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Yamaha Fazer FZ8-SA, Service Manual

The Yamaha Fazer FZ8-SA is a powerful and sleek motorcycle designed for ultimate performance on the road. To ensure optimal maintenance and repair, a comprehensive Service Manual is available for download. Get your free digital copy of this essential manual from manualshive.com to keep your Fazer FZ8-SA running at its best.

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HANDLEBAR

4-66

EAS22860

REMOVING 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. Remove:

• Handlebar grip “1”

TIP

Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push 
the grip off the handlebar.

3. Remove:

• Throttle cable housings “1”
• Throttle grip “2”

TIP

While removing the throttle cable housing, pull 
back the rubber cover “3”.

EAS22880

CHECKING THE HANDLEBAR

1. Check:

• Handlebar

Bends/cracks/damage 

→

 Replace.

WARNING

EWA13690

Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

EAS22931

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

(temporarily)

• Handlebar “1”
• Upper handlebar holders “2”

ECA39P1407

• First, tighten the bolts on the front side of 

the upper handlebar holder, and then on 
the rear side.

• Turn the handlebar all the way to the left 

and right. If there is any contact with the 
fuel tank, adjust the handlebar position.

TIP

• Align the punch mark “a” on the handlebar 

with the left side upper surface of the left 
lower handlebar holder “3”.

• The upper handlebar holders should be 

installed with the arrow marks “b” facing for-
ward.

Upper handlebar holder bolt

24 Nm (2.4 m·kgf, 17 ft·lbf)

Summary of Contents for Fazer FZ8-SA

Page 1: ...SERVICE MANUAL FZ8NA FZ8SA 2011 1BD 28197 E0 ...

Page 2: ...Z8NA FZ8SA SERVICE MANUAL 2010 by Yamaha Motor Co Ltd First edition May 2010 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ... 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 TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert sym...

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

Page 5: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOC TITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

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: ...FUNCTIONS 1 14 ABS OPERATION 1 19 ABS SELF DIAGNOSIS FUNCTION 1 22 ABS WARNING LIGHT AND OPERATION 1 25 IMPORTANT INFORMATION 1 26 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 26 REPLACEMENT PARTS 1 26 GASKETS OIL SEALS AND O RINGS 1 26 LOCK WASHERS PLATES AND COTTER PINS 1 26 BEARINGS AND OIL SEALS 1 27 CIRCLIPS 1 27 BASIC SERVICE INFORMATION 1 28 QUICK FASTENERS 1 28 ELECTRICAL SYSTEM 1 28 SPECIAL ...

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: ...gh the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommo...

Page 12: ...sition sensor 7 Air filter case 8 Fuel tank 9 Fuel pump 10 Battery 11 Atmospheric pressure sensor 12 Relay unit fuel pump relay 13 Lean angle sensor 14 Catalytic converter 15 O2 sensor 16 Fuel hose 17 Fuel injector 18 Crankshaft position sensor 19 Coolant temperature sensor 20 Spark plug 21 Ignition coil 22 Cylinder identification sensor 23 Air cut off valve A FZ8NA B FZ8SA ...

Page 13: ...e ECU Signals that are input from the throttle position sensor sub throttle position sensor crankshaft position sensor intake air pres sure sensor atmospheric pressure sensor intake air temperature sensor coolant temperature sen sor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position senso...

Page 14: ...utton 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 ECA10031 Do not operate the engine in the tachome ter red zone Red zone 11500 r min and ...

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

Page 16: ...ng 1 Use the code re registering key to start the engine TIP 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 ring Immobilizer system keys may cause signal interference which may prevent the engine from starting 2 If the engine starts turn it off and try start ing the engine with the standard keys 3 If one or both ...

Page 17: ...nd lightweight design to help maintain the basic maneuverability of the vehicle 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass centralization ABS layout 1 Hydraulic unit assembly ABS ECU 2 ABS warning light 3 Rear wheel sensor rotor 4 Rear wheel sensor 5 Front wheel sensor 6 Front wheel sensor rotor 7 ABS test coupler 8 Fus...

Page 18: ...n though the wheel speed is reduced Brake force The force applied by braking to reduce the wheel speed Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel Side force The force on the tires which supports the vehicle when cornering Slip ratio When the brakes are applied slipping occurs between the tires and the road surfa...

Page 19: ...eel slippage is represented by the slip ratio Side force is also closely related to wheel slippage See figure A If the brakes are applied while keeping the proper slip ratio it is possible to obtain the maximum brake force without losing much side force ABS allows full use of the tires capabilities even on slippery road surfaces or less slippery road sur faces See figure B a Friction force between...

Page 20: ... a tendency to lock When the wheel slip and the wheel speed reduction rate exceed the preset values the ABS ECU determines that the wheel has a tendency to lock If the slip is large and the wheel has a tendency to lock point A in the following figure the ABS ECU reduces the brake fluid pressure in the brake caliper Once the ABS ECU determines that the tendency of the wheel to lock has diminished a...

Page 21: ... cause the tire to slip side ways WARNING EWA4B56003 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of traction of the tires Even in vehicles equipped with ABS overturning of the vehicle cannot be pre vented if it is braked suddenly The ABS functions to prevent the tendenc...

Page 22: ...l braking even if the ABS is not operating properly When this occurs the ABS warning light on the meter assembly comes on The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and troubleshooting ABS block diagram 1 Rear brake master cylinder 2 Hydraulic unit assembly 3 Front brake master cylinder 4 Inlet solenoid valve 5 ABS motor 6 Hydraulic pump 7 Outlet so...

Page 23: ...ate with the wheels The front sensor rotor has 80 magnetic poles 40 pairs and the rear sensor rotor has 92 magnetic poles 46 pairs They are installed close to the wheel sensors As the sensor rotor rotates the Hall element in the Hall IC installed in the wheel sensor generates pulses The pulse frequency which is proportional to the magnetic flux density is converted into a wave in the Hall IC so th...

Page 24: ...aulic control valves each with a outlet solenoid valve and inlet solenoid valve buffer chambers hydraulic pumps an ABS motor and ABS ECU The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU Hydraulic control valve The hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid val...

Page 25: ...utlet solenoid valve 2 closes and the brake fluid is pressurized again The inlet solenoid valve 1 controls the hydraulic pressure difference between the brake fluid in the upper brake lines brake mas ter cylinder side and the brake fluid in the lower brake lines brake caliper side Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating 1 Buffe...

Page 26: ... 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Main switch 6 ABS ECU fuse 7 ABS motor fuse 8 ABS solenoid fuse 9 Front brake light switch 10 Rear brake light switch 11 Tail brake light 12 Hydraulic unit assembly 13 ABS ECU 14 Solenoid relay 15 ABS motor relay 16 Front brake inlet solenoid 17 Front brake outlet solenoid 18 Rear brake inlet solenoid 19 Rear brake outlet solenoid 20 ABS motor 21 E...

Page 27: ...he ABS ECU e g a blown ABS ECU fuse The ABS performs a self diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on During this test a clicking noise can be heard from under the seat and if the front brake lever or rear brake pedal are even slightly applied a vibration can be felt at the lever or pedal but these do not indicate a malfunction 1 So...

Page 28: ...ressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper At this time the inlet and outlet check valves of the hydraulic pump are closed As a result of elimi nating the orifice the brake master cylinder directly pressurizes the brake caliper during normal braking When the brake lever is released the brake fluid in the brake caliper returns to the brake master...

Page 29: ...er Because the outlet solenoid valve is open the brake fluid is sent to the buffer chamber As a result the hydraulic pressure in the brake caliper is reduced The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hydraulic pump linked to the ABS motor 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoi...

Page 30: ...solenoid valve As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be sent to the brake caliper 1 Brake master cylinder 2 Brake light switch 3 ABS motor 4 Hydraulic pump 5 Buffer chamber 6 Outlet solenoid valve 7 Inlet solenoid valve 8 Brake caliper 9 Wheel sensor 10 ABS ECU 11 ABS warning light 12 Brake fluid pressure 13 Time ...

Page 31: ...a self diagnosis then goes off if there are no problems 2 The ABS warning light comes on while the start switch is being pushed When the engine is being started the ABS warning light comes on while the start switch is being pushed Refer to ELECTRIC STARTING SYSTEM on page 8 11 a ABS warning light b Main switch OFF c Main switch ON d Goes off e Comes on for 2 seconds f ABS self diagnosis a ABS warn...

Page 32: ...flashes if the vehicle is ridden with the test coupler adapter con nected to the ABS test coupler 5 The ABS warning light 1 flashes and a fault code 2 is indicated on the multi function display when the test coupler adapter 3 is connected to the ABS test coupler 4 for troubleshooting the ABS When the test coupler adapter is connected to the ABS test coupler the ABS warning light starts flashing an...

Page 33: ...FEATURES 1 24 ...

Page 34: ...wheels have a tendency to lock by generating a reaction force pulsating action in the front brake lever or rear brake pedal When the ABS is activated the grip between the road sur face and tires is close to the limit The ABS cannot prevent wheel lock on slippery sur faces such as ice when it is caused by engine braking even if the ABS is activated The ABS is not designed to shorten the braking dis...

Page 35: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 36: ...ed grease Oil bearings liberally when installing if appropriate 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 opposit...

Page 37: ...nto the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastener insert the fastener into the part to be secured and tighten the screw a EAS30401 ELEC...

Page 38: ...ater ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the battery lead connections could damage the electrical components ECA16770 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then the negative battery lead If a tool or similar item contacts the vehicle while only the negative battery lead is connected ...

Page 39: ... ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler taking care not to loosen or dam age the leads ECA16640 For waterproof couplers never insert the tester probes directly into the coupl...

Page 40: ... connector do not pull the leads Hold both sections of the connector securely and then disconnect the connector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect several times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up After disassembling and assembling a cou pler pull on the lea...

Page 41: ...th the pocket tester TIP 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 most part stores Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 42: ...id any mistakes TIP 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 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 82 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 70 Radiator cap tester 90890 01325 Mityvac cooling system tester kit YU 24460 A 6 3 Radiator cap teste...

Page 43: ...01436 Universal damping rod bleeding tool set YM A8703 4 75 4 76 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 4 75 4 76 Fork spring compressor 90890 01441 YM 01441 4 71 4 76 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 74 Pivot shaft wrench adapter 90890 01476 5 9 Tool name Tool No Illustration Reference pages ...

Page 44: ...094 Vacuummate YU 44456 3 9 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 32 8 183 8 184 8 185 8 189 8 190 8 191 8 192 8 193 8 194 8 195 8 196 8 197 8 198 8 199 8 200 8 201 8 202 Oil pressure adapter H 90890 03139 3 26 Test coupler adapter 90890 03149 1 23 4 60 4 62 Pressure gauge 90890 03153 YU 03153 3 26 7 4 7 9 Tool name Tool No Illustration Reference pages ...

Page 45: ...03180 Feeler gauge set YU 26900 9 3 6 5 21 5 51 Test harness speed sensor 3P 90890 03208 YU 03208 8 201 Test harness lean angle sensor 6P 90890 03209 YU 03209 8 194 Fuel injector pressure adapter 90890 03210 YU 03210 7 9 Test harness S pressure sensor 5S7 3P 90890 03211 YU 03211 8 201 8 202 Test harness sub throttle position sensor 3P 90890 03214 YU 03214 7 12 Tool name Tool No Illustration Refere...

Page 46: ...er YM 33221 A 6 13 Universal clutch holder 90890 04086 YM 91042 5 49 5 53 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 7 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 5 25 5 31 Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 5 27 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm YM 04112 5 27 Tool name...

Page 47: ... mm YM 04113 5 27 Extension 90890 04136 5 1 Camshaft wrench 90890 04162 YM 04162 5 13 5 17 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 193 Yamaha bond No 1215 Three bond No 1215 90890 85505 5 19 5 34 5 67 Tool name Tool No Illustration Reference pages ...

Page 48: ...SPECIAL TOOLS 1 39 ...

Page 49: ...TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 19 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 25 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 ENGINE OIL LUBRICATION CHART 2 27 LUBRICATION DIAGRAMS 2 29 COOLING SYSTEM DIAGRAMS 2 39 CABLE ROUTING 2 43 ...

Page 50: ...in Overall width 770 mm 30 3 in Overall height FZ8NA 1065 mm 41 9 in FZ8SA 1225 mm 48 2 in Seat height 815 mm 32 1 in Wheelbase 1460 mm 57 5 in Ground clearance 140 mm 5 51 in Minimum turning radius 3000 mm 118 1 in Weight With oil and fuel FZ8NA 216 kg 476 lb FZ8SA 220 kg 485 lb Maximum load FZ8NA 194 kg 428 lb FZ8SA 190 kg 419 lb ...

Page 51: ...il quantity Total amount 3 80 L 4 02 US qt 3 34 Imp qt Without oil filter cartridge replacement 2 90 L 3 07 US qt 2 55 Imp qt With oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt Oil filter Oil filter type Cartridge Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 ...

Page 52: ...stem Chain drive right Camshaft cap inside diameter 24 500 24 521 mm 0 9646 0 9654 in Camshaft journal diameter 24 459 24 472 mm 0 9630 0 9635 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Limit 0 080 mm 0 0032 in Camshaft lobe dimensions Intake A 35 750 35 850 mm 1 4075 1 4114 in Limit 35 650 mm 1 4035 in Intake B 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1...

Page 53: ...n 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 0 0354 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Valve stem diameter exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1595 in Valve guide inside diamet...

Page 54: ...mm 0 067 in Spring tilt exhaust 2 5 1 7 mm 0 067 in Winding direction intake Clockwise Winding direction exhaust Clockwise Cylinder Bore 68 000 68 010 mm 2 6772 2 6776 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 150 mm 0 0059 in Diameter D 67 975 67 990 mm 2 6762 2 6768 in Height H 11 5 mm 0 45 ...

Page 55: ...8 mm 0 0013 0 0023 in Limit 0 09 mm 0 0035 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green Crankshaft Width A 55 20 56 60 mm 2 173 2 228 in Width B 298 75 300 65 mm 11 76 11 84 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 160 0 262 mm 0 0063 0 0103 in Journal oil clearance 0 013 0 037 mm 0 0005 0 0015 in Limit 0 10 mm 0 0039 in Bearing color code 0 White 1 Blue 2 Black 3 Br...

Page 56: ...s 5 76 5 89 mm 0 2268 0 2319 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 6 0 A Fuel pressure 324 0 kPa 3 24 kgf cm 47 0 psi Fuel injector Model quantity 297500 1720 4 Throttle position sensor Resistance 2 64 6 16 kΩ Output voltage at idle 0 63 0 73 V Sub throttle position sensor Resistance 3 7 kΩ Output voltage full close 0 ...

Page 57: ...n Solenoid resistance 18 22 Ω at 20 C 68 F Idling condition Engine idling speed 1150 1250 r min CO 4 0 5 0 Intake vacuum 30 0 kPa 225 mmHg 8 9 inHg Water temperature 90 0 110 0 C 194 00 230 00 F Oil temperature 75 0 95 0 C 167 00 203 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 58: ... BB Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 180 55 ZR17M C 73W Manufacturer model BRIDGESTONE BT021R BB Wear limit rear 1 6 mm 0 06 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Loading condition FZ8NA 90 194 kg 198 428 lb FZ8SA 90 190 kg 198 419 lb Front 250 kPa 2 50 kgf cm 36 ps...

Page 59: ...m 1 50 in Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Center to lock angle left 33 0 Center to lock angle right 33 0 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Front fork travel 130 0 mm 5 12 in Fork spring free length 286 1 mm 11 26 in Limit 280 4 mm 11 04 in Collar length 100 0 mm 3 94 in Installed length 278 6 mm 10 97 in S...

Page 60: ...le No Enclosed gas air pressure STD 1200 kPa 12 0 kgf cm 170 7 psi Spring preload adjusting positions Minimum 1 Standard 5 Maximum 9 Drive chain Type manufacturer 525V10 DAIDO Number of links 122 Drive chain slack 20 0 30 0 mm 0 79 1 18 in 15 link length limit 239 3 mm 9 42 in Shift pedal Installed shift rod length 304 1 306 1 mm 11 97 12 05 in ...

Page 61: ...utput voltage 14 2 14 8 V Rectifier capacity 50 0 A Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 310 Manufacturer GS YUASA Ten hour rate amperage 0 86 A Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 60 W 55 W 1 FZ8SA 12 V 55 W 1 Auxiliary light FZ8NA 12 V 5 0 W 1 FZ8SA 12 V 5 0 W 2 Tail brake light 12 V 5 0 W 21 0 W 1 Front turn signal light ...

Page 62: ...m amperage 3 0 A Coil resistance 1 066 1 114 Ω at 20 C 68 F Turn signal hazard relay Relay type Full transistor Built in self canceling device No Oil level switch Maximum level position resistance 484 536 Ω Minimum level position resistance 114 126 Ω Coolant temperature sensor Resistance 2 45 kΩ at 20 C 68 F 290 354 Ω at 80 C 176 F Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 10 0 A...

Page 63: ...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 kgf ft lbf 10 mm 6 mm 6 0 ...

Page 64: ... 0 m kgf 7 2 ft lbf Oil water pump drive sprocket bolt M6 1 15 Nm 1 5 m kgf 11 ft lbf Oil pump bolt M6 2 12 Nm 1 2 m kgf 8 7 ft lbf Water pump cover bolt M6 5 12 Nm 1 2 m kgf 8 7 ft lbf Thermostat housing cover nut M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Thermostat inlet pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Oil cooler bolt M20 1 63 Nm 6 3 m kgf 46 ft lbf Engine oil drain bolt M14 1 43 Nm 4 3 m kgf 31...

Page 65: ...m kgf 8 7 ft lbf Pickup rotor cover blind bolt M8 1 15 Nm 1 5 m kgf 11 ft lbf Oil filler cap M20 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Main gallery plug oil return M16 3 8 Nm 0 8 m kgf 5 8 ft lbf Main gallery plug M20 1 8 Nm 0 8 m kgf 5 8 ft lbf Oil return pipe bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Oil return plug M12 2 32 Nm 3 2 m kgf 23 ft lbf Stator coil lead bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Stator...

