Yamaha FZ8-N Owner'S Manual Download Page 91

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-41

4. Remove the brake caliper on each

side by removing the bolts.

NOTICE:

Do not apply the brake

after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.

[ECA11051]

5. Pull the wheel axle out, and then

remove the wheel.

EAU39404

To install the front wheel

1. Lift the wheel up between the fork

legs.

2. Insert the wheel axle.
3. Lower the front wheel so that it is

on the ground, and then put the
sidestand down.

4. Install the brake calipers by install-

ing the bolts.

TIP

Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.

5. Install the brake hose holders by

installing the bolt and nut.

6. Tighten the brake caliper bolts and

the brake hose holder bolts to the
specified torques.

7. Tighten the wheel axle, and then

the wheel axle pinch bolt to the
specified torques.

8. Push down hard on the handlebar

several times to check for proper
fork operation.

1. Brake hose holder
2. Bolt and nut

1. Brake caliper bolt
2. Brake caliper

Tightening torques:

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

Brake hose holder bolt:

6 Nm (0.6 m·kgf, 4.3 ft·lbf)

Tightening torques:

Wheel axle:

65 Nm (6.5 m·kgf, 47 ft·lbf)

Front wheel axle pinch bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

U39PE2E0.book Page 41 Thursday, November 8, 2012 9:24 AM

Summary of Contents for FZ8-N

Page 1: ...DIC183 FZ8 N FZ8 NA OWNER S MANUAL Read this manual carefully before operating this vehicle 39P 28199 E2 English E ...

Page 2: ... Hereby declare that the product Type designation 5SL 00 is in compliance with following norm s or documents R TTE Directive 1999 5 EC EN300 330 2 v1 3 1 2006 01 EN300 330 2 v1 5 1 2010 02 EN60950 1 2006 A11 2009 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC 1 2 3 4 Version up the norm of EN60950 to EN60950 1 To change company name version up of the following norm EN300 330 2 ...

Page 3: ...jury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur ...

Page 4: ...tial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NO...

Page 5: ...ANUAL 2012 by Yamaha Motor Co Ltd 1st edition October 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U39PE2E0 book Page 2 Thursday November 8 2012 9 24 AM ...

Page 6: ...ner s tool kit 6 2 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing the cowling and panel 6 8 Checking the spark plugs 6 9 Engine oil and oil filter cartridge 6 10 Coolant 6 13 Replacing the air filter element 6 14 Adjusting the engine idling speed 6 16 Checking the throttle grip free play 6 17 Valve clearance 6 17...

Page 7: ...placing the license plate light bulb 6 38 Replacing the auxiliary light bulb 6 39 Supporting the motorcycle 6 39 Front wheel for non ABS models 6 40 Rear wheel for non ABS models 6 42 Troubleshooting 6 43 Troubleshooting charts 6 45 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U39PE2E0 book Page ...

Page 8: ...u Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks This motorcycle is designed to car ry the operator and a passenger The failure of motorists to detect and recognize...

Page 9: ... main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is not ...

Page 10: ...To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the operator pas senger accessories and cargo must not exceed...

Page 11: ...ge any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fu...

Page 12: ... tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the motor...

Page 13: ...tion system fuse page 6 32 6 Storage compartment page 3 19 7 Owner s tool kit page 6 2 8 Shock absorber assembly spring preload adjusting ring page 3 22 9 Shock absorber assembly rebound damping force adjusting screw page 3 22 10 Shift pedal page 3 13 11 Idle adjusting screw page 6 16 12 Engine oil drain bolt page 6 10 13 Engine oil filter cartridge page 6 10 U39PE2E0 book Page 1 Thursday November...

Page 14: ...em fuse page 6 32 6 Storage compartment page 3 19 7 Owner s tool kit page 6 2 8 Shock absorber assembly spring preload adjusting ring page 3 22 9 Shock absorber assembly rebound damping force adjusting screw page 3 22 10 Shift pedal page 3 13 11 Idle adjusting screw page 6 16 12 Engine oil drain bolt page 6 10 13 Engine oil filter cartridge page 6 10 U39PE2E0 book Page 2 Thursday November 8 2012 9...

