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 105 Replace the lean angle sensor 15 Check the cyl...

Page 359: ... the throttle position sensor 20 Check the sub throttle position sen sor Refer to CHECKING THE SUB THROTTLE POSITION SENSOR on page 8 110 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 8 112 Replace the intake air pressure sensor 22 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPER...

Page 360: ...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 361: ... tripme ter 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 f...

Page 362: ...eing 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 p...

Page 363: ...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 364: ...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 365: ...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 366: ... 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 367: ...in 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 op...

Page 368: ...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 369: ...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 370: ...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 371: ...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 372: ...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 373: ...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 Chec...

Page 374: ... Fault code No 11 Symptom No normal signals are received from the cylinder identifi cation sensor when the engine is started or while the vehicle is being driven Diagnostic code No Orde r 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 375: ...Crankshaft 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 position sensor coupler and ECU cou pler Gray G...

Page 376: ...ue Blue 3 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 112 Fault code No 14 Symptom Intake air pressure sensor faulty intake air pressure sen sor system Diagnostic code No 03 Intake air pressure sensor Orde r Item components and probable cause Check or maintenance job Reinstatement metho...

Page 377: ...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 378: ...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 379: ...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 difected 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 380: ...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 381: ...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 382: ...ins 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 and or sub wire harness 2 Repair or replace if there is an open or short circuit Between atmospheric pressure sensor coupler and ECU cou pler Black Blue Black Blue Pink Pink Blue Blue 3 Defe...

Page 383: ...Gray Green Black Blue Black Blue Pink Black Pink Black Red White Red White 4 Check fuel pressure Refer to THROTTLE BODIES on page 7 4 5 Defective O2 sensor Replace if defective Fault code No 30 Symptom No normal signal is received from the lean angle sensor Diagnostic code No 08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle h...

Page 384: ...ns 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 1 ignition coil coupler and ECU coupler Red Black Red Black Orange Orange 3 De...

Page 385: ... 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 386: ...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 387: ...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 388: ... out Check the locking condition of the couplers If there is a malfunction repair it and connect the copler 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 389: ... 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 390: ...ed sensor by operating the vehicle at 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 sensor cou...

Page 391: ...ce if there is an open or short circuit Between neutral switch coupler and relay unit coupler Sky blue Sky blue Between relay unit coupler and ECU coupler Blue Yellow Blue Yellow B 4 Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective Refer to CHECKING THE SWITCHES on page 8 93 B 5 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION ...

Page 392: ...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 393: ...de Code No 60 to check the faulty cylinder number If mul tiple cylinders are defective the numbers of the faulty cyl inders are displayed alter nately at 2 second intervals 2 Execute the CO adjustment mode and set the exhaust gas volume of the faulty cylinder to 0 If 0 is displayed set the numerical value other than 0 When the malfunction is recovered reset 0 Refer to ADJUSTING THE EXHAUST GAS VOL...

Page 394: ...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 97 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 sho...

Page 395: ...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 396: ...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 397: ...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 398: ...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 399: ...FUEL PUMP SYSTEM 8 75 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 400: ...FUEL PUMP SYSTEM 8 76 1 Main switch 6 Fuse main 7 Battery 8 Fuse fuel injection 13 Fuel pump relay 16 Fuel pump 23 ECU 46 Multi function meter 56 Engine stop switch 78 Fuse ignition ...

Page 401: ... 8 97 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the immobilizer kit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 93 Replace the right handlebar switch 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 8 100 Replace the relay unit 6 Check the fuel pump R...

Page 402: ...FUEL PUMP SYSTEM 8 78 ...

Page 403: ...IMMOBILIZER SYSTEM 8 79 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 404: ...IMMOBILIZER SYSTEM 8 80 1 Main switch 4 Fuse backup 5 Immobilizer unit 6 Fuse main 7 Battery 23 ECU 41 Immobilizer indicator 46 Multi function meter 78 Fuse ignition ...

Page 405: ...odes 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 after any code re registering and keep the code re registering key in a safe place Do not submer...