Page 66: ...ch the specified angle 56 61 Shift rod locknut front M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Shift rod locknut rear M6 1 8 Nm 0 8 m kgf 5 8 ft lbf Left thread Shift rod joint bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Shift arm bolt M6 1 16 Nm 1 6 m kgf 12 ft lbf Neutral switch M10 1 17 Nm 1 7 m kgf 12 ft lbf Coolant temperature sensor M12 1 18 Nm 1 8 m kgf 13 ft lbf Cylinder identification sensor bolt M6 1 8 Nm...

Page 67: ...TIGHTENING TORQUES 2 18 ...

Page 68: ... Nm 1 7 m kgf 12 ft lbf Right rear view mirror FZ8NA M10 1 17 Nm 1 7 m kgf 12 ft lbf Left thread Grip end and handlebar bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Horn bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Lower headlight stay and lower bracket bolt FZ8NA M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Lower headlight stay and brake hose nut FZ8NA M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Lower headlight stay and brake hose bolt FZ8...

Page 69: ...M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Drive chain guide bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bolt front M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bolt rear M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bracket bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank cap bolt M5 3 6 Nm 0 6 m kgf 4 3 ft lbf Fuel pump bolt M5 6 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel tank c...

Page 70: ...m kgf 1 8 ft lbf Rear wheel sprocket nut M10 6 80 Nm 8 0 m kgf 58 ft lbf Drive chain adjusting locknut M8 2 16 Nm 1 6 m kgf 12 ft lbf Rear brake hose union bolt M10 2 30 Nm 3 0 m kgf 22 ft lbf Sidestand nut M10 1 48 Nm 4 8 m kgf 35 ft lbf Sidestand bracket bolt M10 2 63 Nm 6 3 m kgf 46 ft lbf Sidestand switch bolt M5 2 4 3 Nm 0 43 m kgf 3 1 ft lbf Footrest bracket bolt M8 4 30 Nm 3 0 m kgf 22 ft l...

Page 71: ...1 ft lbf Lower hydraulic unit bracket and upper hydraulic unit bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Brake fluid reservoir tank stay and upper hydraulic unit bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake pipe joint assembly flare nut M10 4 16 Nm 1 6 m kgf 12 ft lbf Brake hose holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front brake hose stay and frame bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Fr...

Page 72: ...mp rotors inner and outer O ring oil nozzle O ring main gallery plug Damper crankcase left side Water or silicone fluid Idler gear and idler gear shaft Starter clutch assembly Starter clutch gear thrust surface Primary driven gear Pull rod Oil water pump assembly drive sprocket inner surface Oil water pump assembly drive sprocket collar and washer Transmission gears wheel and pinion Main axle and ...

Page 73: ...ON POINTS AND LUBRICANT TYPES 2 24 Left crankcase cover three mating surface Yamaha bond No 1215 Three bond No 1215 Crankcase cover lead grommet Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant ...

Page 74: ... shaft Swingarm head pipe end bush and dust cover lips Oil seal relay arm connecting arm and rear shock absorber Sidestand pivoting point and metal to metal moving parts Sidestand switch contact point Sidestand hook and spring contact point Shift shaft joint rod moving parts Shift pedal pivoting parts Rear footrest ball and metal to metal moving parts Front wheel oil seal left and right Rear wheel...

Page 75: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ...

Page 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART ...

Page 77: ...mp 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 Crankshaft 14 Piston cooler 15 Timing chain tensioner 16 Intake camshaft 17 Exhaust camshaft ...

Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS ...

Page 79: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil delivery pipe 2 Oil level switch 3 Oil filter cartridge 4 Crankshaft ...

Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 2 3 4 5 6 7 8 1 ...

Page 81: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump ...

Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...

Page 83: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler ...

Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...

Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Oil pipe 3 Drive axle ...

Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ...

Page 87: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Main gallery 5 Crankshaft ...

Page 88: ...COOLING SYSTEM DIAGRAMS 2 39 EAS20420 COOLING SYSTEM DIAGRAMS ...

Page 89: ...COOLING SYSTEM DIAGRAMS 2 40 1 Thermostat 2 Water pump 3 Radiator 4 Radiator fan 5 Oil cooler ...

Page 90: ...COOLING SYSTEM DIAGRAMS 2 41 ...

Page 91: ...COOLING SYSTEM DIAGRAMS 2 42 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat ...

Page 92: ...CABLE ROUTING 2 43 EAS20430 CABLE ROUTING Handlebar front view FZ8NA ...

Page 93: ...the vehicle than the center of the front fork The headlight side cover and front fork must not be pinched C The horn lead and lower headlight stay must not interfere with each other D Clamp the horn lead to the Lower headlight stay and face the head of the clamp to out side of the vehicle and the end of the clamp to the rear of the vehicle Cut off the excess end of the clamp leaving 2 4 mm 0 08 0 ...

Page 94: ...CABLE ROUTING 2 45 Handlebar front view FZ8SA ...

Page 95: ...lead and lower bracket must not interfere with each other D Clamp the horn lead to the horn bracket and face the head of the clamp to outside of the vehicle and the end of the clamp to the rear of the vehicle Cut off the excess end of the clamp leaving 2 4 mm 0 08 0 16 in E Insert the bullet terminal of the horn lead in the direction shown in the illustration F The horn lead should not protrude ou...

Page 96: ...CABLE ROUTING 2 47 Handlebar right side view ...

Page 97: ...he tube part of the brake pipe joint assembly hydraulic unit to front brake calipers as a guide permissible range 0 10 mm 0 0 39 in When clamping them route the front wheel sen sor lead so that it comes to the top of the vehicle F To the throttle body G Clamp the coolant reservoir hose and radi ator inlet hose and face the head of the clamp to inside of the vehicle and the end of the clamp to the ...

Page 98: ...CABLE ROUTING 2 49 Engine right side view ...

Page 99: ...ugh the cable guide The white paint mark on the fuel tank drain hose should be under the cable guide D Route the AC magneto lead and rectifier regulator lead further to the front of the vehicle than the cable guide E Route the fuel tank breather hose and fuel tank drain hose through the opening of the rear brake light switch stay F The clamp position should be inside the rear frame joint section G...

Page 100: ...CABLE ROUTING 2 51 Handlebar left side view ...

Page 101: ...on the clutch cable swaging metal further to the front of the vehicle than the clamp and face the clamp opening to outside of the vehicle D Clamp the clutch cable left radiator fan motor lead and water pump breather hose and face the head of the clamp to the top of the vehicle and the end of the clamp to inside of the vehicle Use the position of the cylinder head cover shown in the illus tration a...

Page 102: ...CABLE ROUTING 2 53 Engine left side view ...

Page 103: ... than the water pump breather hose and water pump inlet pipe G More than 10 mm 0 39 in H Route the sidestand switch lead further to the front of the vehicle than the water pump breather hose and water pump inlet pipe I Route the oil level switch lead further to the front of the vehicle than the water pump breather hose and water pump inlet pipe J There should be no exposure of bare con ductors due...

Page 104: ...CABLE ROUTING 2 55 Rear frame left side view ...

Page 105: ...se A Clamp the wire harness starter motor lead and battery negative lead further to the front than the branch of the fuse box 2 lead Face the head of the clamp to inside of the vehicle and the end of the clamp down B Route the ground lead between the rear frame bracket and battery box The ground rivet on the wire harness stem side should not be caught with the rear frame bracket C Upper side of th...

Page 106: ...CABLE ROUTING 2 57 Frame top view ...

Page 107: ... vehi cle F Clamp the left handlebar switch lead main switch lead and immobilizer lead at the white tape marks Order insignificant Face the head of the clamp to the rear of the vehicle and the end of the clamp to the bottom of the vehicle Cut off the excess end of the clamp leaving 2 4 mm 0 08 0 16 in G Insert the immobilizer coupler into ECU engine control unit holder H Route each lead under the ...

Page 108: ...CABLE ROUTING 2 59 Frame top view ...

Page 109: ...coolant reservoir hose inside of the fast idle plunger outlet hose E To the fuel pump F Bring the engine ground lead down and the battery negative lead up Install each lead so that the lead convex comes to the top of the vehicle G Route the wire harness under the clutch cable H Insert the wire harness wrapping clamp to the hole of the frame I To the rear brake light switch J Atmospheric opening K ...

Page 110: ...CABLE ROUTING 2 61 Frame top view ...

Page 111: ... lead under the turn signal hazard relay H Route the license plate light lead and rear right turn signal light lead between the ribs of the battery box I Route the license plate light lead and rear right turn signal light lead under the rubber cover J Route the tail brake light lead and rear left turn signal light lead under the rubber cover K The ABS check coupler should not cover the top of the ...

Page 112: ...CABLE ROUTING 2 63 Fuel tank left and bottom view ...

Page 113: ...en the fuel tank nipple and clamp E Fit the black double lock side to the engine side F Fuel pump side G Insert the connector until the click sound is heard and check that the connector does not come off Make sure that no foreign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equivalent coverings H After item G mentioned above is finished check that the ...

Page 114: ...CABLE ROUTING 2 65 Front brake right side view ...

Page 115: ...ront of the vehicle to the brake hose D Install the connector metal fittings of the brake hose hydraulic unit to front brake calipers and front brake hose front brake master cylinder to hydraulic unit pushing against each other E Install the block metal fitting of the brake hose hydraulic unit to front brake calipers pushing projection to the stopper F Align the notch of the horn with the projec t...

Page 116: ...CABLE ROUTING 2 67 Front brake left side ...

Page 117: ... at the outside of the vehicle to the brake hose C Put the front wheel sensor lead and the brake hose through The front wheel sen sor lead must be positioned at the upper side of the vehicle to the brake hose D Install the clamp so that the distance from the clamp lower surface to the end of the brake hose offset bracket may be 30 50 mm 1 18 1 97 in The front wheel sensor lead must be positioned a...

Page 118: ...CABLE ROUTING 2 69 Rear brake ...

Page 119: ...f the grommet of the brake hose G Insert the brake hose holder claw firmly into the swingarm H 10 20 mm 0 39 0 79 in I Insert the holder of the rear wheel sensor bracket between the ribs behind the rear wheel sensor protector J Route the rear wheel sensor lead along the brake hose grommet and then clamp it K 140 150 mm 5 51 5 91 in Clamp posi tion of the rear wheel sensor lead L 213 233 mm 8 39 9 ...

Page 120: ...CABLE ROUTING 2 71 Hydraulic unit top view ...

Page 121: ...ll the brake pipe joint assembly hydraulic unit to front brake calipers in the area between 88 92 B Clamp the brake hose hydraulic unit to rear brake caliper and brake hose rear brake master cylinder to hydraulic unit to the brake hose holder and then tighten the hoses C 15 D Affix the damper aligning the end of the damper with the end of the upper hydraulic unit bracket E Soapy water may be appli...

Page 122: ...CABLE ROUTING 2 73 Hydraulic unit front view ...

Page 123: ...t bracket 9 Hydraulic unit A Install the brake pipe joint assembly hydraulic unit to front brake calipers in the area between 45 49 B 26 C Insert the claw of the rear brake hose holder firmly into the hole of the rear brake hose guide D Insert the clamp opening facing the open ing to the front of the vehicle as shown in the illustration E Install the collar from outside of the lower hydraulic unit...

Page 124: ...CABLE ROUTING 2 75 Hydraulic unit left side view ...

Page 125: ...eservoir tank stay 4 Rear frame 5 Battery box 6 Upper hydraulic unit bracket 7 Damper 8 Quick fastener 9 Lower hydraulic unit bracket 10 Under cover 11 Brake hose hydraulic unit to rear brake caliper 12 Brake hose rear brake master cylinder to hydraulic unit A Affix the damper aligning the end of the damper with the end of the bending part of the upper hydraulic unit bracket ...

Page 126: ...CABLE ROUTING 2 77 ...

Page 127: ...SC BRAKE 3 15 CHECKING THE REAR BRAKE PADS 3 16 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 16 CHECKING THE FRONT BRAKE HOSES 3 17 CHECKING THE REAR BRAKE HOSE 3 17 CHECKING THE WHEELS 3 18 CHECKING THE TIRES 3 18 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM OPERATION 3 19 ADJUSTING THE DRIVE CHAIN SLACK 3 19 LUBRICATING THE DRIVE CHAIN 3 20 CHECKING AND ADJUSTING THE STEERING HEAD 3 21 LUBRIC...

Page 128: ...D LUBRICATING THE CABLES 3 29 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 30 CHECKING AND CHARGING THE BATTERY 3 30 CHECKING THE FUSES 3 30 REPLACING THE HEADLIGHT BULB FZ8NA 3 30 REPLACING THE HEADLIGHT BULBS FZ8SA 3 32 ADJUSTING THE HEADLIGHT BEAM FZ8NA 3 33 ADJUSTING THE HEADLIGHT BEAMS FZ8SA 3 33 ...

Page 129: ......

Page 130: ...tead From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills EAS39P1301 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi ...

Page 131: ...ack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 1000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas 11 Steering bearings Check bearing play and steer ing for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 12 Chassis fasteners Make sure that all nuts bolts and screws are p...

Page 132: ... the brake fluid Replace the brake hoses every four years and if cracked or damaged 23 Engine oil filter cartridge Replace 24 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free pl...

Page 133: ...llowing procedure applies to all of the spark plugs 1 Remove Inner panel side panel front cowling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Radiator upper cover FZ8NA Radiator upper panel FZ8SA Radiator upper bolt Radiator lower bolt Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plu...

Page 134: ...to GENERAL CHASSIS on page 4 1 Inner panel side panel front cowling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 5 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 Radiator Radiator fan motor Refer to RADIATOR on page 6 1 2 Rem...

Page 135: ...cylinders starting with cylinder 1 at TDC turn the crankshaft clockwise as specified in the following table 5 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 11 When removing the timing chain and cam shafts fasten the timing chain with a wire to retrieve it if it falls into the crankcase 6 Adjust Valve clearance Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Valve clearance measuring seq...

Page 136: ...the valve pad is marked 158 the pad thickness is 1 58 mm 0 062 in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad number Example 1 58 mm 0 062 in 0 05 mm 0 002 in 1 63 mm 0 064 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suitable valve pad TIP Refer t...

Page 137: ...peed the throttle bodies synchronization should be adjusted properly the air filter element should be clean and the engine should have ade quate compression 1 Start the engine and let it warm up for sev eral minutes 2 Install Digital tachometer Use goods on the market 3 Check Engine idling speed Out of specification Adjust 4 Adjust Engine idling speed a Turn the idle adjusting screw 1 in direction...

Page 138: ...ce the vehicle on a suitable stand 2 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Inner panel side panel front cowling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 3 Remove Synchronizing hoses 1 4 Install Vacuum gauge 1 onto the synchronizing hose Digital tachometer Use goods on the mar...

Page 139: ...ttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Measure Engine idling speed Out of specification Adjust Make sure that the vacuum pressure is within specification 3 Stop the engine and remove the measuring equipment 4 Install Synchronizing hoses 5 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3...

Page 140: ...crease the selected cylinder number press the RESET button To increase the selected cylinder number press the SELECT button 6 After selecting the cylinder simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selec tion 7 Change the CO adjustment volume by pressing the SELECT and RESET but tons TIP The CO adjustment volume appears on the tripmeter LCD To decrease t...

Page 141: ...tly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Inner panel side panel front cowling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20961 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Inner panel side panel front cowling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer ...

Page 142: ...event any air leaks 5 Install Fuel tank Refer to FUEL TANK on page 7 1 Inner panel side panel front cowling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch cable free play a Out of specification Adjust 2 Adjust Clutch cable free play Handlebar side a Turn the adjusting bolt 1 in direc...

Page 143: ... brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the...

Page 144: ...50 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators 1 almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 30 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 spec...

Page 145: ...r allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a ...

Page 146: ...to i and then fill the primary circuit with the recommended brake fluid l Tighten the bleed screw to specification m Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedu...

Page 147: ... suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE 2 Check Tire surfaces Damage wear Replace the tire WARNING EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear...

Page 148: ...l of the wheel bearings 1 Check Wheel bearings Refer to CHECKING THE FRONT WHEEL on page 4 14 and CHECKING THE REAR WHEEL on page 4 24 EAS39P1309 CHECKING THE SWINGARM OPERATION 1 Check Swingarm operation Swingarm not working properly Check the swingarm Refer to SWINGARM on page 4 88 2 Check Swingarm excessive play Refer to SWINGARM on page 4 88 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK ECA13550 A ...

Page 149: ...The drive chain consists of many interacting parts If the drive chain is not maintained prop erly it will wear out quickly Therefore the drive chain should be serviced especially when the vehicle is used in dusty areas This vehicle has a drive chain with small rub ber O rings between each side plate Steam cleaning high pressure washing certain sol vents and the use of a coarse brush can dam age th...

Page 150: ... a cou ple of times to check that it moves smoothly c Loosen the lower ring nut 6 completely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD o...

Page 151: ...just 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position c Tighten both locknuts d Make sure the installed shift rod length is within specification EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS39P1310 CHECKING THE SIDESTAND SWITCH Ref...

Page 152: ...the rear suspension EAS39P1311 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Refer to CHECKING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 85 EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Adjust th...

Page 153: ...t add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERV ING II or higher Do not allow foreign materials to enter the crankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again TIP Before checki...

Page 154: ... Engine oil drain bolt along with the gasket 7 Fill Crankcase with the specified amount of the recom mended engine oil 8 Install Engine oil filler cap along with the O ring 9 Start the engine warm it up for several minutes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 24 Oil filter wrench 90890 01426 YU 38411 Oi...

Page 155: ...ge 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification Check 6 Install Oil gallery bolt ECA39P1301 Be careful to tighten too much EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on a suitable stand Make sure the vehicle is upright Pressure gauge 90890 03153 YU 03153 Oil pressure adapter H 90890 03139 Oil pressu...

Page 156: ...may be used 3 Start the engine warm it up for several minutes and then turn it off 4 Check Coolant level TIP 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...