Page 15: ...t reservoir page 6 13 6 Engine oil filler cap page 6 10 7 Front fork rebound damping force adjusting screw page 3 20 8 Front fork spring preload adjusting bolt page 3 20 9 Front fork compression damping force adjusting screw page 3 20 10 Engine oil level check window page 6 10 11 Brake pedal page 3 14 12 Rear brake light switch page 6 22 U39PE2E0 book Page 3 Thursday November 8 2012 9 24 AM ...

Page 16: ...5 Coolant reservoir page 6 13 6 Engine oil filler cap page 6 10 7 Front fork rebound damping force adjusting screw page 3 20 8 Front fork spring preload adjusting bolt page 3 20 9 Front fork compression damping force adjusting screw page 3 20 10 Engine oil level check window page 6 10 11 Brake pedal page 3 14 U39PE2E0 book Page 4 Thursday November 8 2012 9 24 AM ...

Page 17: ...3 2 Left handlebar switches page 3 11 3 Multi function meter unit page 3 8 4 Main switch steering lock page 3 2 5 Front brake fluid reservoir page 6 23 6 Right handlebar switches page 3 11 7 Throttle grip page 6 17 8 Brake lever page 3 13 U39PE2E0 book Page 5 Thursday November 8 2012 9 24 AM ...

Page 18: ...DIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the co...

Page 19: ...and only use it for code re registering EAU38530 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical...

Page 20: ...y in and then turn it to OFF while still pushing it EAU34341 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to NOTICE ECA11020 Do not use the parking position for an extend...

Page 21: ... malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU1142A Coolant temperature wa...

Page 22: ...n gine if it is overheating TIP For radiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If the engine overheats see page 6 46 for further instructions U39PE2E0 book Page 5 Thursday November 8 2012 9 24 AM ...

Page 23: ... with riding 117 134 C 243 274 F Coolant temperature flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 46 Above 134 C Above 274 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 46 ABS ABS U39PE2E0 book Page 6 Thursday November 8 2012 9...

Page 24: ...warning light does not go off after traveling at a speed of 10 km h 6 mi h or higher or if the warning light comes on or flashes while riding the brake system re verts to conventional braking If ei ther of the above occurs or if the warning light does not come on at all use extra caution to avoid possi ble wheel lock during emergency braking Have a Yamaha dealer check the brake system and electri ...

Page 25: ...turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep ...

Page 26: ... TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 4 L 0 90 US gal 0 75 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the display...

Page 27: ...t Coolant temperature display The coolant temperature display indi cates the temperature of the coolant NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If a problem is detected in any of those circuits the engine trouble warning light will come on and the display ...

Page 28: ...on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from starting 2 If the engine starts turn it off and try starting the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the stan dard keys re registered NOTI...

Page 29: ...r when the throttle cable is stuck EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU44711 The engine trouble warning light and ABS warning light ABS model only may come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12733 Hazard switch With...

Page 30: ...the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU26824 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever toward the throttle grip The brake lever is equipped with a brake lever position adjusting dial To adjust the distance between the brake lever and the throttle grip turn the ad justing dial while ...

Page 31: ...distance may be longer with the ABS than without The ABS is monitored by an ECU which will revert the system to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the key is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h or higher During this test a clicking noise can be heard from under the...

Page 32: ...the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover TIP The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11091 Make sure that the fuel tank cap is properly closed after filling f...

Page 33: ...ce fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on yo...

Page 34: ... clean if necessary Make sure that each hose is rout ed through the clamp Make sure that the paint mark on the fuel tank overflow hose is be low the clamp EAU13433 Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING EWA10862 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards...

Page 35: ...g the key in that posi tion lift the rear of the passenger seat and pull it off To install the passenger seat 1 Insert the projections on the front of the passenger seat into the seat holders as shown and then push the rear of the seat down to lock it in place 2 Remove the key Rider seat To remove the rider seat Pull back the rear of the rider seat as shown remove the bolts and then pull the seat ...