Page 406: ...ctions in the section below Standby mode To enable the 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 All keys have been lost including code re registering key Code re regist...

Page 407: ...then turn the key to ON within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer 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 ...

Page 408: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 409: ...terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 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 immobilizer system s circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page ...

Page 410: ...ace the ECU 54 IMMOBILIZER UNIT Codes do not match between ECU and immobilizer unit Noise interference or dis connected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnection of the communication harness 3 Immobilizer unit failure 4 ECU failure When the used parts form other vehicles are used the code re reg istering key ID is not registered to the ECU 1 Register the code re reg...

Page 411: ...IMMOBILIZER SYSTEM 8 87 a Light on b Light off ...

Page 412: ...IMMOBILIZER SYSTEM 8 88 ...

Page 413: ...ELECTRICAL COMPONENTS 8 89 EAS27970 ELECTRICAL COMPONENTS ...

Page 414: ...90 1 Main switch immobilizer unit 2 Front brake light switch 3 Starter relay 4 Battery 5 Fuse box 6 Rear brake light switch 7 Neutral switch 8 Sidestand switch 9 Oil level switch 10 Radiator fan motor 11 Horn 12 Ignition coil ...

Page 415: ...ELECTRICAL COMPONENTS 8 91 ...

Page 416: ...emperature sensor 3 Intake air pressure sensor 4 Fuel pump 5 ECU 6 Lean angle sensor 7 Starting circuit cut off relay 8 Headlight relay on off 9 Radiator fan motor relay 10 Turn signal relay 11 Recifier regulator 12 Throttle position sensor 13 Sub throttle position sensor ...

Page 417: ...ELECTRICAL COMPONENTS 8 93 EAS27980 CHECKING THE SWITCHES ...

Page 418: ...3 Dimmer switch 4 Pass switch 5 Turn signal switch 6 Hazard switch 7 Clutch switch 8 Sidestand switch 9 Engine stop switch 10 Front brake light switch 11 Start switch 12 Oil level switch 13 Neutral switch 14 Rear brake light switch 15 Fuse box 16 O2 sensor ...

Page 419: ...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 420: ... 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 transparency of the glass the li...

Page 421: ...he correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition syste...

Page 422: ...attery NOTE Since MF batteries are sealed it is not possi ble to check the charge state of the battery by measuring the specific gravity of the electro lyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rider and passenger seat 2 Disconnect Battery leads from the battery terminals CAUTION ECA13640 First disconnect the negative batt...

Page 423: ...e should be measured 30 minutes after the machine is stopped b Connect a charged and AMP meter to the battery and start charging NOTE Set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high the battery will be over charged c Make sure that the current is higher than the standard charging current written on the battery NOTE If the current is lower than...

Page 424: ...ection Connect properly 9 Lubricate Battery terminals 10 Install Rider and passenger seat EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the continuity reading is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester Ω 1 and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specific...

Page 425: ... 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 Po...

Page 426: ...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 ET2D1021 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 Turn signal...

Page 427: ... Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Yel low Black 2 FZ1 N Black Yellow 2 FZ1 S No continuity Positive tester probe Yel low Black 2 FZ1 N Black Yellow 2 FZ1 S 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 ...

Page 428: ... switch and gradually increase the spark gap until a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 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 429: ...m the electric starting system troubleshooting starting with step5 Refer to TROUBLESHOOTING on page 8 9 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flam...

Page 430: ...egulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the charging voltage EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace a Disconnect the horn leads from the horn terminals b Connect the pocket tester Ω 1 to the horn terminals Stator coil resistance 0 14 0 18 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester...

Page 431: ...e fuel sender resistance EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Horn terminal 1 Negative tester probe Horn terminal 2 Fuel sender resistance Full position of the float ...

Page 432: ...special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k to the coolant temperature sensor 1 as shown b Immerse the coolant temperature sensor in a container filled with coolant 2 NOTE Make sure the coolant temperature...