Page 157: ...Connect Coolant reservoir hose 11 Install Coolant reservoir tank 12 Fill Cooling system with the specified amount of the recom mended coolant Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING EWA13040 If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away...

Page 158: ...page 8 175 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing a Hold the main body 1 of the rear brake light s...

Page 159: ...the specified throttle cable free play is obtained c Tighten the locknut 1 WARNING EWA39P1301 After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change EAS21760 CHECKING AND CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 EAS21770 CHECKING THE ...

Page 160: ...ight bulb holder ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 8 Install Headlight bulb holder 9 Install Headlight bulb cover 10 Connect Hea...

Page 161: ... CHASSIS on page 4 1 2 Disconnect Headlight coupler 1 3 Remove Headlight bulb cover 1 4 Remove Headlight bulb holder 1 5 Remove Headlight bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulb with the headlight bulb holder Headlight bolt 7 Nm 0 7 m k...

Page 162: ...lly a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in direction a or b EAS39P1314 ADJUSTING THE HEADLIGHT BEAMS FZ8SA The following procedure applies to both of the headlights 1 Adjust Headlight beam vertically a Turn the adjusting screw 1 in direction a or b 2 Adjust Headlight beam horizontally a Turn the adjusting screw 1 in dir...

Page 163: ...PERIODIC MAINTENANCE 3 34 Right headlight Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right ...

Page 164: ...PERIODIC MAINTENANCE 3 35 ...

Page 165: ...EAR WHEEL 4 24 CHECKING THE REAR WHEEL 4 24 DISASSEMBLING THE REAR WHEEL 4 24 CHECKING THE REAR WHEEL DRIVE HUB 4 24 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 25 ASSEMBLING THE REAR WHEEL 4 25 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR 4 25 ADJUSTING THE REAR WHEEL STATIC BALANCE 4 28 INSTALLING THE REAR WHEEL REAR BRAKE DISC 4 28 FRONT BRAKE 4 30 INTRODUCTION 4 35 CHECKING THE F...

Page 166: ...IPES 4 59 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 59 HYDRAULIC UNIT OPERATION TESTS 4 60 TRIAL RUN 4 63 HANDLEBAR 4 64 REMOVING THE HANDLEBAR 4 66 CHECKING THE HANDLEBAR 4 66 INSTALLING THE HANDLEBAR 4 66 FRONT FORK 4 69 REMOVING THE FRONT FORK LEGS 4 71 DISASSEMBLING THE FRONT FORK LEGS 4 71 CHECKING THE FRONT FORK LEGS 4 72 ASSEMBLING THE FRONT FORK LEGS 4 73 INSTALLING THE FRONT FORK LEGS 4 77...

Page 167: ...NGARM 4 89 INSTALLING THE SWINGARM 4 90 CHAIN DRIVE 4 91 REMOVING THE DRIVE CHAIN 4 92 CHECKING THE DRIVE CHAIN 4 92 CHECKING THE DRIVE SPROCKET 4 93 CHECKING THE REAR WHEEL SPROCKET 4 93 CHECKING THE REAR WHEEL DRIVE HUB 4 93 INSTALLING THE DRIVE CHAIN 4 94 ...

Page 168: ...eat and battery Order Job Parts to remove Q ty Remarks 1 Passenger seat 1 2 Rider seat 1 3 Tool kit 1 4 Battery negative lead 1 5 Battery positive lead 1 6 Main fuse 1 7 Battery band 1 8 Battery 1 9 Battery seat 1 For installation reverse the removal proce dure ...

Page 169: ...light assembly 1 5 Headlight sub wire harness coupler 1 Disconnect 6 Left turn signal light lead connector 2 Disconnect 7 Right turn signal light lead connector 2 Disconnect 8 Left headlight side cover 1 9 Right headlight side cover 1 10 Headlight sub wire harness 1 11 Meter coupler 1 Disconnect 12 Meter assembly 1 13 Meter bracket 1 14 Meter seat 1 For installation reverse the removal proce dure ...

Page 170: ... 1 2 Left inner panel 1 3 Headlight sub wire harness coupler 2 Disconnect 4 Left turn signal light lead connector 2 Disconnect 5 Right turn signal light lead connector 2 Disconnect 6 Left side panel 1 7 Right side panel 1 8 Front cowling assembly 1 9 Front cowling bracket 2 For installation reverse the removal proce dure ...

Page 171: ... 3 Windshield 1 4 Rear view mirror 2 5 Auxiliary light lead coupler 2 Disconnect 6 Ground lead 1 Disconnect 7 Front cowling stay 1 8 Meter coupler 1 Disconnect 9 Meter assembly 1 10 Headlight coupler 2 Disconnect 11 Headlight assembly 1 12 Headlight sub wire harness 1 13 Front cowling 1 14 Front cowling trim 2 For assembly reverse the disassembly pro cedure ...

Page 172: ... Q ty Remarks 1 Left bottom cowling 1 2 Left bottom cowling bracket 1 3 Right bottom cowling 1 4 Rectifier regulator coupler 1 Disconnect 5 Rectifier regulator 1 6 Right bottom cowling bracket 1 7 Rectifier regulator bracket 1 For installation reverse the removal proce dure ...

Page 173: ...e cover 1 3 Tail brake light lead coupler 1 Disconnect 4 Upper tail cover 1 5 Tail brake light bracket 1 6 Tail brake light assembly 1 7 Left turn signal light lead connector 2 Disconnect 8 Right turn signal light lead connector 2 Disconnect 9 License plate light lead connector 2 Disconnect 10 Mud guard assembly 1 11 Lower tail cover 1 For installation reverse the removal proce dure ...

Page 174: ... 3 Assist grip 2 4 Tail brake light lead coupler 1 Disconnect 5 Upper tail cover 1 6 Tail brake light bracket 1 7 Tail brake light assembly 1 8 Left turn signal light lead connector 2 Disconnect 9 Right turn signal light lead connector 2 Disconnect 10 License plate light lead connector 2 Disconnect 11 Mud guard assembly 1 12 Lower tail cover 1 For installation reverse the removal proce dure ...

Page 175: ...owling side panel FZ8SA Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Air filter case cover 1 2 Air filter 1 3 Crankcase breather hose 1 Disconnect 4 Throttle body hose 2 Disconnect 5 Funnel 2 6 Air induction system hose 1 Disconnect 7 Air filter case 1 For installation reverse the removal proce dure 2 0 Nm 0 20 m kgf 1 5 ft Ibf T R ...

Page 176: ...n the projections of the inner panel with the slots of the front cowling and then slide the panel forward c Fit inner panel bracket a into the slot of the inner panel so that the bracket is securely inserted to the stop position d Press the rear of the inner panel downward to engage projections b e Install the quick fastener and bolts EAS39P1406 REMOVING THE SIDE PANEL FZ8SA 1 Remove Side panel 1 ...

Page 177: ...ng side panel 1 a Remove the side panel and the inner panel bracket b Disengage projections a and b sliding the front of the front cowling side panel slightly inward TIP Be careful not to damage projection c of the front cowling side panel c Remove the front cowling side panel slid ing it rearward EAS39P1409 INSTALLING THE FRONT COWLING SIDE PANEL FZ8SA 1 Install Front cowling side panel a Insert ...

Page 178: ... 11 EAS39P1410 INSTALLING THE HEADLIGHT ASSEMBLY FZ8SA 1 Install Headlight assembly a Temporarily tighten the screw 1 b Tighten the screw 2 c Tighten the screw 1 d Tighten the screws 3 not specified can be in any order ...

Page 179: ...rder Job Parts to remove Q ty Remarks 1 Brake hose holder 1 2 Front brake caliper 2 3 Front wheel sensor 1 4 Wheel axle pinch bolt 1 Loosen 5 Wheel axle 1 6 Collar 2 7 Front wheel sensor housing 1 8 Front wheel 1 9 Front brake disc 2 For installation reverse the removal proce dure ...

Page 180: ...L 4 13 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 1 4 Spacer 1 5 Wheel bearing 1 For assembly reverse the disassembly pro cedure ...

Page 181: ...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 18 and CHECKING THE WHEELS on page 3 18 3 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limits Replace 4 Check Wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings Oil seal Damag...

Page 182: ...er 1 between the socket 2 and the bearing so that both the inner race 3 and outer race 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 d Install the new oil seals EAS22010 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ECA4B56004 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the front wheel h...

Page 183: ...ake lever when removing the brake caliper 3 Remove Front wheel sensor rotor Checking the front wheel sensor and sen sor rotor 1 Check Front wheel sensor 1 Cracks bends distortion Replace Iron powder dust Clean 2 Check Front wheel sensor rotor Cracks damage Replace 3 Measure Wheel sensor rotor deflection Out of specification Clean the installa tion surface of the wheel sensor rotor and correct the ...

Page 184: ...P Measure the distance a only if the wheel bearings wheel sensor rotor or both were replaced Distance a between the wheel sensor rotor 1 and wheel sensor housing 2 Out of specification Reinstall the bear ing or replace the wheel sensor rotor 3 Install Front wheel sensor 1 Brake caliper 2 Front wheel sensor lead holders 3 Clamps 4 ECA14480 To route the front wheel sensor lead refer to CABLE ROUTING...

Page 185: ...IP 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 front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same spot ...

Page 186: ...e the brake disc bolts with new ones TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 35 3 Lubricate Oil seal lips 4 Install Collars Front wheel Wheel axle TIP Install the tire and wheel with the marks 1 pointing in the direction of wheel rotation 5 Tighten Wheel axle Wheel axle pinch bolt ECA39P1401 ...

Page 187: ...face b and then tighten the wheel axle pinch bolt If end a is not flush with sur face b align the ends manually or with a plastic hammer 6 Install Front brake caliper WARNING EWA13500 Make sure the brake hose is routed prop erly Front brake caliper bolt 40 Nm 4 0 m kgf 29 ft lbf ...

Page 188: ...ensor protector 1 2 Rear wheel sensor 1 3 Rear wheel sensor bracket 1 4 Locknut 2 Loosen 5 Adjusting bolt 2 Loosen 6 Wheel axle nut 1 7 Washer 1 8 Wheel axle 1 9 Left adjusting block 1 10 Right adjusting block 1 11 Rear wheel 1 12 Brake caliper bracket 1 13 Rear wheel sensor housing 1 14 Rear wheel sensor lead stay 1 For installation reverse the removal proce dure ...

Page 189: ...procket Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Collar 1 3 Rear wheel sprocket 1 4 Rear wheel drive hub 1 5 Rear wheel drive hub damper 6 6 Collar 1 7 Oil seal 1 8 Bearing 1 9 Rear wheel 1 For installation reverse the removal proce dure ...

Page 190: ...L 4 23 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Rear wheel sensor rotor 1 2 Oil seal 1 3 Wheel bearing 1 4 Spacer 1 5 Wheel bearing 1 For assembly reverse the disassembly pro cedure ...

Page 191: ...r wheel forward and remove the drive chain from the rear wheel sprocket EAS22091 CHECKING THE REAR WHEEL 1 Check Wheel axle Wheel bearings Oil seals Refer to CHECKING THE FRONT WHEEL on page 4 14 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 18 and CHECKING THE WHEELS on page 3 18 3 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHE...

Page 192: ... THE REAR WHEEL 1 Install Wheel bearings Oil seal Refer to ASSEMBLING THE FRONT WHEEL on page 4 15 EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA4B56008 Keep magnets including magnetic pick up tools magnetic screwdrivers etc away from the rear wheel hub 1 otherwise the wheel sensor rotor equipped in the wheel hub may be damaged resulting in improper performance of the ABS ECA14...

Page 193: ...or Cracks bends distortion Replace Iron powder dust Clean 2 Check Rear wheel sensor rotor Cracks damage Replace 3 Measure Wheel sensor rotor deflection Out of specification Clean the installa tion surface of the wheel sensor rotor and correct the wheel sensor rotor deflection or replace the wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SEN SOR ROTOR on page 4 15 Installing ...

Page 194: ... wheel sensor 1 TIP When installing the rear wheel sensor check the rear wheel sensor lead for twists and the sensor electrode for foreign materials ECA14500 To route the rear wheel sensor lead refer to CABLE ROUTING on page 2 43 5 Install Clamps 1 Brake hose holders 2 6 Connect Rear wheel sensor coupler 1 ECA14500 To route the rear wheel sensor lead refer to CABLE ROUTING on page 2 43 7 Check Rea...

Page 195: ...to CHECKING THE REAR BRAKE DISC on page 4 49 3 Lubricate Oil seal lips 4 Install Collar Rear wheel sensor housing Brake caliper bracket Rear wheel Adjusting blocks Wheel axle Washer Wheel axle nut TIP Do not install the brake caliper Align the projection a in the swingarm with the slot b of the brake caliper bracket Align the slot c in the rear wheel sensor housing with the projection d of the bra...

Page 196: ... bolts WARNING EWA13500 Make sure the brake hose is routed prop erly TIP When tightening the wheel axle nut there should be no clearance a between the adjust ing block 1 and adjusting bolt 2 Drive chain slack 20 0 30 0 mm 0 79 1 18 in Wheel axle nut 150 Nm 15 m kgf 108 ft lbf Rear brake caliper retaining bolt front 27 Nm 2 7 m kgf 20 ft lbf Rear brake caliper retaining bolt rear 22 Nm 2 2 m kgf 16...

Page 197: ... Parts to remove Q ty Remarks The following procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Bleed screw 1 For installation reverse the removal proce dure ...

Page 198: ...6 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Brake lever 1 5 Front brake light switch lead connector 2 Disconnect 6 Front brake light switch 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder assembly 1 For assembly r...

Page 199: ...T BRAKE 4 32 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 200: ...emarks The following procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Front brake caliper 1 For installation reverse the removal proce dure ...

Page 201: ...s The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 202: ... 1 Remove Front wheel Refer to FRONT WHEEL on page 4 12 2 Check Front 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 brake disc deflection turn the handlebar to the left or right to ensure that the fro...

Page 203: ...der Front brake caliper Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 3 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 4 Install Brake pads Brake pad spring TIP Always install new brake pads and new 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 contai...

Page 204: ...re applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Brake hose gaskets 2 Brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22361 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 R...

Page 205: ...als and brake caliper piston seals EAS22411 ASSEMBLING THE FRONT BRAKE CALI PERS WARNING EWA13621 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 as they will cause the brake caliper piston dust seals and brake cali per piston seals to swell and distort Whenever a brake caliper is disa...

Page 206: ...type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore alw...

Page 207: ...ssed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir 1 Brake master cylinder reservoir dia phragm holder 2 Cracks damage Replace Brake master cylinder reservoir dia phragm 3 Damage wear Replace 4 Check Brake hoses 1 Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MAS TER CYLINDER WARNING EWA13520 Before installation all int...

Page 208: ...parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluid...

Page 209: ...FRONT BRAKE 4 42 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 ...

Page 210: ...ear 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 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 For installation reverse the removal proce dure ...

Page 211: ...UEL TANK on page 7 1 Right side cover Refer to GENERAL CHASSIS on page 4 1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir hose 1 6 Rear brake light switch coupler 1 Disconnect 7 Brake hose union bolt 1 8 Brake ho...

Page 212: ...BRAKE 4 45 Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 11 Rear brake light switch 1 12 Rear brake master cylinder assembly 1 For installation reverse the removal proce dure ...

Page 213: ...e rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder yoke 1 2 Brake master cylinder kit 1 3 Hose joint 1 4 Bushing 1 5 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure ...

Page 214: ...E 4 47 Removing the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 For installation reverse the removal proce dure ...

Page 215: ... Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 For assembly reverse the disassembly pro cedure ...

Page 216: ...to REAR WHEEL on page 4 21 2 Check Rear brake disc Damage galling Replace 3 Measure 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 35 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 DISC...

Page 217: ...to contact the brake pads Remove any excess grease e Install the brake pads and brake pad spring TIP The longer tangs a of the brake pad spring must point in the direction of the brake caliper piston 3 Lubricate Rear brake caliper retaining bolt front ECA2S31022 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plug ...

Page 218: ...er piston 1 Brake caliper piston dust seal 2 Brake caliper piston seal 3 a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston ...

Page 219: ...internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston dust seal and brake caliper piston seal EAS22670 INSTALLING THE REAR BRAKE CALIPER...

Page 220: ...d cause vapor lock 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 16 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 7 Check Brake...

Page 221: ...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 1 Install Brake master cylinder kit EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Brake hose gaskets Brake hose Brake fluid reservoir hose Brake hose union bolt WARNING EWA13530 Proper brake hose routing is essential to ins...

Page 222: ...gnificantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 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 16 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Ref...

Page 223: ...fer to GENERAL CHASSIS Fuel tank Refer to FUEL TANK Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 1 Under cover 1 2 Fuel tank bracket 1 3 Brake fluid reservoir tank 1 4 Brake fluid reservoir tank stay 1 5 Fuse box 2 1 6 Waterproof coupler 1 7 ABS ECU coupler 1 Disconnect 8 Rear brake hose holder 1 9 Brake pipe joint assembly hydraulic unit to front brake calipers 1 Disconnect ...

Page 224: ...nnect 11 Brake pipe joint assembly front brake master cylinder to hydraulic unit 1 Disconnect 12 Brake pipe joint assembly rear brake master cylinder to hydraulic unit 1 Disconnect 13 Lower hydraulic unit bracket bolt 4 14 Upper hydraulic unit bracket 1 15 Lower hydraulic unit bracket 1 16 Rear brake hose guide 1 17 Hydraulic unit 1 For installation reverse the removal proce dure ...

Page 225: ...for the hydraulic unit assembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Remove Brake pipes Brake hoses TIP Do not operate the brake lever and brake pedal while removing the brake hoses and brake pipes ECA4B56015 When removing the brake hoses and brake pipes cover the area around the hydraulic unit assembly to catch any spilt brake fluid Do not...