Page 36: ...he storage compartment is located under the passenger seat See page 3 18 When storing the Owner s Manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com partment 1 Bol...

Page 37: ... screw NOTICE ECA10101 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b The spring preload setti...

Page 38: ...ber of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num Spring preload setting Minimum soft Distance A 14 0 mm 0 55 in Standard Distance A 11 0 mm 0 43 in Maximum hard Dista...

Page 39: ...To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench and the extension bar included in the own er s tool kit to make th...

Page 40: ...s Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping pe...

Page 41: ...e built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See the following section for an expla nation of the ignition circuit cut off sys tem WARNING EWA10241 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and...

Page 42: ...ctions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off sy...

Page 43: ...Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch...

Page 44: ...nts ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank breather hose and overflow hose for obstructions cracks or dam age and check hose connections 3 16 3 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 Coolant Check coolant level in reservoir If necessar...

Page 45: ...le grip free play and lubricate cable and grip housing 6 17 6 28 Control cables Make sure that operation is smooth Lubricate if necessary 6 27 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 25 6 27 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 18 6 20 Brake and shift pedals Make sur...

Page 46: ...ightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 3 24 ITEM CHECKS PAGE U39PE2E0 book Page 3 Thursday November 8 2012 9 24 AM ...

Page 47: ...engine auto stop system The engine stops automatically if left idling for 20 minutes If the engine stops simply push the start switch to restart the engine EAU51790 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled an...

Page 48: ...t 3 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one at tempt NOTICE ECA11042 For maximum engine life never ac celerate hard when the engine is cold EAU16671 Shifting Shifting g...

Page 49: ... no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do...

Page 50: ...e EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass o...

Page 51: ...performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 1 3 for more in formation about carbon monox ide WARNING EWA15460 Brake discs calipers dr...

Page 52: ...he owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit 1 U39PE2E0 book Page 2 Thursday November...

Page 53: ...he 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 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Fuel injection Adjust engine idling speed and synchroniz...

Page 54: ...e pads Whenever worn to the limit 4 Rear brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 5 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 6 Brake fluid Replace Every 2 years 7 Wheels Check runout and for damage 8 Tires Check tread depth and for dam age Replace if necessary Check air p...

Page 55: ...ke lever pivot shaft Lubricate with silicone grease 15 Brake pedal pivot shaft Lubricate with lithium soap based grease 16 Clutch lever pivot shaft Lubricate with lithium soap based grease 17 Shift pedal pivot shaft Lubricate with lithium soap based grease 18 Sidestand Check operation Lubricate with lithium soap based grease 19 Sidestand switch Check operation 20 Front fork Check operation and for...

Page 56: ...nge coolant Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 29 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 2000...

Page 57: ... filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U39PE2E0 book Page 7 Thursday N...

Page 58: ...me the cowling or panel needs to be re moved and installed FZ8 NA EAU46740 Cowling A To remove the cowling Remove the bolts and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the bolts EAU19151 Panel A To remove the panel Remove the bolt and then pull the pan el off as shown 1 Cowling A 1 1 Panel A 1 Cowling A 2 Bolt 1 1 2 U39PE2E0 boo...

Page 59: ...s ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before i...

Page 60: ...uld be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and...

Page 61: ... filler cap the engine oil drain bolt and its gasket to drain the oil from the crankcase TIP Skip steps 6 8 if the oil filter cartridge is not being replaced 6 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a Yamaha dealer 7 Apply a thin coat of clean engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is proper...

Page 62: ...or several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause TIP After the engine is started the engine oil level warning light should go off if the oil level is sufficient NOTICE ECA10401 If the oil level warning light flickers or remains on even if the oil level is correct immediately turn the engine off and have a Yamaha dealer ...

Page 63: ...voir See page 6 8 4 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot EWA15161 NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If w...