Page 433: ...stance Out of specification Replace the throttle position sensor c Connect the pocket tester Ω 1k to the throttle position sensor as shown d While slowly opening the throttle check that the throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the throttle position sensor 3 Install Throttle position sensor Pocket tester 9089...

Page 434: ...nut check that the sub throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the sub throt tle position sensor NOTE Check mainly that the resistance changes gradually when turning the sub throttle worm nut since the readings from closed to wide open sub throttle may differ slightly from those specified 3 Install Sub throttle...

Page 435: ...A TION SENSOR 1 Check Cylinder identification sensor output volt age Out of specification Replace a Connect the pocket tester DC 20 V to the cylinder identification sensor coupler wire harness side as shown Air induction system solenoid resistance 18 22 Ω at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown 1 Negative tester probe Brown Red 2 Atmospher...

Page 436: ... 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 air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the intake air temperature sensor terminal as shown b Measure the intake air temperature sen...

Page 437: ...ELECTRICAL COMPONENTS 8 113 ...

Page 438: ...DLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 ...

Page 439: ...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 440: ...t in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS...

Page 441: ...Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction B...

Page 442: ... tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged o...

Page 443: ...p 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 turn signal light left 69 Front turn signal light right 70 Rear turn signal light left 71 Rear turn signal light right 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail ...

Page 444: ...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 turn signal light left 69 Front turn signal light right 70 Rear turn signal light left 71 Rear turn signal light right 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight ...

Page 445: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 446: ...FZ1 N V 2006 WIRING DIAGRAM FZ1 N V 2006 SCHEMA DE CABLAGE FZ1 N V 2006 SCHALTPLAN FZ1 N V 2006 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 N V 2006 ...

Page 447: ...FZ1 S V 2006 WIRING DIAGRAM FZ1 S V 2006 SCHEMA DE CABLAGE FZ1 S V 2006 SCHALTPLAN FZ1 S V 2006 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 S V 2006 ...

Page 448: ... 76 77 78 79 80 81 83 84 82 74 56 57 85 6 7 8 9 10 52 53 54 55 73 72 70 70 71 58 59 60 61 65 11 12 13 66 67 68 69 64 62 63 51 38 14 16 39 40 41 42 43 44 45 46 47 48 49 50 50 34 35 36 37 20 19 18 17 15 21 22 26 23 26 24 26 25 26 27 28 29 30 31 32 33 FZ1 N V 2006 WIRING DIAGRAM FZ1 N V 2006 SCHEMA DE CABLAGE FZ1 N V 2006 SCHALTPLAN FZ1 N V 2006 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 N V 2006...

Page 449: ... B B B 5 4 1 2 3 76 77 78 79 80 81 82 84 85 83 74 75 56 57 86 6 7 8 9 10 52 53 54 55 73 72 70 70 71 71 58 59 60 61 65 11 12 13 66 67 68 69 64 62 63 51 38 14 16 39 40 41 42 43 44 45 46 47 48 49 50 50 34 35 36 37 20 19 18 17 15 21 22 26 23 26 24 26 25 26 27 28 29 30 31 32 33 FZ1 S V 2006 WIRING DIAGRAM FZ1 S V 2006 SCHEMA DE CABLAGE FZ1 S V 2006 SCHALTPLAN FZ1 S V 2006 SCHEMA ELETTRICO DIAGRAMA DE C...

Page 450: ...FZ1 N V 2006 WIRING DIAGRAM FZ1 N V 2006 SCHEMA DE CABLAGE FZ1 N V 2006 SCHALTPLAN FZ1 N V 2006 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 N V 2006 ...

Page 451: ...RE HARNESS HEADLIGHT SUB WIRE HARNESS 2 WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 1 WIRE HARNESS SUB WIRE HARNESS 1 B OFF RUN FREE PUSH B B B FZ1 S V 2006 WIRING DIAGRAM FZ1 S V 2006 SCHEMA DE CABLAGE FZ1 S V 2006 SCHALTPLAN FZ1 S V 2006 SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES DE FZ1 S V 2006 ...

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