Page 226: ...raulic unit assembly 2 Remove Rubber plugs or bolts M10 1 0 3 Connect ABS ECU coupler 1 TIP Push down the coupler ejection slider until a click is heard making sure that is installed securely 4 Install Brake pipe joint assemblies 1 Brake pipe joint assembly flare nuts 2 ECA4B56017 If the brake pipe flare nut does not turn eas ily replace the hydraulic unit brake pipes and related parts as a set 5 ...

Page 227: ... Refer to TRIAL RUN on page 4 63 EAS22800 HYDRAULIC UNIT OPERATION TESTS The reaction force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehi cle is stopped The hydraulic unit operation can be tested using the following two methods Hydraulic unit operation test 1 this test checks the function of the ABS after the sys tem was disasse...

Page 228: ... pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit assembly If the operation of the hydraulic unit is normal delete all of the fault codes Hydraulic unit operation test 2 WARNING EWA13120 Securely support the vehicle so that there...

Page 229: ...cond after the brake lever and brake pedal are operated simultaneously and continues for approximately 1 5 seconds TIP The reaction force pulsating action consists of quick pulses Be sure to continue operating the brake lever and brake pedal even after the pulsating action has stopped 11 After the pulsating action has stopped in the front brake lever it is generated in the rear brake pedal 1 0 5 s...

Page 230: ...nd brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check that the brake hoses and brake pipes are con nected correctly to the hydraulic unit assembly 13 Turn the main switch to OFF 14 Remove the test coupler adapter from the ABS test coupler 15 Turn the main switch to ON 16 Set the engine stop switch to 17 Chec...

Page 231: ... 2 Front brake light switch connector 2 Disconnect 3 Front master cylinder holder 1 4 Front brake master cylinder assembly 1 5 Right handlebar switch 1 6 Throttle cable housing 2 7 Throttle cable 2 Disconnect 8 Grip end 2 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect 11 Left handlebar switch 1 12 Handlebar grip 1 13 Clutch cable 1 Disconnect 14 Clutch lever holder 1 ...

Page 232: ...HANDLEBAR 4 65 Removing the handlebar Order Job Parts to remove Q ty Remarks 15 Upper handlebar holder 2 16 Handlebar 1 17 Lower handlebar holder 2 For installation reverse the removal proce dure ...

Page 233: ...handle bar as this may dangerously weaken it EAS22931 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 temporarily Handlebar 1 Upper handlebar holders 2 ECA39P1407 First tighten the bolts on the front side of the upper handlebar holder and then on the rear si...

Page 234: ...n page 4 40 7 Install Throttle cable clamp 1 TIP Using side a of the master cylinder as a guide install the clamp between side a and protector 2 of the throttle cable decelerator cable with the claw down and the damper facing to the master cylinder When clamping protector 3 of the throttle cable accelerator cable should be on the throttle grip side 8 Install Clutch lever holder 1 Clutch cable TIP ...

Page 235: ...There should be 1 3 mm 0 04 0 12 in of clearance a between the handlebar grip and the grip end 10 Install Left handlebar switch TIP Align the projection a on the left handlebar switch with the hole b in the handlebar 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 30 12 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page ...

Page 236: ...The following procedure applies both of the front fork legs Front wheel Refer to FRONT WHEEL on page 4 12 1 Front fender 1 2 Band 1 Left side only 3 Upper bracket pinch bolt 1 Loosen 4 Cap bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal proce dure ...

Page 237: ...re applies both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Fork spring 1 5 Locknut 1 6 Outer tube 1 7 Dust seal 1 8 Oil seal clip 1 9 Oil seal 1 10 Washer 1 11 Damper rod assembly bolt 1 12 Copper washer 1 13 Damper rod assembly 1 14 Inner tube 1 For assembly reverse the disassembly pro cedure ...

Page 238: ...RONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper rod assembly Spacer 2 Locknut 3 a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the lock nut 3 and the spacer 2 TIP Use the side of the rod holder that is marked B c Hold the cap bolt and loosen the locknut d Remove the cap bolt e Remove ...

Page 239: ...tempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air ECA39P1405 The front fork leg has a very sophisti cated internal construction which are particularly sensitive to foreign material When disassembling and assembl...

Page 240: ...g make sure all of the components are clean 1 Install Damper rod assembly 1 ECA39P1406 Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube TIP The left side damper rod assembly has the two holes of oil path unlike the right side 2 Tighten Damper rod assembly bolt along with the copper wash...

Page 241: ...l clip so that it fits into the outer tube s groove 8 Install Dust seal 1 with the fork seal driver 2 9 Fill Front fork leg with the specified amount of the recom mended fork oil ECA14230 Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 90890 01442 Adju...

Page 242: ...nd the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any resid ual air 13 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct 14 Install Fork spring 1 Spacer 2 Locknut 3 Cap bolt 4 along with the O ring a Remove the rod puller and rod puller attachment b Install the f...

Page 243: ...r tighten it WARNING EWA13670 Always use a new cap bolt O ring j Hold the cap bolt 1 and tighten the locknut 2 to specification k Remove the rod holder and fork spring compressor 15 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch ...

Page 244: ...nd lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 1 Cap bolt 2 Upper bracket pinch bolt 3 WARNING EWA13680 Make sure the brake hoses are routed prop erly Lower bracket pinch bolt 23 Nm 2 3 m kgf 17 ft lbf Cap bolt 23 Nm 2 3 m kgf 17 ft lbf Upper bracket pinch bolt 26 Nm 2 6 m kgf 19 ft lbf ...

Page 245: ... on page 4 1 Meter assembly Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 64 Front fork legs Refer to FRONT FORK on page 4 69 1 Upper headlight stay 1 2 Main switch coupler 2 Disconnect 3 Immobilizer coupler 1 Disconnect 4 Steering stem nut 1 5 Upper bracket 1 6 Front brake hose joint 2 Disconnect 7 Horn lead connector 2 Disconnect 8 Horn 1 9 Lower headlight stay 1 ...

Page 246: ...ob Parts to remove Q ty Remarks 10 Lock washer 1 11 Upper ring nut 1 12 Rubber washer 1 13 Lower ring nut 1 14 Lower bracket 1 15 Bearing cover 1 16 Lower bearing dust seal 1 17 Upper bearing 1 18 Lower bearing 1 For installation reverse the removal proce dure ...

Page 247: ...to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 64 Front fork legs Refer to FRONT FORK on page 4 69 1 Main switch coupler 2 Disconnect 2 Immobilizer coupler 1 Disconnect 3 Horn lead connector 2 Disconnect 4 Horn 1 5 Front brake hose joint 2 Disconnect 6 Horn bracket 1 7 Cable holder 2 8 Steering stem nut 1 9 Upper bracket 1 ...

Page 248: ...ob Parts to remove Q ty Remarks 10 Lock washer 1 11 Upper ring nut 1 12 Rubber washer 1 13 Lower ring nut 1 14 Lower bracket 1 15 Bearing cover 1 16 Lower bearing dust seal 1 17 Upper bearing 1 18 Lower bearing 1 For installation reverse the removal proce dure ...

Page 249: ...1 Wash Bearings Bearing races 2 Check Bearings 1 Bearing races 2 Damage pitting Replace the bearings and bearing races as a set 3 Replace Bearings Bearing races a Remove the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing races ECA14270 If the bear...

Page 250: ...r 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 21 3 Install Upper bracket Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK on page 4 69 TIP Temporarily tighten the upper and lower bracket pinch bolts 5 Tighten Steering stem nut Recommended lubricant Lithium soap based grease Steering stem n...

Page 251: ...cover Refer to GENERAL CHASSIS on page 4 1 Brake fluid reservoir bolt Refer to REAR BRAKE on page 4 43 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 4 Relay arm 2 5 Self locking nut bolt collar 1 1 1 6 Connecting arm 1 7 Collar oil seal bearing 2 4 2 8 Self locking nut bolt collar 1 1 1 9 Rear shock absorber assembly 1 10 Collar 1 For installation reverse the ...

Page 252: ... a 2 3 mm 0 08 0 12 in hole through the rear shock absorber at a point 25 30 mm 0 98 1 18 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 danger of it falling over TIP Place t...

Page 253: ... the oil seals outside 3 Install Rear shock absorber assembly Connecting arm 1 Relay arms 2 TIP Install the rear shock absorber upper bolt and frame and connecting arm bolt from the right Install the rear shock absorber lower bolt relay arm and connecting arm bolt and relay arm and swingarm bolt from the left When installing the rear shock absorber assembly lift up the swingarm Recommended lubrica...

Page 254: ...ut Relay arm and connecting arm nut 3 Frame 4 Swingarm A Left side B Right side Rear shock absorber assembly upper nut 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly lower nut 40 Nm 4 0 m kgf 29 ft lbf Frame and connecting arm nut 40 Nm 4 0 m kgf 29 ft lbf Relay arm and swingarm nut 40 Nm 4 0 m kgf 29 ft lbf Relay arm and connecting arm nut 40 Nm 4 0 m kgf 29 ft lbf ...

Page 255: ...Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 84 Chain Refer to CHAIN DRIVE on page 4 91 1 Rear fender 1 2 Drive chain guard 1 3 Brake hose holder 2 4 Drive chain adjusting bolt locknut washer 2 2 2 5 Pivot shaft nut washer 1 1 6 Pivot shaft 1 7 Swingarm 1 8 Dust cover 2 9 Drive chain guide 1 10 Spacer 1 11 Bearing 2 12 Collar oil seal bearing 1 2 1 For installation reverse the removal proce dur...

Page 256: ...play A by mov ing the swingarm from side to side If the swingarm has side to side play check the spacer bearings and dust covers c Check the swingarm vertical movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft spacer bearings and dust cov ers 4 Remove Drive chain Refer to REMOVING THE DRIVE CHAIN on page 4 92 S...

Page 257: ...ls out side 3 Install Swingarm Pivot shaft 4 Install Drive chain Refer to INSTALLING THE DRIVE CHAIN on page 4 94 Rear shock absorber assembly Connecting arm Relay arms Rear wheel Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 84 and REAR WHEEL on page 4 21 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 Recommended lubricant Lithium soap based grease Installed de...

Page 258: ...RIVE 4 91 EAS23400 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 3 1 Drive chain 1 For installation reverse the removal proce dure ...

Page 259: ...th c between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length a of the 15 link sec tion of the drive chain using the following formula Drive chain 15 link section length a length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is...

Page 260: ...rwise the O rings can be damaged 4 Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Damage wear Replace the drive chain Drive chain side plates 3 Damage wear cracks Replace the drive chain 5 Lubricate Drive chain EAS23460 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sp...

Page 261: ... inside of the connecting link 3 and inside of the connecting plate 1 is 14 1 14 3 mm 0 56 0 65 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 3 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too l...

Page 262: ...CHAIN DRIVE 4 95 ...

Page 263: ...5 21 CHECKING THE CYLINDER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 25 CHECKING THE VALVES AND VALVE GUIDES 5 26 CHECKING THE VALVE SEATS 5 28 CHECKING THE VALVE SPRINGS 5 29 CHECKING THE VALVE LIFTERS 5 30 INSTALLING THE VALVES 5 30 GENERATOR 5 32 REMOVING THE GENERATOR 5 34 INSTALLING THE GENERATOR 5 34 STARTER CLUTCH 5 36 REMOVING THE START...

Page 264: ...EVER 5 56 INSTALLING THE SHIFT SHAFT 5 56 OIL PUMP 5 57 REMOVING THE OIL PAN 5 60 CHECKING THE SPROCKET AND CHAIN 5 60 CHECKING THE OIL PUMP 5 60 CHECKING THE RELIEF VALVE 5 61 CHECKING THE OIL DELIVERY PIPES 5 61 CHECKING THE OIL STRAINER 5 61 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL WATER PUMP 5 62 INSTALLING THE OIL PAN 5 63 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 67 CHECKING THE CR...

Page 265: ...CHECKING THE CRANKSHAFT 5 81 INSTALLING THE CRANKSHAFT 5 83 TRANSMISSION 5 84 REMOVING THE TRANSMISSION 5 89 CHECKING THE SHIFT FORKS 5 89 CHECKING THE SHIFT DRUM ASSEMBLY 5 90 CHECKING THE TRANSMISSION 5 90 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 91 INSTALLING THE TRANSMISSION 5 91 ...

Page 266: ...9P1501 To prevent sparking the plug remove all ignition coil couplers and fuel injector cou plers before cranking the engine TIP The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm 15 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If t...

Page 267: ...ENGINE INSPECTION 5 2 6 Install Spark plug 7 Install Ignition coils Spark plug 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 268: ...rts to remove Q ty Remarks Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Joint 1 5 Drive sprocket cover 1 6 Plate 1 7 Drive sprocket nut 1 8 Washer 1 9 Drive sprocket 1 For installation reverse the removal proce dure ...

Page 269: ...ge 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Drive sprocket cover Refer to ENGINE REMOVAL on page 5 3 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler cover 1 4 Muffler clamp 1 Loosen 5 Muffler 1 6 Muffler gasket 1 7 Exhaust pipe 1 8 Exhaust pipe gasket 1 9 Exhaust pipe bracket 1 For installation reverse the removal proce dure ...

Page 270: ...age 7 5 Thermostat assembly Refer to THERMOSTAT on page 6 7 Oil cooler Refer to OIL COOLER on page 6 5 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Battery negative lead 1 Disconnect 2 Battery positive lead 1 Disconnect 3 Clutch cable 1 Disconnect 4 Ground lead 2 Disconnect 5 Starter motor lead 1 Disconnect 6 Ignition coil sub wire harness coupler 1 Disconnect ...

Page 271: ...arts to remove Q ty Remarks 7 Stator coil assembly lead coupler 1 Disconnect 8 Crankshaft position sensor lead coupler 1 Disconnect 9 Oil level switch lead coupler 1 Disconnect 10 Neutral switch connector 1 Disconnect For installation reverse the removal proce dure ...

Page 272: ...ove Q ty Remarks 1 Right front engine mounting bolt 1 1 2 Left front engine mounting bolt 1 3 Upper engine mounting bolt nut 1 1 4 Lower engine mounting bolt nut 1 1 5 Engine mounting adjust bolt 2 Loosen 6 Engine 1 For installation reverse the removal proce dure ...

Page 273: ...ounting bolt 1 Upper engine mounting bolt 2 TIP Do not install the engine mounting 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 TIP 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...

Page 274: ...he left front engine mounting bolt 1 and then tighten the right front engine mounting bolt 1 2 10 Install Shift arm 1 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wrench adapter 90890 01476 Lower engine mounting nut 51 Nm 5 1 m kgf 37 ft lbf Upper engine mounting nut 51 Nm 5 1 m kgf 37 ft lbf Left front engine mounting bolt 45 Nm 4 5 m kgf 33 ft lbf Right front engine m...

Page 275: ...e crankcase EAS39P1501 INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket Washer Drive sprocket nut 1 TIP While applying the rear brake tighten the drive sprocket nut Stake the drive sprocket nut 1 at a cutout a in the drive axle Drive sprocket nut 85 Nm 8 5 m kgf 61 ft lbf LOCTITE New ...

Page 276: ...to THROTTLE BODIES on page 7 5 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 15 1 Cylinder identification sensor coupler 1 Disconnect 2 Cylinder identification sensor 1 3 Ignition coil coupler 4 Disconnect 4 Ignition coil 4 5 Spark plug 4 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Timing chain guide top side 1 For installation reverse the removal proce dure ...

Page 277: ...engine side Disconnect Refer to CLUTCH on page 5 45 1 Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Intake camshaft cap 3 4 Exhaust camshaft cap 3 5 Intake camshaft 1 6 Exhaust camshaft 1 7 Camshaft sprocket 2 8 Timing chain guide intake side 1 9 Timing chain guide exhaust side 1 10 Timing chain 1 For installation reverse the removal proce dure ...

Page 278: ... the camshaft lobes are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove Intake camshaft caps 1 Exhaust camshaft caps 2 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 5 Remove Intake camshaft 1 Exhaust camshaft 2 TIP To pre...

Page 279: ...Install the camshaft into the cylinder head without the camshaft caps b Position strip of Plastigauge 1 onto the camshaft journal as shown Camshaft lobe dimension limit Intake A 35 750 35 850 mm 1 4075 1 4114 in Limit 35 650 mm 1 4035 in Intake B 27 950 28 050 mm 1 1004 1 1043 in Limit 27 850 mm 1 0965 in Exhaust A 34 750 34 850 mm 1 3681 1 3720 in Limit 34 650 mm 1 3642 in Exhaust B 27 950 28 050...

Page 280: ...3870 CHECKING THE TIMING CHAIN AND CAM SHAFT SPROCKET 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft and camshaft sprocket as a set 2 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain g...

Page 281: ...g chain tensioner rod TIP Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain tensioner housing a Install the timing chain tensioner spring timing chain tensioner spring seat and tim ing chain tensioner rod 1 b Squeeze the timing chain tensioner clip 2 and then push the timing chain tensioner rod 3 into the timing chain tensioner hous ing TIP Do not releas...

Page 282: ...e engine TIP Install the camshaft projection a at the posi tion shown in the illustration Tighten the camshaft sprocket bolt with the camshaft wrench 3 3 Install Exhaust camshaft 1 Intake camshaft 2 TIP Make sure the punch mark a on each cam shaft faces up 4 Install Intake camshaft caps Exhaust camshaft caps TIP Make sure each camshaft cap is installed in its original place Refer to the identifica...

Page 283: ...g 6 Check Camshaft punch mark a Make sure the punch mark a on the camshaft is aligned with the camshaft cap alignment mark b 7 Install Timing chain tensioner gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 WARNING EWA39P1502 Always use a new timing chain tensioner gasket ECA5D01011 The arrow mark a on the timing chain ten sioner should face up 8 Turn Crankshaft several turns clockwi...

Page 284: ...r faces a of the cylinder head cover and cyl inder head cover gasket Apply bond Yamaha bond No 1215 Three bond No 1215 onto the mating surfaces b of the cylinder head cover gasket and cylin der head Tighten the cylinder head cover bolts stages and in a crisscross pattern 13 Install Spark plugs Ignition coils 1 TIP Assemble ignition coils 1 in the direction shown in the illustration Cylinder head c...