Page 64: ...eplace the air filter element more frequently if you are riding in un usually wet or dusty areas 1 Remove the rider seat See page 3 18 2 Remove the fuel tank cowling bolts on both sides 3 Pull the bottom of the cowling out ward on both sides then remove the cowling by moving it forward and then lifting it up 4 Remove the fuel tank bolt on both sides 5 Lift the front of the fuel tank and carefully ...

Page 65: ...lement installed otherwise the piston s and or cylinder s may become excessively worn ECA10481 9 Install the air filter case cover by in stalling the screws 10 Place the fuel tank in the original position Make sure that the fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose and the fuel tank overflow hose in the original position WARNING Befor...

Page 66: ...vals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment Check the engine idling speed and if necessary adjust it to specification by turning the idle adjusting screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b 1 Fuel tank overflow hose 2 Original...

Page 67: ...grip Periodi cally check the throttle grip free play and if necessary have a Yamaha deal er adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Engine idling...

Page 68: ...otal weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re pl...

Page 69: ...re air valves and cast wheels Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked by tire specialists to ascertain their suitability for further use WARNING EWA10481 The front and rear tires should be of the same make and de ...

Page 70: ...ns EAU21962 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or oth er damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be r...

Page 71: ...ed above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU37913 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14211 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there...

Page 72: ...which is activated by the brake pedal and brake lever should come on just before braking takes ef fect If necessary adjust the rear brake light switch as follows but the front brake light switch should be adjusted by a Yamaha dealer Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in di...

Page 73: ...amaha dealer replace the brake pads as a set EAU46291 Rear brake pads Each rear brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that a wear indicator groove almost appears have a Yamaha dealer replace the brake pads...

Page 74: ... 4 may result in a harmful chemical reaction Be careful that water or dust does not enter the brake fluid reservoir when refilling Water will significantly lower the boil ing point of the fluid and may re sult in vapor lock and dirt may clog the ABS hydraulic unit valves NOTICE ECA17640 Brake fluid may damage painted sur faces or plastic parts Always clean up spilled fluid immediately As the brake...

Page 75: ...ack should be checked before each ride and adjusted if necessary EAU22774 To check the drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EA...

Page 76: ... keep the drive chain slack with in the specified limits ECA10571 TIP Using the alignment marks on each side of the swingarm make sure that both drive chain pullers are in the same position for proper wheel alignment 3 Tighten the axle nut then the lock nuts to their specified torques 4 Make sure that the drive chain pull ers are in the same position the drive chain slack is correct and the drive ...

Page 77: ...pe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive chain as they may contain substances that could damage the O rings ECA11111 EAU23095 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ...

Page 78: ...talled Even though the cover is installed correctly it does not completely protect the cable from water entry Therefore use care not to pour water directly onto the cover or cable when washing the vehicle If the cable or cover becomes dirty wipe clean with a moist cloth EAU44273 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before...

Page 79: ...should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricants Brake lever Silicone gr...

Page 80: ...t fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23283 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a ...

Page 81: ...ns sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batterie...

Page 82: ... be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When install ing the battery be sure the key is turned to OFF then con nect the positive lead before connecting the negative lead ECA16840 4 After installation make sure that the battery leads are properly con nected to the battery terminals NOT...

Page 83: ...p fuse for clock and immobilizer sys tem 6 Right radiator fan fuse 7 Left radiator fan fuse 8 Headlight fuse 9 Spare fuse 2 1 9 8 3 4 5 6 7 1 Fuse box 2 Ignition fuse 3 Signaling system fuse 4 Headlight fuse 5 Backup fuse for clock and immobilizer sys tem 6 ABS solenoid fuse 7 ABS motor fuse 8 Spare fuse 9 ABS control unit fuse 10 Right radiator fan fuse 2 1 8 9 10 3 4 5 6 7 8 U39PE2E0 book Page 3...

Page 84: ...3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Left radiator fan fuse 2 Taillight fuse 3 Spare fuse 1 2 3 1 Starter relay cover 2 Fuel injection system fuse 3 Fuel injection system spare fuse 1 2 3 Specified fuses Main fuse 50 0 A Headlight fuse 15 0 A Taill...