Page 285: ...VAL on page 5 3 Intake camshaft Refer to CAMSHAFTS on page 5 11 Exhaust camshaft Refer to CAMSHAFTS on page 5 11 1 Coolant pipe 1 2 Fast idle plunger inlet hose 1 3 Coolant temperature sensor 1 4 Right front engine mounting bolt 2 1 5 Cylinder head 1 6 Cylinder head gasket 1 7 Dowel pin 2 For installation reverse the removal proce dure ...

Page 286: ... Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cyl inder head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using...

Page 287: ...g surface with engine oil 4 Tighten Cylinder head nuts 1 10 Cylinder head bolts 11 12 TIP Tighten the cylinder head nuts in the tightening sequence as shown and torque them in 3 stages 5 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAM SHAFTS on page 5 17 Cylinder head nut 1st 25 Nm 2 5 m kgf 18 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf 3rd Nut 1 7 10 80 Nut 8 9 100 Cylinder head bo...

Page 288: ...ngs Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Intake valve lifter 8 2 Intake valve pad 8 3 Intake valve cotter 16 4 Intake valve spring retainer 8 5 Intake valve spring 8 6 Intake valve 8 7 Intake valve stem seal 8 8 Intake valve spring seat 8 9 Intake valve guide 8 ...

Page 289: ...move Q ty Remarks 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve spring retainer 8 14 Exhaust valve spring 8 15 Exhaust valve 8 16 Exhaust valve stem seal 8 17 Exhaust valve spring seat 8 18 Exhaust valve guide 8 For installation reverse the removal proce dure ...

Page 290: ... the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 5 28 a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spr...

Page 291: ...guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven a 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 Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Valve stem to valv...

Page 292: ...alve margin thickness a Out of specification Replace the valve 6 Measure Valve stem runout Out of specification Replace the valve TIP When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the valve stem seal Valve guide remover ø4 90890 04111 Valve guide remover 4 0 mm YM 04111 Valve guide installer ø4 90890 04112 Valve guide installer 4 0 mm...

Page 293: ...ng will have been removed 4 Lap Valve face Valve seat TIP After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face ECA13790 Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the val...

Page 294: ...alve seat to make a clear impression j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Compressed valve spring force a Out of specification Repl...

Page 295: ...th the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its origi nal place Install the valve springs with the larger pitch a facing up Installed compression spring force intake 130 60 150 20 N 13 32 15 32 kgf 29 36 33 76 lbf Installed compression spring force exhaust...

Page 296: ...ive force could damage the valve 6 Lubricate Valve pad with the recommended lubricant Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachm...

Page 297: ...NERAL 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 24 1 Stator coil assembly lead coupler 1 Disconnect 2 Plug 1 3 Idle adjust screw holder 1 4 Generator rotor cover 1 5 Gasket 1 6 Dowel pin 2 7 Generator rotor assembly 1 8 Stator coil assembly lead holder 1 9 Stator coil assembly 1 10 Dowel pin 2 ...

Page 298: ...moving the generator Order Job Parts to remove Q ty Remarks 11 Bearing housing 1 12 Collar 1 13 Bearing 1 14 Starter clutch idler gear 1 15 Idler gear shaft 1 16 Bearing 1 For installation reverse the removal proce dure ...

Page 299: ...ly loosened remove them 2 Remove Generator rotor and starter clutch assem bly 1 3 Remove Idle gear shaft bolt 1 Washer 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 Apply Sealant onto the stator coil lead grommet 1 Idle gear shaft bolt 10 Nm 1 0 m kgf 7 2 ft lbf...

Page 300: ...tor cover 1 TIP First tighten 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 M8 22 Nm 2 2 m kgf 16 ft lbf Generator rotor cover bolt M6 12 Nm 1 2 m kgf 8 7 ft lbf New ...

Page 301: ...r Job Parts to remove Q ty Remarks 1 Spacer 1 2 O ring 1 3 Washer 1 4 Starter clutch drive gear 1 5 Collar 1 6 Washer 1 7 Driven gear 1 8 Damper 3 9 Starter clutch assembly plate 1 10 Starter clutch assembly 1 11 Generator rotor 1 For installation reverse the removal proce dure ...

Page 302: ...n gear 1 Dampers 2 4 Remove Starter clutch assembly plate 1 Starter clutch assembly 2 EAS5D01018 CHECKING THE DAMPER 1 Check Dampers 1 Damage wear Replace EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s ...

Page 303: ...ch drive gear clockwise B it should turn freely other wise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Starter clutch assembly 1 Starter clutch assembly plate 2 ECA24590 Be sure to install the starter clutch assem bly to the driven gear so that the white paint mark is outside 2 Install Generator rotor 1 Dampers 2 Driven gear 3 TIP Be sure to i...

Page 304: ...y Remarks Rider 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 24 1 Crankshaft position sensor lead coupler 1 Disconnect 2 Crankshaft position sensor 1 3 Plug 1 4 Pickup rotor cover 1 5 Gasket 1 For installation reverse the removal proce dure ...

Page 305: ...lt 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 rings Crankshaft position sensor 2 Connect Crankshaft position sensor lead coupler Pickup rotor cover bolt 12 Nm 1 2 m kgf 8 7 ft lbf Crankshaft position sensor bolt 10 Nm 1 0 m kgf 7 2 ft l...

Page 306: ...marks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Throttle bodies Refer to THROTTLE BODIES on page 7 5 Right throttle body joint Refer to THROTTLE BODIES on page 7 5 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure ...

Page 307: ...embly and rear cover replace the starter motor assembly Disassembling the starter motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 308: ...e the armature assembly resis tances with the digital circuit tester b If any resistance is out of specification replace the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of specification Replace the brush holder set Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer ...

Page 309: ... STARTER MOTOR 1 Install Brush holder set 2 Install Rear cover 1 Starter motor yoke 2 Front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the front and rear cover EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor bolts 2 2 Connect Starter motor lead 3 Starter motor bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 310: ...r Order Job Parts to remove Q ty Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 For installation reverse the removal proce dure ...

Page 311: ... Removing the pull lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal proce dure ...

Page 312: ...essure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 Green paint mark 6 Clutch plate 1 6 7 Friction plate 2 6 Purple paint mark 8 Clutch boss nut 1 9 Washer 1 10 Clutch boss 1 11 Wire circlip 1 12 Clutch plate 2 1 13 Friction plate 3 1 14 Clutch damper spring 1 15 Clutch damper spring seat 1 ...

Page 313: ...CLUTCH 5 48 Removing the clutch Order Job Parts to remove Q ty Remarks 16 Thrust plate 1 17 Clutch housing 1 18 Bearing 1 For installation reverse the removal proce dure ...

Page 314: ...y loosened remove them 2 Remove 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 a 6 Loosen Clutch boss nut 1 TIP While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 ...

Page 315: ... EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric tion plates as a set TIP Measure the friction plate at four places EAS25111 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutc...

Page 316: ...age pitting wear Deburr the clutch housing dogs or replace the clutch hous ing TIP 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 TIP Pitting on the clutch boss splines will cause erratic clutch operatio...

Page 317: ...Clutch damper spring seat 1 Clutch damper spring 2 2 Install Friction plate 3 1 Clutch plate 2 2 3 Install Wire circlip 1 4 Install Clutch housing 1 TIP Make sure to fit the projections a of the oil water pump assembly drive sprocket to the concave b of the clutch housing 5 Install Thrust plate Clutch boss assembly 1 Washer Clutch boss nut 2 TIP Install the washer on the main axle with the OUT mar...

Page 318: ...ate shifting half phase Assemble friction plate 1 to the clutch boss assembly so that red paint marks a on fric tion plate 1 is aligned with red paint mark b of friction plates 2 and 3 as shown in the illustration 8 Install Bearing Pull rod 1 Pressure plate 2 Clutch springs Clutch spring bolts 3 TIP Apply lithium soap based grease onto the pull rod Position the pull rod so that the teeth a face to...

Page 319: ...ull lever TIP Install the pull lever with the O mark facing toward lower side When installing the pull lever 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 11 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 13 Clutch ...

Page 320: ...r to CLUTCH on page 5 45 Shift arm and shift rod Refer to ENGINE REMOVAL on page 5 3 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Shift shaft spring 1 6 Collar 1 7 Shift shaft spring stopper 1 8 Stopper lever 1 9 Washer 1 10 Stopper lever spring 1 11 Bearing 1 12 Oil seal 1 13 Bearing 1 For installation reverse the removal proce dure ...

Page 321: ...SHIFT SHAFT 1 Install Washer Stopper lever 1 Shift shaft spring stopper 2 Stopper lever spring 3 TIP Hook the ends of the stopper lever spring onto the stopper lever and the spring hook Mesh the stopper lever with the shift drum segment assembly 2 Install Bearing Washer Collar Shift shaft spring 1 Shift shaft 2 TIP Hook the end of the shift shaft spring onto the shift shaft spring stopper 3 Instal...

Page 322: ...E OIL on page 3 24 O2 sensor Refer to ENGINE REMOVAL on page 5 3 Muffler Refer to ENGINE REMOVAL on page 5 3 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 3 Clutch assembly Refer to CLUTCH on page 5 45 Water pump inlet pipe Refer to RADIATOR on page 6 1 Water pump outlet pipe Refer to OIL COOLER on page 6 5 1 Oil level switch lead coupler 1 Disconnect 2 Oil level switch lead holder 1 3 O...

Page 323: ... 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 18 Oil water pump assembly 1 For installation reverse the removal proce dure ...

Page 324: ...ing the oil 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 rotor assembly 1 7 Pin 1 For assembly reverse the disassembly pro cedure ...

Page 325: ...il water pump assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Oil pump housing 2 Cracks damage wear Replace the defective part s 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clear ance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the defec tive part s Inner rotor to ...

Page 326: ...Damage wear Replace the relief valve assembly EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 Oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent 1 Inner rotor 2 Outer rotor 3 Oil pump ...

Page 327: ...l pump side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 60 EAS25030 INSTALLING THE OIL WATER PUMP 1 Install O ring Oil water pump assembly 1 Dowel pin Bolts 2 2 Install Washer Oil water pump assembly drive chain 1 Oil water pump assembly drive sprocket 2 Collar ECA5D01016 After installing the oil water pump assem bly drive chain and drive sprocket make sure the oil water pu...

Page 328: ...5 Install Relief valve assembly 1 O ring Oil strainer 2 O ring Oil pipe 3 O rings Drain pipe 4 O rings EAS25050 INSTALLING THE OIL PAN 1 Install Dowel pins Gasket Oil pan 1 Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil delivery pipe bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil strainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil pipe bolt 10 Nm 1 0 m kgf 7 2 ...

Page 329: ...12820 Always use new copper washers TIP Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with lith ium soap based grease Oil level switch bolt 10 Nm 1 0 m kgf 7 2 ft lbf Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf ...

Page 330: ...EMOVAL on page 5 3 Cylinder head Refer to CYLINDER HEAD on page 5 20 Shift shaft assembly Refer to SHIFT SHAFT on page 5 55 Crankshaft position sensor Refer to CRANKSHAFT POSITION SEN SOR on page 5 39 Oil water pump assembly Refer to OIL PUMP on page 5 57 Starter motor Refer to ELECTRIC STARTER on page 5 41 1 Oil return pipe 1 2 Blind plug 1 3 Neutral switch 1 ...

Page 331: ...ng the crankcase Order Job Parts to remove Q ty Remarks 4 Crankcase breather hose 1 5 Ventilation chamber cover 1 6 Ventilation chamber cover gasket 1 7 Left side cover 1 8 O ring 1 9 Lower crankcase 1 10 Dowel pin 3 For installation reverse the removal proce dure ...

Page 332: ... the position of each part very carefully 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 mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS25650 ASSEMBLING THE CRANKCASE 1 Lubri...

Page 333: ...E to the screw of the bolt 11 and engine oil to the bearing surface Tighten the bolts in the tightening sequence cast on the crankcase M9 105 mm 4 1 in bolts with washers 1 10 M8 60 mm 2 4 in bolt 11 M8 60 mm 2 4 in bolts 12 16 M8 50 mm 2 0 in bolts 13 15 M6 70 mm 2 8 in bolts 19 21 23 M6 65 mm 2 5 in shoulder bolts 17 18 M6 60 mm 2 4 in bolt and copper washer 22 M6 60 mm 2 4 in bolts 24 25 M6 50 ...

Page 334: ... Q ty Remarks Lower crankcase Refer to CRANKCASE on page 5 65 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 13 Dowel pin 2 For installation reverse the removal proce dure ...

Page 335: ...to drive the piston pin out TIP 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 3 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open th...

Page 336: ...replace the piston and piston rings as a set EAS24430 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set TIP Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 68 000 68 010 mm 2 6772 2 6776 in Taper limit 0 050 mm 0 0020 in Out of round limit...

Page 337: ... 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrica tion system 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 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 Piston ring end gap Top ring 0 25 0 35 mm 0 0098...

Page 338: ...gs must be installed in their orig inal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rods halves b Install the big end upper bearing into the connecting rod and the big end lower bear ing into the connecting rod cap TIP 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 Plastig...

Page 339: ... that the sections shown a and b are flush with each other by touching the surface TIP 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 f 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 TI...

Page 340: ... each other by touch ing the surface k Remove the connecting rod and big end bearings l Measure the compressed Plastigauge width on the crankshaft pin If the crank shaft pin to big end bearing clearance is out of specification select replacement big end bearings 2 Select Big end bearings P1 P4 TIP The numbers A stamped into the crank shaft web and the numbers 1 on the con necting rods are used to ...

Page 341: ... rod bolts using the plastic region tightening angle method Always install new bolts TIP Install by carrying out the following procedures in order to assemble in the most suitable con dition a Replace the connecting rod bolts with new ones b Clean the connecting rod bolts and lubri cate the bolt threads and seats with molyb denum disulfide oil c After installing the big end bearing assem ble the c...

Page 342: ...ctive connecting rod 2 Piston pin 3 Piston pin clips 4 TIP Apply engine oil onto the piston pin Make sure that the Y mark a on the con necting rod faces left when the punch mark b on the piston is pointing up as shown Install the piston pin clips so that the clip ends are 3 mm 0 12 in c or more from the cutout in the piston Reinstall each piston into its original cylinder 5 Lubricate Piston Piston...

Page 343: ...re that the projection b on the con necting rod cap faces the same direction as the Y mark a on the connecting rod Apply Molybdenum disulfide oil to the bolt threads and bearing surface of the connect ing rod bolt and connecting rod cap 11 Tighten Connecting rod bolts 1 TIP Tighten the connecting rod bolts using the fol lowing procedure a Tighten the connecting rod bolts with a torque wrench b Put...

Page 344: ...the procedure again ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle d After the installation check that the section shown a is flush with each other by touch ing the surface WARNING EWA39P1503 If the connecting rod and cap are not flush with each other remove the connecting rod bolts and big end bearing and restart from step 1 In this case make sure to...

Page 345: ...CRANKCASE on page 5 65 Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 70 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 4 Washer 1 5 Timing chain drive sprocket 1 6 Straight key 1 7 Pickup rotor 1 8 Oil nozzle 4 For installation reverse the removal proce dure ...

Page 346: ...Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings ECA13920 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 a Clean the crankshaft journal be...

Page 347: ...gs h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crank shaft web and the numbers B stamped into the lower crankcase are used to determine the replacement cra...

Page 348: ...pper bearings into the upper crankcase Crankshaft journal lower bearings into the lower crankcase Crankshaft TIP Align the projections a on the crankshaft journal bearings 1 with the notches b in the crankcase Be sure to install each crankshaft journal bearings in its original place ...

Page 349: ...ve Q ty Remarks Crankcase lower Separate Refer to CRANKCASE on page 5 65 1 Drive axle assembly 1 2 Oil seal 1 3 Bearing 1 4 Washer 1 5 Shift fork guide bar retainer 2 6 Spring 2 7 Shift fork guide bar 2 8 Shift fork L 1 9 Shift fork R 1 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle retainer 1 13 Main axle assembly 1 ...

Page 350: ...SSION 5 85 Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 14 Oil pipe 1 15 Oil baffle plate 1 16 Bearing 2 For installation reverse the removal proce dure ...

Page 351: ...ar 1 install the gear with groove a facing to the toothed lock washer 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 352: ...sher 1 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 ...

Page 353: ...TRANSMISSION 5 88 Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks 20 Collar 1 21 Bearing 1 22 Circlip 1 23 Drive axle 1 For assembly reverse the disassembly pro cedure ...

Page 354: ... 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 355: ...2 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 Tran...

Page 356: ...iner 1 Toothed lock washer 2 TIP With the toothed lock washer retainer 1 in the groove a in the axle align the projection c on the retainer with an axle spline b and then install the toothed lock washer 2 Be sure to align the projection on the toothed lock washer that is between the alignment marks e with the alignment mark d on the retainer EAS26350 INSTALLING THE TRANSMISSION 1 Install Bearing 1...

Page 357: ...n 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 TIP 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 axle Make sure that the drive axle bearing circlip a is inserted into the grooves in the upper crankcase 4 Check Transmission Rough movement Repa...

Page 358: ...TRANSMISSION 5 93 ...

Page 359: ...R 6 5 CHECKING THE OIL COOLER 6 6 INSTALLING THE OIL COOLER 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 9 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 9 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 ...

Page 360: ...1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Drive sprocket cover Refer to ENGINE REMOVAL on page 5 3 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Radiator side cover 2 2 Coolant reservoir hose 1 Disconnect 3 Radiator inlet hose 1 Disconnect 4 Water pump breather hose 1 1 Disconnect 5 Oil cooler outlet hose 1 6 Radiator outlet hose 1...

Page 361: ... to remove Q ty Remarks 8 Radiator upper panel 1 FZ8SA 9 Radiator fan motor coupler 2 Disconnect 10 Radiator 1 11 Radiator fan motor 2 12 Water pump breather hose 2 1 Disconnect 13 Water pump inlet pipe 1 For installation reverse the removal proce dure ...

Page 362: ...k Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 41 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 27 2 Check Cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator Rad...

Page 363: ...2 7 kPa 1 23 kgf cm 17 8 psi of pressure c Measure the indicated pressure with the gauge 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 364: ...efer to CHANGING THE COOLANT on page 3 27 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 1 Water jacket joint inlet hose 1 2 Oil cooler inlet hose 1 3 Oil cooler union bolt 1 4 Washer 1 5 Oil cooler 1 6 Water pump outlet pipe 1 7 Water jacket joint 1 For installation reverse the removal proce dure ...

Page 365: ...soap based grease to the O ring 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 27 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 24 4 Check Cooling sy...

Page 366: ... Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 5 Coolant Drain Refer to CHANGING THE COOLANT on page 3 27 1 Band 1 2 Radiator inlet hose 1 3 Thermostat assembly 1 4 Thermostat assembly inlet hose 1 5 Coolant reservoir breather hose 1 6 Coolant reservoir hose 1 7 Coolant reservoir cap 1 8 Coolant reservo...

Page 367: ...ERMOSTAT 6 8 Disassembling the thermostat assembly Order Job Parts to remove Q ty Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly reverse the disassembly pro cedure ...

Page 368: ... s indicated tem perature TIP If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating 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 TIP Install the thermostat with its breath...

Page 369: ... the recom mended coolant Refer to CHANGING THE COOLANT on page 3 27 2 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 3 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 ...

Page 370: ...remove Q ty Remarks Oil water pump assembly Refer to OIL PUMP on page 5 57 Oil pump rotor Refer to OIL PUMP on page 5 57 1 Water pump cover 1 2 Pin 2 3 Impeller shaft along with the impeller 1 4 Water pump seal 1 5 Oil seal 1 6 Bearing 1 For assembly reverse the disassembly pro cedure ...

Page 371: ...rewdriver TIP Do not scratch the impeller shaft EAS26541 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller 2 Cracks damage wear Replace Water pump housing 3 Cracks damage wear Replace the oil water pump assembly 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Water pump inlet pipe Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Bearin...

Page 372: ... 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 ECA14090 Make sure the rubber damper and rubber damper holder are flush with the impeller Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 2 Water pump housing 3 Mechanical seal installer 4 Middle driven s...

Page 373: ...CKING THE FUEL PRESSURE 7 4 THROTTLE BODIES 7 5 REMOVING THE FUEL HOSE THROTTLE BODY SIDE 7 8 CHECKING THE FUEL INJECTORS 7 8 INSTALLING THE INJECTORS 7 8 CHECKING THE INJECTOR PRESSURE 7 8 CHECKING AND CLEANING THE THROTTLE BODIES 7 9 INSTALLING THE FUEL HOSE THROTTLE BODY SIDE 7 11 ADJUSTING THE THROTTLE POSITION SENSOR 7 11 ADJUSTING THE SUB THROTTLE POSITION SENSOR 7 12 AIR INDUCTION SYSTEM 7 ...

Page 374: ...to GENERAL CHASSIS on page 4 1 1 Fuel tank cover 1 2 Fuel hose connector cover 1 3 Fuel hose connector 1 Disconnect 4 Fuel sender coupler 1 Disconnect 5 Fuel pump coupler 1 Disconnect 6 Fuel tank drain hose 1 Disconnect 7 Fuel tank breather hose 1 Disconnect 8 Fuel tank 1 9 Fuel pump bracket 1 10 Fuel pump 1 11 Fuel pump gasket 1 12 Filler cap assembly 1 For installation reverse the removal proce ...

Page 375: ... with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose ECA14B1003 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools TIP To remove the fuel hose from the fuel pump press the two buttons 1 on the sides of the connector and then remove the hose Before removing the hose place a few rags ...

Page 376: ...033 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel pump until a distinct click is heard It is prohibited to wear the cotton work gloves or equivalent coverings Attach the fuel hose connector...

Page 377: ...9P1702 Cover fuel hose connection with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose ECA14B1003 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools d Connect the pressure gauge 2 and fuel pressure adapter 3 to the fuel hose e Start the engine f Measure the fuel pressure Faulty Repla...

Page 378: ...age 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle cable handlebar side Disconnect Refer to HANDLEBAR on page 4 64 1 Fuel hose 1 2 Fuel injection system sub wire harness coupler 1 Disconnect 3 Sub throttle position sensor coupler 1 Disconnect 4 Throttle body hose 2 5 Fast idle plunger outlet hose 1 Disconnect 6 Fast idle plunger inlet hose 1 Disconnect 7 Idle adjust screw wire 1...

Page 379: ... 7 6 Removing the throttle bodies Order Job Parts to remove Q ty Remarks 10 Coolant temperature sensor coupler 1 Disconnect 11 Throttle bodies 1 12 Throttle body joint 2 For installation reverse the removal proce dure ...

Page 380: ...ose joint 5 3 Negative pressure hose Thin 11 4 Negative pressure hose Thick 4 5 Intake air pressure sensor 1 6 Throttle position sensor 1 7 Sub throttle position sensor 1 8 Idle adjust screw wire 1 9 Air screw set 4 10 Collar 1 11 Fuel rail 2 12 Fuel rail joint 1 13 Fuel injector 4 For installation reverse the removal proce dure ...

Page 381: ... the battery terminal before checking the injectors ECA39P1701 When checking the injectors do not allow any foreign material to enter or adhere to the injectors fuel rail or O rings If an injector is subject to strong shocks or excessive force replace it 1 Check Injectors Damage defective Replace Refer to FUEL INJECTION SYSTEM on page 8 47 EAS39P1705 INSTALLING THE INJECTORS ECA39P1702 Always use ...

Page 382: ... the fuel injectors EAS39P1706 CHECKING AND CLEANING THE THROT TLE BODIES TIP Before cleaning the throttle bodies check the following items Valve clearance Spark plugs Compression pressure Air filter element Throttle body joints Fuel hose Air induction system Exhaust system Breather hoses Vacuum hoses Throttle body hoses Fast idle plunger inlet hose Fast idle plunger outlet hose WARNING EWA14B1021...

Page 383: ...the open position WARNING EWA14B1022 When cleaning the throttle bodies be care ful not to injure yourself on the throttle valves or other components of the throttle bodies ECA39P1704 Do not open the sub throttle valves by sup plying electrical power to the throttle bod ies d Apply a petroleum based solvent to the throttle valves and the inside of the throttle bodies to remove any carbon deposits T...

Page 384: ...TLE BODY SIDE 1 Connect Fuel hose throttle body side ECA14B1033 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose securely onto the fuel rail joint until a distinct click is heard To install the fuel hose onto the fu...

Page 385: ...ENSOR WARNING EWA39P1701 Handle the sub throttle position sensor with special care Never subject the sub throttle position sensor to strong shocks If the sub throt tle position sensor is dropped replace it 1 Check Sub throttle position sensor Refer to CHECKING THE SUB THROT TLE POSITION SENSOR on page 8 199 2 Adjust Sub throttle position sensor angle a Remove the throttle bodies and temporary tigh...

Page 386: ...in the spec ified range g After adjusting the sub throttle position sensor angle tighten the sub throttle posi tion sensor screw 2 h Remove the test harness sub throttle posi tion sensor 3P and install the throttle bod ies Positive tester probe Green yellow wire harness color Negative tester probe Black blue wire harness color Output voltage 0 3 0 4 V Sub throttle position sensor screw 3 5 Nm 0 35...

Page 387: ...THROTTLE BODIES 7 14 ...

Page 388: ...AIR INDUCTION SYSTEM 7 15 EAS27040 AIR INDUCTION SYSTEM ...

Page 389: ...AIR INDUCTION SYSTEM 7 16 1 Air filter case 2 Air induction system hose air filter case to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover ...

Page 390: ...ANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Radiator Refer to RADIATOR on page 6 1 1 Air induction system hose air cut off valve to reed valve cover 1 2 Air induction system hose air cut off valve to reed valve cover 1 3 Air cut off valve coupler 1 Disconnect 4 Air cut off valve 1 5 Air induction system hose air filter case to air cut off valve 1 6 Reed valve cover 2 7 Ree...

Page 391: ...the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Reed valve seat Cracks damage Replace the reed valve...

Page 392: ... 7 19 Reed valve assembly TIP Install the reed valve assembly so that the open side turns to the exhaust side of the engine 2 Install Reed valve cover A Exhaust side Reed valve cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE ...

Page 393: ...NALING SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 TROUBLESHOOTING 8 35 COOLING SYSTEM 8 41 CIRCUIT DIAGRAM 8 41 TROUBLESHOOTING 8 45 FUEL INJECTION SYSTEM 8 47 CIRCUIT DIAGRAM 8 47 ECU SELF DIAGNOSTIC FUNCTION 8 51 TROUBLESHOOTING METHOD 8 53 DIAGNOSTIC MODE 8 54 TROUBLESHOOTING DETAILS 8 55 DIAGNOSTIC CODE TABLE 8 107 FUEL PUMP SYSTEM 8 109 CIRCUIT DIAGRAM 8 109 TROUBLESHOOTING 8 113 IMMOBILIZER SYSTEM 8 1...

Page 394: ... 174 ELECTRICAL COMPONENTS 8 175 CHECKING THE SWITCHES 8 179 CHECKING THE BULBS AND BULB SOCKETS 8 184 CHECKING THE FUSES 8 185 CHECKING AND CHARGING THE BATTERY 8 186 CHECKING THE RELAYS 8 189 CHECKING THE TURN SIGNAL HAZARD RELAY 8 190 CHECKING THE RELAY UNIT DIODE 8 191 CHECKING THE IGNITION COILS 8 192 CHECKING THE CRANKSHAFT POSITION SENSOR 8 193 CHECKING THE LEAN ANGLE SENSOR 8 194 CHECKING ...

Page 395: ......

Page 396: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...

Page 397: ...cut off relay 17 Neutral switch 18 Sidestand switch 21 Lean angle sensor 23 Cylinder identification sensor 24 Crankshaft position sensor 25 ECU engine control unit 26 Ignition coil 1 27 Ignition coil 2 28 Ignition coil 3 29 Ignition coil 4 30 Spark plug 56 Right handlebar switch 58 Engine stop switch 61 Left handlebar switch 62 Clutch switch 85 Ignition fuse ...

Page 398: ...IGNITION SYSTEM 8 3 ...

Page 399: ...cut off relay 17 Neutral switch 18 Sidestand switch 21 Lean angle sensor 23 Cylinder identification sensor 24 Crankshaft position sensor 25 ECU engine control unit 26 Ignition coil 1 27 Ignition coil 2 28 Ignition coil 3 29 Ignition coil 4 30 Spark plug 56 Right handlebar switch 58 Engine stop switch 61 Left handlebar switch 62 Clutch switch 86 Ignition fuse ...

Page 400: ...w to the ECU when both the neutral switch and sidestand switch are set to OFF thereby preventing the spark plugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the side stand switch circuit is closed The transmission is in neutral the neutral switch circuit is closed an...

Page 401: ...M 8 6 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignition coil 7 Spark plug 8 ECU engine control unit 9 Sidestand switch 10 Relay unit diode 11 Neutral switch 12 Battery negative lead ...

Page 402: ...E FUSES on page 8 185 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 4 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION COILS on page 8 192 Ignition system is OK 5 Check the i...

Page 403: ...tch 10 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the clutch switch 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 ...

Page 404: ...IGNITION SYSTEM 8 9 NG OK 16 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 405: ...IGNITION SYSTEM 8 10 ...

Page 406: ...ELECTRIC STARTING SYSTEM 8 11 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...

Page 407: ...ound 9 Battery 10 Negative battery ground lead 12 Starter relay 13 Starter motor 14 Relay unit 15 Starting circuit cut off relay 17 Neutral switch 18 Sidestand switch 56 Right handlebar switch 58 Engine stop switch 59 Start switch 61 Left handlebar switch 62 Clutch switch 85 Ignition fuse ...

Page 408: ...ELECTRIC STARTING SYSTEM 8 13 ...

Page 409: ...ound 9 Battery 10 Negative battery ground lead 12 Starter relay 13 Starter motor 14 Relay unit 15 Starting circuit cut off relay 17 Neutral switch 18 Sidestand switch 56 Right handlebar switch 58 Engine stop switch 59 Start switch 61 Left handlebar switch 62 Clutch switch 86 Ignition fuse ...

Page 410: ...osed 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 ...

Page 411: ...STAND 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 Diode 13 Starter relay 14 Starter motor ...

Page 412: ...fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 194 Starter motor is OK Perform the elec tric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE STARTER MOTOR on ...

Page 413: ... switch 10 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the sidestand switch 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the clutch switch 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the right h...

Page 414: ...CHARGING SYSTEM 8 19 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...

Page 415: ...CHARGING SYSTEM 8 20 FZ8NA 2 Rectifier regulator 3 AC magneto 6 Main fuse 7 Frame ground 8 Engine ground 9 Battery 10 Negative battery ground lead ...

Page 416: ...CHARGING SYSTEM 8 21 ...

Page 417: ...CHARGING SYSTEM 8 22 FZ8SA 2 Rectifier regulator 3 AC magneto 6 Main fuse 7 Frame ground 8 Engine ground 9 Battery 10 Negative battery ground lead ...

Page 418: ...CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 195 Replace the stator coil assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 195 Replace the rectifier regulator 5 Check the entire charging system s wiring Refer to CIRCUIT DIAGR...

Page 419: ...CHARGING SYSTEM 8 24 ...

Page 420: ...LIGHTING SYSTEM 8 25 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...

Page 421: ...y ground lead 25 ECU engine control unit 43 Meter assembly 51 High beam indicator light 54 Meter light 61 Left handlebar switch 63 Pass switch 64 Dimmer switch 74 Headlight 75 Auxiliary light 76 License plate light 77 Tail brake light 78 Headlight relay on off 84 Taillight fuse 85 Ignition fuse 88 Headlight fuse ...

Page 422: ...LIGHTING SYSTEM 8 27 ...

Page 423: ... ECU engine control unit 43 Meter assembly 51 High beam indicator light 54 Meter light 61 Left handlebar switch 63 Pass switch 64 Dimmer switch 74 Auxiliary light 75 Headlight high beam 76 Headlight low beam 77 License plate light 78 Tail brake light 79 Headlight relay on off 85 Taillight fuse 86 Ignition fuse 89 Headlight fuse ...

Page 424: ...HE BULBS AND BULB SOCKETS on page 8 184 Replace the bulb s and bulb socket s 2 Check the fuses Main headlight ignition FZ8SA and taillight Refer to CHECKING THE FUSES on page 8 185 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page ...

Page 425: ... relay on off Refer to CHECKING THE RELAYS on page 8 189 Replace the headlight relay 8 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on page 8 25 Properly connect or repair the lighting system s wiring Replace the ECU or meter assembly ...

Page 426: ...SIGNALING SYSTEM 8 31 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...

Page 427: ...nction meter 52 Turn signal indicator light 55 Oil level switch 56 Right handlebar switch 57 Front brake light switch 60 Rear brake light switch 61 Left handlebar switch 65 Hazard switch 66 Turn signal switch 67 Horn switch 68 Horn 69 Turn signal hazard relay 70 Rear right turn signal light 71 Rear left turn signal light 72 Front right turn signal light 73 Front left turn signal light 77 Tail brak...

Page 428: ...SIGNALING SYSTEM 8 33 ...

Page 429: ...nction meter 52 Turn signal indicator light 55 Oil level switch 56 Right handlebar switch 57 Front brake light switch 60 Rear brake light switch 61 Left handlebar switch 65 Hazard switch 66 Turn signal switch 67 Horn switch 68 Horn 69 Turn signal hazard relay 70 Rear right turn signal light 71 Rear left turn signal light 72 Front right turn signal light 73 Front left turn signal light 78 Tail brak...

Page 430: ... Air filter case 10 Throttle bodies NG OK NG OK NG OK NG OK 1 Check the fuses Main ignition signal and taillight Refer to CHECKING THE FUSES on page 8 185 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the main swi...

Page 431: ...rly connect or repair the signal ing system s wiring This circuit is OK 1 Check the tail brake light bulb and socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 184 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING TH...

Page 432: ...e left handlebar switch 3 Check the hazard switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the left handlebar switch 4 Check the turn signal hazard relay Refer to CHECKING THE TURN SIGNAL HAZARD RELAY on page 8 190 Replace the turn signal hazard relay 5 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 31 Properly connect or repair the signal ing system s wi...

Page 433: ...e 8 179 Replace the oil level switch 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 31 Properly connect or repair the signal ing system s wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 197 Replace the fuel pump assembly 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 31 Properly ...

Page 434: ...nt temperature warning light fails to come on NG OK NG OK 2 Check the entire speed sensor wir ing Refer to TIP Properly connect or repair the speed sensor wiring Replace the hydraulic unit assembly ECU meter assembly 1 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 198 Replace the coolant temperature sen sor 2 Check the entire signaling system s wi...

Page 435: ...SIGNALING SYSTEM 8 40 ...

Page 436: ...COOLING SYSTEM 8 41 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...

Page 437: ...ine ground 9 Battery 10 Negative battery ground lead 25 ECU engine control unit 40 Coolant temperature sensor 79 Radiator fan motor relay 80 Right radiator fan motor fuse 81 Right radiator fan motor 82 Left radiator fan motor fuse 83 Left radiator fan motor 85 Ignition fuse ...

Page 438: ...COOLING SYSTEM 8 43 ...

Page 439: ...ine ground 9 Battery 10 Negative battery ground lead 25 ECU engine control unit 40 Coolant temperature sensor 80 Radiator fan motor relay 81 Right radiator fan motor fuse 82 Right radiator fan motor 83 Left radiator fan motor fuse 84 Left radiator fan motor 86 Ignition fuse ...

Page 440: ...ce the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 198 Replace the radiator fan motor s 5 Check the radiat...

Page 441: ...COOLING SYSTEM 8 46 NG OK 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 41 Properly connect or repair the cooling system s wiring Replace the ECU ...