Page 85: ...ted Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove the headlight unit top cov er by removing its bolts 2 Remove the bolt behind the head light unit as shown 3 Remove the...

Page 86: ...headlight cou pler 9 Connect the coupler then insert the projection on the headlight unit into the grommet on the vehicle to fit the headlight unit in its original position 10 Install the headlight unit bolts 11 Install the bolt behind the headlight unit 12 Place the top cover in its original position and then install its bolts 1 Coupler 1 Headlight coupler 2 Headlight bulb cover 1 1 2 1 Headlight...

Page 87: ...it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the passenger seat EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out bulb by pushing it in and turning it counter cloc...

Page 88: ...se plate light unit by removing the screws 2 Remove the license plate light bulb socket together with the bulb by pulling it out 3 Remove the burnt out bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the license plate light unit by installing the screws 1 Turn signal light bulb 1 1 Screw 2 License plate light unit 1...

Page 89: ...ear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by p...

Page 90: ...el WARNING EWA10821 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 2 Lift the front wheel off the ground according to the procedure in the previous section Supporting the motorcycle 3 Remove the brake hose holder on each side by removing the bolt and nut 1 Front wheel axl...

Page 91: ...e between the brake pads before install ing the brake calipers onto the brake discs 5 Install the brake hose holders by installing the bolt and nut 6 Tighten the brake caliper bolts and the brake hose holder bolts to the specified torques 7 Tighten the wheel axle and then the wheel axle pinch bolt to the specified torques 8 Push down hard on the handlebar several times to check for proper fork ope...

Page 92: ...chain slack adjust ing bolts fully in direction a and push the wheel forward 6 Remove the drive chain from the rear sprocket TIP If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be disas sembled 7 While supporting the brake caliper bracket pull the wheel axle out and ...

Page 93: ...actory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools exp...

Page 94: ...ODIC MAINTENANCE AND ADJUSTMENT 6 44 6 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U39PE2E0 book Page 44 Thursday November 8 2012 9 24 AM ...

Page 95: ...ave a Yamaha dealer check the vehicle Operate the electric starter 4 Compression There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The engine does not star...

Page 96: ...issing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the ...

Page 97: ...tlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always ...

Page 98: ...ld detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosi...

Page 99: ... to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26182 Stor...

Page 100: ...he engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively tur...

Page 101: ...th oil filter cartridge replacement 3 10 L 3 28 US qt 2 73 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 25 L 2 38 US qt 1 98 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Fuel tank capacity 17 0 L 4 49 US gal ...

Page 102: ...99 kg 198 439 lb FZ8 NA 90 194 kg 198 428 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Specified brake fluid DOT 4 ...

Page 103: ...indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light FZ8 NA LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 15 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Radiator fan fuse 10 0 A 2 Fuel in...

Page 104: ... number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26470 Model label The model label is affixed to the frame under the rider seat See page 3 18 Record the information on this label in the space prov...

Page 105: ...3 Fuel tank breather hose and overflow hose 3 17 Fuel tank cap 3 15 Fuses replacing 6 32 H Handlebar switches 3 11 Hazard switch 3 12 Headlight bulb replacing 6 35 High beam indicator light 3 4 Horn switch 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 25 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator lights and warning lights 3 4 L License plate light...

Page 106: ...ght 3 4 Turn signal light bulb replacing 6 37 Turn signal switch 3 12 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheel front for non ABS models 6 40 Wheel rear for non ABS models 6 42 Wheels 6 20 U39PE2E0 book Page 2 Thursday November 8 2012 9 24 AM ...

Page 107: ...U39PE2E0 book Page 3 Thursday November 8 2012 9 24 AM ...

Page 108: ...PRINTED IN JAPAN 2012 12 0 3 1 CR E DIC183 PRINTED ON RECYCLED PAPER ...

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Yamaha FZ8-N, Owner'S Manual

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