Page 442: ...FUEL INJECTION SYSTEM 8 47 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...

Page 443: ...ntrol unit 26 Ignition coil 1 27 Ignition coil 2 28 Ignition coil 3 29 Ignition coil 4 30 Spark plug 31 Injector 1 32 Injector 2 33 Injector 3 34 Injector 4 35 Air induction system solenoid 36 Sub throttle servo motor 37 Sub throttle position sensor 38 Intake air pressure sensor 39 Throttle position sensor 40 Coolant temperature sensor 41 Intake air temperature sensor 42 O2 sensor 43 Meter assembl...

Page 444: ...FUEL INJECTION SYSTEM 8 49 ...

Page 445: ...ntrol unit 26 Ignition coil 1 27 Ignition coil 2 28 Ignition coil 3 29 Ignition coil 4 30 Spark plug 31 Injector 1 32 Injector 2 33 Injector 3 34 Injector 4 35 Air induction system solenoid 36 Sub throttle servo motor 37 Sub throttle position sensor 38 Intake air pressure sensor 39 Throttle position sensor 40 Coolant temperature sensor 41 Intake air temperature sensor 42 O2 sensor 43 Meter assembl...

Page 446: ...splayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the following conditions is present and the start switch is pushed Checking the engine trouble warning light The engine trouble warning light comes on for around 2 seconds after the main switch has been set to O...

Page 447: ...ng light and provides the engine with alternate operating instruc tions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the condi...

Page 448: ...tory The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sen sors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 55 If a malfunction is detected in the sensors or actuators repair or replace all faulty parts If no malfunction is detected in the sensors and actuators check and repair the inn...

Page 449: ...D 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 buttons TIP The diagnostic code number appears on the clock LCD d01 d70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the...

Page 450: ...upler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or loc...

Page 451: ...eck or maintenance job Sensor inspection proce dure 1 Connection of crankshaft position sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Crank the engine and check the fault code indication No fault code indicated Recovered Fault code indicated Check ...

Page 452: ...r short circuit detected no nor mal signals are received from the intake air pressure sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 03 Meter display Displays the intake air pressure Procedure Set the engine stop switch to and then operate the throttle while pushing the start switch If the display value changes the performance is OK Item components and prob...

Page 453: ...cuit Replace the wire harness Black blue Black blue Pink white Pink white Blue Blue Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Sensor installation status Check the mounting sec tion for loose or pinched mounting Incorrect installation Rein stall or repair the sensor Place the main switch ...

Page 454: ...re sensor Sensor inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 201 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Fault code No 13 Item Intake air pressure sensor open or short circuit detected no nor mal signals are received f...

Page 455: ...ed discon nected clogged twisted or bent Repair or replace the sensor hose Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Intake air pressure sensor malfunction Check in the diagnostic mode Code No d03 When engine is stopped Atmospheric pressure at the current altitude and weath...

Page 456: ...r connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Connection of fuel injection system sub wire harness coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor ...

Page 457: ...on Check the diagnostic mode Code No d01 When throttle is fully closed A value of 14 20 is indicated If the indication is outside of range Replace the throttle position sensor Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 8 ECU malfunction Replace the ECU Fault code No 15 Item Throttle positio...

Page 458: ...sor inspection proce dure 1 Sensor installation status Check for loose mounting pinched mounting or hard mounting Make sure that the mounting position is correct Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 11 Place the main switch to the ON position and then open and close the throttle No fault code indicated Recovered Fault code indicated Check the next step 2 Throttle position sen...

Page 459: ...nection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication when the sidestand is retracted and extended No fault code indicated Recovered Fault code indicated Chec...

Page 460: ...d Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 19 Item Sidestand switch a break or disconnection of the blue yellow lead of the ECU is detected no normal signals are received from the sid estand switch Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No d 20 Meter display Sidestand switch ON sidestand retracted OF...

Page 461: ...ped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 3000 m above sea level Approx 70 kPa Incorrect indication Sensor malfunction Replace the intake air pressure sensor Sensor inspection procedure Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 201 Place the main switch to the ON position and check the fault code indicat...

Page 462: ... Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step Fault code No 20 Item Int...

Page 463: ...he ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 Coolant temperature sensor malfunction Check in the diagnostic mode Code No d06 During cold starting A tem perature close to the ambient temperature is indicated Indication is incorrect Replace the coolant tempera ture sensor Sensor inspection procedure Refer to CHECKING ...

Page 464: ...indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Faul...

Page 465: ...Meter display Displays the atmospheric pressure Procedure Compare the actually measured atmospheric pressure with the meter display value Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of atmospheric pressure sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor conn...

Page 466: ...dicated Recovered Fault code indicated Check the next step 4 Installation status of atmo spheric pressure sensor Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step Fault code No 23 Item Atmos...

Page 467: ...C PRES SURE SENSOR on page 8 200 Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 23 Item Atmospheric pressure sensor open or short circuit detected no normal signals are received from the atmospheric pressure sensor Fail safe system Able to start e...

Page 468: ...fault code indicated Recovered Fault code indicated Check the next step 3 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Either start and warm up the engine and then racing it or reset it with diagnostic code d63 No fault cod...

Page 469: ... Check or maintenance job Sensor inspection proce dure 1 Turnover of vehicle Raise the vehicle to the upright position Place the main switch to the ON position however the engine cannot be restarted unless the main switch is first turned OFF No fault code indicated Recovered Fault code indicated Check the next step 2 Sensor installation status Check for a loose mounting pinched mounting or sensor ...

Page 470: ...il five times at one second inter vals Illuminates the engine trouble warning light Procedure Check that a spark is generated five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or lock...

Page 471: ... Orange Orange Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately 5 seconds Then check the fault ...

Page 472: ...ted five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for approximately 5 seconds ...

Page 473: ... red Gray red Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately 5 seconds Then check the fault c...

Page 474: ...ted five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for approximately 5 seconds ...

Page 475: ...reen Orange green Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately 5 seconds Then check the fau...

Page 476: ...ted five times Connect an ignition checker Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Connection of ignition coil coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or replace the wire harness Start and idle the engine for approximately 5 seconds ...

Page 477: ...reen Gray green Start and idle the engine for approximately 5 seconds Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Ignition coil installation status Check the mounting section for a loose or pinched mount ing Make sure that the mounting position is correct Start and idle the engine for approximately 5 seconds Then check the fault...

Page 478: ...ce the defective ECU Fault code No 36 Item Cylinder 4 ignition coil open or short circuit detected in the pri mary lead of the cylinder 4 ignition coil Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No d 33 Actuation Actuates the cylinder 4 ignition coil five times at one second int...

Page 479: ...tuation Actuates injector 4 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 4 is actuated five times by listening for the operating sound Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Locate the malfunction Check in the diagnostic mode Code No d36 d37 d38 d39 Locate the injector with no opera...

Page 480: ...m the injector Fail safe system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No d 36 d 37 d 38 d 39 d 36 Actuation Actuates injector 1 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 1 is actuated five times by listening for the operati...

Page 481: ...e number of faulty cylinders Diagnostic code No d 36 d 37 d 38 d 39 d 36 Actuation Actuates injector 1 five times at one second intervals Illuminates the engine trouble warning light Procedure Check that injector 1 is actuated five times by listening for the operating sound d 37 Actuation Actuates injector 2 five times at one second intervals Illuminates the engine trouble warning light Procedure ...

Page 482: ... the OFF position first and then rotate it to the ON position again Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the harness R...

Page 483: ...ault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No 41 Item Lean angle sensor open or short circuit detected no normal sig nals are received from the lean angle sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No d 08 Meter display Lean angle sensor output voltage 0 4 1 4 upright 3 7 4 4 overturned Procedure Remove the lean ...

Page 484: ...e No d 21 Meter display Clutch switch ON Gear is in other than neutral operating clutch and storing sidestand OFF Gear is in other than neutral operating clutch and using sidestand Procedure Shift the transmission clutch lever and sidestand Item components and probable cause Check or maintenance job Sensor inspec tion procedure Locate the malfunction Check in the diagnostic mode Code No d07 Rotate...

Page 485: ...t securely or repair replace the wire harness Check in the diagnostic code Code No d07 With the rear wheel rotated check the pulse input Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 3 Continuity of wire harness Open or short circuit Replace the wire harness White red White red White White Blue white Blue white White yellow White ye...

Page 486: ...e engine Ride the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Recon nect or repair the coupler Start the engine Ride the v...

Page 487: ...place the shift drum Start the engine Ride the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 7 ECU malfunction Replace the ECU Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 Adjusting the clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FR...

Page 488: ...e fault code indication No fault code indicated Recovered Fault code indicated Check the next step 5 Continuity of leads between clutch switch and relay unit coupler Open or short circuit Replace the wire harness Yellow black Yellow black Start the engine Ride the vehicle at a low speed approx 20 30 km h Then check the fault code indication No fault code indicated Recovered Fault code indicated Ch...

Page 489: ...tion of main relay coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position for approxi mately 5 seconds Then check the fault code indication No fault indicated Recov ered Fault code indicated Check the next step 2 Connection...

Page 490: ...lt code No 43 Item Fuel system voltage incorrect voltage supplied to the fuel injector fuel pump and main relay Fail safe system Able to start engine Able to drive vehicle Diagnostic code No d 09 d 50 d 09 Meter display Fuel system voltage battery voltage Approximately 12 0 Procedure Set the engine stop switch to and then compare the actually measured battery voltage with the meter display value I...

Page 491: ...ror for adjustment of CO concentra tion of cylinder 1 Change the CO concentra tion of cylinder 1 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 11 After this adjustment is made the memory is not recovered when the main switch is turned OFF and ON again Replace the ECU Place the main switch to the ON position Then check the fault code indication No fault code indicated Re...

Page 492: ...NG THE EXHAUST GAS VOLUME on page 3 11 After this adjustment is made the memory is not recovered when the main switch is turned OFF and ON again Replace the ECU Place the main switch to the ON position Then check the fault code indication No fault code indicated Recovered Fault code indicated Return to Step 1 to carry out the check again If the condi tion persists proceed to Step 6 6 ECU malfuncti...

Page 493: ...ble cause Check or maintenance job Sensor inspection proce dure 1 Installation status of sub throttle position sensor Check the mounting section for a loose or pinched mount ing Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of sub throttle position sensor coupler Check the connect...

Page 494: ...si tion sensor Refer to CHECKING THE SUB THROTTLE POSITION SENSOR on page 8 199 Sub throttle position sensor malfunction Replace the sub throttle position sensor Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 6 ECU malfunction Replace the ECU Fault code No 47 Item Sub throttle position sensor o...

Page 495: ...osition sensor coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Check in the diagnostic code Code No d55 Check the sub throttle servo motor for proper operation Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indica...

Page 496: ...rive vehicle Diagnostic code No Meter display Procedure Item components and probable cause Check or maintenance job Sensor inspection proce dure 1 ECU malfunction Replace the ECU Place the main switch to the ON position Then check that no fault code indicated Fault code No 48 Item Sub throttle servo motor stuck sub throttle servo motor detected signal from sub throttle position sensor will not cha...

Page 497: ...ion of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is se...

Page 498: ...cation No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code ind...

Page 499: ...ion No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No fault code indica...

Page 500: ... code indication No fault code indicated Recovered Fault code indicated Check the next step 2 Connection of wire harness ECU coupler Check the connection of the coupler is secure Remove the coupler and check each pin for bending wear or locking Poor connection Connect it securely or repair replace the wire harness Place the main switch to the ON position and check the fault code indication No faul...

Page 501: ...ered Fault code indicated Check the next step 5 ECU malfunction Replace the ECU Fault code No Er 4 Item ECU internal malfunction input signal error non registered data has been received from the meter Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display Procedure Item components and probable cause Check or maintenance job Sensor inspection proce dure ...

Page 502: ...warning light Check the operating sound of the radiator fan motor relay five times d 52 Headlight relay Actuates the headlight relay for five cycles of five seconds ON 2 seconds OFF 3 sec onds Illuminates the engine trou ble warning light Check the operating sound of the headlight relay five times d 61 Malfunction history code display No history 00 History exists Fault code Nos d11 70 If more than...

Page 503: ...responding fault code No the information is shown in DIAGNOSTIC CODE TABLE Refer to DIAGNOSTIC CODE TABLE on page 8 107 d 63 Malfunction code reinstate ment for fault code No d24 only No malfunction code 00 Malfunction code exists Fault code No d24 If more than one code number is detected the dis play alternates every two seconds to show all the detected code numbers When all code numbers are show...

Page 504: ...FUEL PUMP SYSTEM 8 109 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...

Page 505: ...in fuse 7 Frame ground 8 Engine ground 9 Battery 10 Negative battery ground lead 11 Fuel injection system fuse 14 Relay unit 16 Fuel pump relay 19 Fuel pump 25 ECU engine control unit 56 Right handlebar switch 58 Engine stop switch 85 Ignition fuse ...

Page 506: ...FUEL PUMP SYSTEM 8 111 ...

Page 507: ...in fuse 7 Frame ground 8 Engine ground 9 Battery 10 Negative battery ground lead 11 Fuel injection system fuse 14 Relay unit 16 Fuel pump relay 19 Fuel pump 25 ECU engine control unit 56 Right handlebar switch 58 Engine stop switch 86 Ignition fuse ...

Page 508: ...er to CHECKING THE FUSES on page 8 185 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the main switch immobilizer unit 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the right h...

Page 509: ...FUEL PUMP SYSTEM 8 114 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 109 Properly connect or repair the fuel pump system s wiring Replace the ECU ...

Page 510: ...IMMOBILIZER SYSTEM 8 115 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...

Page 511: ...ch 4 Backup fuse 5 Immobilizer unit 6 Main fuse 7 Frame ground 8 Engine ground 9 Battery 10 Negative battery ground lead 25 ECU engine control unit 43 Meter assembly 44 Immobilizer system indicator light 48 Multi function meter 85 Ignition fuse ...

Page 512: ...IMMOBILIZER SYSTEM 8 117 ...

Page 513: ...ch 4 Backup fuse 5 Immobilizer unit 6 Main fuse 7 Frame ground 8 Engine ground 9 Battery 10 Negative battery ground lead 25 ECU engine control unit 43 Meter assembly 44 Immobilizer system indicator light 48 Multi function meter 86 Ignition fuse ...

Page 514: ...egistered during production therefore re registering at purchase is not neces sary ECA14971 DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immob...

Page 515: ...ng key TIP Check that the immobilizer system indicator light comes on for one second then goes off When the immobilizer system indicator light goes off the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below Parts to be replaced Key registration requirement Main switch immobilizer unit Standa...

Page 516: ...ng key turn the main switch to ON then OFF and then remove the key within 5 seconds 3 Insert the first standard key to be registered into the main switch then turn the key to ON within 5 seconds to activate the key registration mode TIP 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 s...

Page 517: ...b 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 registe...

Page 518: ...battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 186 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 179 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 115 Properly connect or repair the immobi lizer system wiring Check the condition of...

Page 519: ... con secutive attempts 2 Signal received from unregistered stan dard key 1 Place the immo bilizer unit at least 50 mm away from the transponder of other vehicles 2 Register the standard key 53 IMMOBILIZER UNIT Codes cannot be transmitted between the ECU and the immobilizer unit Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected com munication harne...

Page 520: ...55 IMMOBILIZER UNIT Key code registra tion malfunction Same standard key was attempted to be regis tered two consecutive times Register another standard key 56 ECU Undefinition code is received Noise interference or dis connected lead cable 1 Check the wire harness and con nector 2 Replace the main switch immobilizer unit 3 Replace the ECU Fault code Part Symptom Cause Action a Light on b Light of...

Page 521: ...IMMOBILIZER SYSTEM 8 126 ...

Page 522: ...ABS ANTI LOCK BRAKE SYSTEM 8 127 EAS28790 ABS ANTI LOCK BRAKE SYSTEM EAS27730 CIRCUIT DIAGRAM ...

Page 523: ... control unit 43 Meter assembly 48 Multi function meter 53 ABS warning light 56 Right handlebar switch 57 Front brake light switch 58 Engine stop switch 59 Start switch 60 Rear brake light switch 77 Tail brake light 85 Ignition fuse 87 Signal fuse 89 ABS motor fuse 90 ABS solenoid fuse 91 ABS ECU fuse 92 ABS ECU electronic control unit 93 ABS test coupler 94 Front wheel sensor 95 Rear wheel sensor...

Page 524: ...ABS ANTI LOCK BRAKE SYSTEM 8 129 ...

Page 525: ... control unit 43 Meter assembly 48 Multi function meter 53 ABS warning light 56 Right handlebar switch 57 Front brake light switch 58 Engine stop switch 59 Start switch 60 Rear brake light switch 78 Tail brake light 86 Ignition fuse 88 Signal fuse 90 ABS motor fuse 91 ABS solenoid fuse 92 ABS ECU fuse 93 ABS ECU electronic control unit 94 ABS test coupler 95 Front wheel sensor 96 Rear wheel sensor...

Page 526: ...ABS ANTI LOCK BRAKE SYSTEM 8 131 EAS27740 ABS COMPONENTS CHART ...

Page 527: ...NTI LOCK BRAKE SYSTEM 8 132 1 Hydraulic unit assembly ABS ECU 2 ABS warning light 3 Rear wheel sensor rotor 4 Rear wheel sensor 5 Front wheel sensor 6 Front wheel sensor rotor 7 ABS test coupler 8 Fuse box 1 ...

Page 528: ...ABS ANTI LOCK BRAKE SYSTEM 8 133 EAS27750 ABS COUPLER LOCATION CHART ...

Page 529: ...ABS ANTI LOCK BRAKE SYSTEM 8 134 1 Meter assembly coupler 2 Rear wheel sensor coupler 3 ABS test coupler 4 Front wheel sensor coupler 5 ABS ECU coupler ...

Page 530: ...ion The following troubleshooting describes the problem identification and service method according to the indications by the multi function display For troubleshooting items other than the following items follow the normal service method WARNING EWA4B56006 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle...

Page 531: ...ing on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled The malfunction history is stored in the memory of the ABS ECU Delete the fault codes when the service is finished This is because the past fault codes will be displayed again if another malfunc tion occurs EAS27800 BASIC INSTRUCTIONS FOR T...

Page 532: ...ABS ANTI LOCK BRAKE SYSTEM 8 137 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...

Page 533: ... on for 2 seconds then goes off B 4 EAS4B56013 B 1 THE ABS WARNING LIGHT FAILS TO COME ON 1 Only the ABS warning light fails to come on when the main switch is turned to ON C 1 2 The ABS warning light and all other indicator lights fail to come on C 2 EAS4B56014 B 2 THE ABS WARNING LIGHT FLASHES 1 Test coupler adapter Check if the test coupler adapter is connected to the ABS test coupler If the te...

Page 534: ...f the ABS ECU The ABS warning light flashes quicker if a fault code is displayed on the multi function display If no fault code is displayed make sure that the customer understands the possible conditions that may cause the ABS warning light to come on or flash even if the system is normal TIP The ABS fault codes will not be displayed if a fault code for the fuel injection system is displayed on t...

Page 535: ... the ABS ECU coupler and check that the ABS warning light comes on when the main switch is turned to ON If the ABS warning light does not come on the meter assembly circuit including the ABS warning light LED is defective Replace the meter assembly If the ABS warning light comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS4B56019 C 2 ALL INDICATOR LIGHTS FAIL TO COME ON 1 Ma...

Page 536: ... the wire harness is defective Properly repair or replace the wire har ness 5 There is a break in the wire harness between the ABS ECU and the meter assembly ABS warn ing light Check for continuity between the Green Red terminal of the ABS ECU coupler and the Green Red terminal of the meter assembly coupler If there is no continuity the wire harness is defective Properly repair or replace the defe...

Page 537: ...BS_27 Incorrect signal from the rear wheel sensor is detected Installation of the rear wheel sensor Rear wheel Rear wheel sensor housing Rear wheel sensor rotor Hydraulic unit assembly ABS_15 No continuity in the front wheel sensor circuit Continuity of the front wheel sensor circuit Wire harness ABS circuit Connection of the front wheel sensor cou pler and ABS ECU coupler Front wheel sensor ABS_1...

Page 538: ...ECU to release the hydraulic pres sure Brake dragging Brake fluid Hydraulic unit operation tests Front wheel brake lines Hydraulic unit assembly ABS_42 ABS_47 Rear wheel will not recover from the locking tendency even though the sig nal is continuously transmitted from the ABS ECU to release the hydraulic pres sure Brake dragging Brake fluid Hydraulic unit operation tests Rear wheel brake lines Hy...

Page 539: ...BS_15 front wheel and ABS_16 rear wheel are indicated if a defective con nection is detected in the front or rear wheel sensor when the vehicle is not being ridden ABS_56 Hydraulic unit sensor power monitor cir cuit is abnormal Hydraulic unit assembly ABS_63 Front wheel sensor power is abnormal Front wheel sensor lead Wire harness Hydraulic unit assembly ABS_64 Rear wheel sensor power is abnormal ...

Page 540: ...off Perform a trial run at a con stant speed of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor rotor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sen...

Page 541: ...ng light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor rotor Check the components for loose ness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 24 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and s...

Page 542: ...ot come on 2 Installed condition of wheel bearings axle sensor housing and sensor rotor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if...

Page 543: ...of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage replace the sensor rotor Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25 5 ...

Page 544: ...he ground and the green terminal 2 or green terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the blue terminal 1 and the green terminal 2 and between the blue terminal 3 and the green terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness 5 ABS...

Page 545: ...eel sensor circuit Order Item components and probable cause Check or maintenance job Reinstatement confirmation method 1 Connections Rear wheel sensor coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or con...

Page 546: ... ground and the white red termi nal 2 or white red terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wire har ness Check that there is no continuity between the white terminal 1 and the white red terminal 2 and between the white terminal 3 and the white red terminal 4 If there is continuity the wire harness is defective Properly repair or replace the wi...

Page 547: ... Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform a trial run at a con stant speed of 30 km h and check that the ABS warning light does not come on 2 Foreign material inside sensor hous ing Check the interior of the sensor housing and t...

Page 548: ...ng Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25 3 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage replace the sensor rotor Fault code No ABS_...

Page 549: ...for 2 seconds then goes off Check that the ABS warning light comes on while the start switch is being pushed 2 Connections Starter relay coupler ABS ECU coupler Right handlebar switch coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before dis...

Page 550: ... main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off 2 Connections ABS ECU coupler Front brake light switch connectors Rear brake light switch coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before disc...

Page 551: ... fuse If the ABS solenoid fuse is blown replace the fuse and check the wire harness Refer to CHECKING THE FUSES on page 8 185 3 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or connect ing a coupler ...

Page 552: ...tement confirmation method 1 Short circuit in solenoid relay Replace the hydraulic unit assem bly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hydraulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal 2 Hydraulic unit assembly internal mal function Replace the hydraulic unit assem bly ...

Page 553: ...or fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the fuse and check the wire har ness Refer to CHECKING THE FUSES on page 8 185 3 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF...

Page 554: ...able cause Check or maintenance job Reinstatement confirmation method 1 Short circuit in ABS motor relay Replace the hydraulic unit assem bly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hydraulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal ...

Page 555: ...es smoothly Check the front wheel axle for loose bearings and bends and the brake discs for distortion Refer to CHECKING THE FRONT BRAKE DISCS on page 4 35 Perform hydrau lic unit opera tion test 1 and check that the operation of the hydraulic unit is normal 2 Brake master cylinder and brake cali per Check that the brake fluid pres sure is correctly transmitted to the brake calipers when the front...

Page 556: ...draulic unit and from the hydraulic unit to the front brake calipers are correct See WARNING and TIP 5 Hydraulic unit assembly If the malfunction is not corrected after checking items 1 to 3 and front brake hose outlet replace the hydraulic unit assembly Be sure to connect the brake pipes and coupler correctly and securely Check the hydraulic unit operation Refer to HYDRAULIC UNIT OPERATION TESTS ...

Page 557: ...sponding and then it will be pushed back slowly without pulsating when the final check on page D 3 FINAL CHECK on page 8 174 is per formed If the front and rear brake pipe connections are reversed on the hydraulic unit the pulsating action in the front brake lever and rear brake pedal will be performed in the reverse order when the final check on page D 3 FINAL CHECK on page 8 174 is performed ...

Page 558: ...draulic unit is normal 2 Brake master cylinder and brake cali per Check that the brake fluid pres sure is correctly transmitted to the brake caliper when the rear brake pedal is operated and that the pressure decreases when the pedal is released 3 Brake fluid Visually check the brake fluid in the brake master cylinder reser voir for water foreign materials solidification and contamination Check fo...

Page 559: ...ons are reversed on the hydraulic unit the pulsating action in the front brake lever and rear brake pedal will be performed in the reverse order when the final check on page D 3 FINAL CHECK on page 8 174 is performed 5 Hydraulic unit assembly If the malfunction is not corrected after checking items 1 to 4 replace the hydraulic unit assem bly Be sure to connect the brake hose brake pipe and coupler...

Page 560: ... of 30 km h and check that the ABS warning light does not come on 2 Installed condition of wheel bearings axle sensor housing and sensor rotor Check the components for loose ness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 14 3 Foreign material inside sensor hous ing Check the interior of the sensor housing and the surface of the sensor rotor for foreign material such as metal...

Page 561: ...sor housing and the surface of the sensor rotor for foreign material such as metal particles Clean the sensor housing and sensor rotor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 25 4 Defective sensor rotor Check the surface of the sensor rotor for damage If there is visible damage replace the sensor rotor Fault code No ABS_51 ABS_52 Symptom Power voltage ...

Page 562: ...off Perform a trial run and check that the ABS warning light does not come on 2 Connections ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or connect ing a coupler 3 Open or short circuit in wire harness Repair o...

Page 563: ...come on 2 Connections ABS ECU coupler Starter relay coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely TIP Turn the main switch to OFF before disconnecting or connect ing a coupler 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit B...

Page 564: ...cause Check or maintenance job Reinstatement confirmation method 1 Defective internal monitor circuit sen sor power Replace the hydraulic unit assem bly Turn the main switch to ON and check that the ABS warning light comes on for 2 seconds then goes off Perform hydraulic unit operation test 1 and check that the oper ation of the hydraulic unit is normal ...

Page 565: ...ctive Prop erly repair or replace the wire harness TIP Disconnect the ABS ECU coupler before checking the wire harness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in front wheel sensor lead Check that there is no short cir cuit between the white terminal 3 and the gray terminal 4 Check that there is no short cir cuit betwee...

Page 566: ... defective Prop erly repair or replace the wire harness TIP Disconnect the ABS ECU coupler before checking the wire harness Turn the main switch to ON and check that the ABS warn ing light comes on for 2 sec onds then goes off 2 Short circuit in rear wheel sensor lead Check that there is no short cir cuit between the white terminal 3 and the gray terminal 4 Check that there is no short cir cuit be...

Page 567: ...isplay switches to the odometer tripmeter fuel reserve tripmeter display and the ABS warning light flashes in 0 5 second intervals while the fault codes are being deleted 6 Turn the main switch to OFF 7 Turn the main switch to ON again TIP If fault codes are still displayed in the multi function display the malfunctions have not been repaired Diagnose the malfunctions using the fault codes 8 Turn ...

Page 568: ...he ABS ECU coupler b Push the start switch c Measure the ABS ECU voltage 8 If the above mentioned checks are within specification replace the hydraulic unit assembly Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Brown white 1 Negative tester probe Black 2 Continuity is all right Digital circuit tester 90890 03174 Model 88 Multimeter with tach...

Page 569: ...eel sensor housings and wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL FRONT BRAKE DISCS on page 4 19 and INSTALLING THE REAR WHEEL REAR BRAKE DISC on page 4 28 3 Perform hydraulic unit operation test 1 or 2 Refer to HYDRAULIC UNIT OPERATION TESTS on page 4 60 4 Delete the fault codes Refer to D 1 DELETING THE FAULT CODES on page 8 172 5 Perform a trial run Refer to TRIA...

Page 570: ...ELECTRICAL COMPONENTS 8 175 EAS27973 ELECTRICAL COMPONENTS ...

Page 571: ...witch 4 Clutch switch 5 Ignition coil 6 Fuse box 2 7 Main fuse 8 Battery 9 Fuse box 1 10 Fuel injection system fuse 11 Starter relay 12 Rear brake light switch 13 O2 sensor 14 Sidestand switch 15 Rectifier regulator 16 Oil level switch 17 Neutral switch 18 Radiator fan motor 19 Horn ...

Page 572: ...ELECTRICAL COMPONENTS 8 177 ...

Page 573: ...essure sensor 6 Relay unit 7 Lean angle sensor 8 Turn signal hazard relay 9 Headlight relay 10 Radiator fan motor relay 11 Rear wheel sensor 12 Coolant temperature sensor 13 Crankshaft position sensor 14 Sub throttle servo motor 15 Sub throttle position sensor 16 Throttle position sensor 17 Front wheel sensor 18 Cylinder identification sensor ...

Page 574: ...ELECTRICAL COMPONENTS 8 179 EAS27981 CHECKING THE SWITCHES ...

Page 575: ...tch 2 Pass switch 3 Dimmer switch 4 Hazard switch 5 Turn signal switch 6 Horn switch 7 Main switch 8 Oil level switch 9 Sidestand switch 10 Front brake light switch 11 Engine stop switch 12 Start switch 13 Neutral switch 14 Rear brake light switch ...

Page 576: ...ELECTRICAL COMPONENTS 8 181 ...

Page 577: ...tch 2 Pass switch 3 Dimmer switch 4 Hazard switch 5 Turn signal switch 6 Horn switch 7 Main switch 8 Oil level switch 9 Sidestand switch 10 Front brake light switch 11 Engine stop switch 12 Start switch 13 Neutral switch 14 Rear brake light switch ...

Page 578: ...e 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 given switch ...

Page 579: ...lowing procedure applies to all of the bulbs 1 Remove Bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 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 ...

Page 580: ...t tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Nev...

Page 581: ...e the sealing caps because the balance between cells will not be maintained and battery perfor mance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid bat tery should be charged according to the appropriate charging method If the bat tery is overch...

Page 582: ...ery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging proc...

Page 583: ...e after leaving the battery unused for more than 30 minutes Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the battery TIP ...

Page 584: ...g 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 specification Replace Starter relay Relay unit starting circuit cut off relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 N...

Page 585: ...rminal as shown 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Resu...

Page 586: ...main switch to ON c Measure the turn signal hazard relay out put voltage EAS28050 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification Replace TIP The pocket tester or the analog pocket tester readings are shown in the following table Turn signal hazard relay output voltage DC 12 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown white 1 ...

Page 587: ... 1 Negative tester probe Yellow black 2 No continuity Positive tester probe Yellow black 2 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue yellow 3 No continuity Positive tester probe Blue yellow 3 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Sky blue white 4 No continuity Positive tester ...

Page 588: ...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 a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Secondary coil resistance 8 50 11 50 kΩ Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe Red black 1 Positi...

Page 589: ...ation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 17 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 lead otherwise the jumper lead may burn This check is likely to produc...

Page 590: ...ster AC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approxi mately 5000 r min d Measure the rectifier regulator input volt age Stator coil resistance 0 153 0 187 Ω at 20 C 68 F W W Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Positive tester probe White 1 Negative tester probe White 2 Positive tester probe White 1 Negativ...

Page 591: ...al circuit tester to the horn terminals c Measure the horn resistance 2 Check Horn sound Faulty sound Replace EAS28190 CHECKING THE ENGINE OIL LEVEL SWITCH 1 Drain Engine oil 2 Remove Oil level switch from the oil pan 3 Check Oil level switch resistance Rectifier regulator output volt age 14 2 14 8 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red 1 Negative tes...

Page 592: ...ction circuit 1 Check Oil level warning light 1 Turn the main switch to ON Warning light comes on for a few sec onds then goes off Warning light is OK Warning light does not come on Replace the meter assembly Warning light flashes ten times then goes off for 2 5 seconds in a repeated cycle malfunction detected in oil level switch Replace the oil level switch Pocket tester 90890 03112 Analog pocket...

Page 593: ...ocks 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 1 k 100 to the coolant temperature sensor as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coolant temperature sensor ter minals do not get wet c Place a thermometer 3 in the c...

Page 594: ...sition sensor adjust its angle properly Refer to ADJUST ING THE THROTTLE POSITION SENSOR on page 7 11 EAS39P1803 CHECKING THE SUB THROTTLE POSITION SENSOR 1 Remove Sub throttle position sensor from the throttle body 2 Check Sub throttle position sensor a Connect the pocket tester Ω 1 k to the sub throttle position sensor as shown b Measure the sub throttle position sensor maximum resistance Out of...

Page 595: ...m solenoid resistance Out of specification Replace a Remove the air induction system solenoid coupler from the air induction system sole noid b Connect the pocket tester Ω 1 to the air induction system solenoid terminal as shown c Measure the air induction system solenoid resistance EAS28380 CHECKING THE ATMOSPHERIC PRES SURE SENSOR 1 Check Atmospheric pressure sensor output volt age Out of specif...

Page 596: ...AS28411 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness S pressure sen sor 5S7 3P 1 to the intake air pressure sensor and wire harness as shown Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Test harness S pressure sen sor 5S7 3P 90890 03211 YU 03211 Positive tester pr...

Page 597: ...ster Ω 1 k 100 to the intake air temperature sensor termi nal as shown b Immerse the intake air temperature sensor 1 in a container filled with water 2 TIP Make sure that the intake air temperature sen sor terminals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the intake air temperature sensor resistance 3 ...

Page 598: ...ELECTRICAL COMPONENTS 8 203 ...

Page 599: ...EDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 TROUBLESHOOTING AT THE ABS WARNING LIGHT 9 4 ...

Page 600: ...ump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s...

Page 601: ... Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position...

Page 602: ...ERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Ben...

Page 603: ...ircuit Faulty main switch Faulty dimmer switch Headlight bulb life expired Tail brake light does not come on Wrong 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 co...

Page 604: ...t handlebar switch 62 Clutch switch 63 Pass switch 64 Dimmer switch 65 Hazard switch 66 Turn signal switch 67 Horn switch 68 Horn 69 Turn signal hazard relay 70 Rear right turn signal light 71 Rear left turn signal light 72 Front right turn signal light 73 Front left turn signal light 74 Headlight 75 Auxiliary light 76 License plate light 77 Tail brake light 78 Headlight relay on off 79 Radiator f...

Page 605: ...switch 63 Pass switch 64 Dimmer switch 65 Hazard switch 66 Turn signal switch 67 Horn switch 68 Horn 69 Turn signal hazard relay 70 Rear right turn signal light 71 Rear left turn signal light 72 Front right turn signal light 73 Front left turn signal light 74 Auxiliary light 75 Headlight high beam 76 Headlight low beam 77 License plate light 78 Tail brake light 79 Headlight relay on off 80 Radiato...

Page 606: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 607: ...WIRING DIAGRAM FZ8NA SCHEMA DE CABLAGE FZ8NA SCHALTPLAN FZ8NA SCHEMA ELETTRICO FZ8NA DIAGRAMA DE CONEXIONES DE FZ8NA ...

Page 608: ...WIRING DIAGRAM FZ8NA SCHEMA DE CABLAGE FZ8NA SCHALTPLAN FZ8NA SCHEMA ELETTRICO FZ8NA DIAGRAMA DE CONEXIONES DE FZ8NA ...

Page 609: ...WIRING DIAGRAM FZ8SA SCHEMA DE CABLAGE FZ8SA SCHALTPLAN FZ8SA SCHEMA ELETTRICO FZ8SA DIAGRAMA DE CONEXIONES DE FZ8SA ...

Page 610: ...WIRING DIAGRAM FZ8SA SCHEMA DE CABLAGE FZ8SA SCHALTPLAN FZ8SA SCHEMA ELETTRICO FZ8SA DIAGRAMA DE CONEXIONES DE FZ8SA ...

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