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Yamaha FZ8-NA, Service Manual

The Yamaha FZ8-NA is a powerful and sleek motorcycle that promises an exhilarating ride. For those who want to explore its full potential or learn how to properly maintain it, our website offers a free Owner's Manual download. Visit manualshive.com to unlock the full potential of your Yamaha FZ8-NA.

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TROUBLESHOOTING

9-4

3. Front fork leg(s)

• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both 

front fork legs)

• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube

4. Swingarm

• Worn bearing or bushing
• Bent or damaged swingarm

5. Rear shock absorber assembly(-ies)

• Faulty rear shock absorber spring
• Leaking oil or gas

6. Tire(s)

• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear

7. Wheel(s)

• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout

8. Frame

• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race

EAS28710

FAULTY LIGHTING OR SIGNALING SYS-
TEM

Headlight does not come on

• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main or light switch)
• Burnt-out headlight bulb

Headlight bulb burnt out

• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• 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 come on

• Faulty turn signal switch
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse

Turn signal blinks slowly

• Faulty turn signal/hazard relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal bulb

Turn signal remains lit

• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb

Turn signal blinks quickly

• Incorrect turn signal bulb
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb

Horn does not sound

• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness

EAS4S81006

TROUBLESHOOTING AT THE ABS WARN-
ING LIGHT

Refer to “BASIC PROCESS FOR TROUBLE-
SHOOTING” on page 8-137.

Summary of Contents for FZ8-NA

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

Page 2: ...8NA 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...

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 specification...

Page 4: ...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...

Page 5: ...TION 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 clea...

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: ...UNCTIONS 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 GA...

Page 10: ...S20140 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 in...

Page 11: ...h 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...

Page 12: ...ition 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...

Page 13: ...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 sen...

Page 14: ...tton 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 needl...

Page 15: ...SET 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 travelin...

Page 16: ...g 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 Im...

Page 17: ...d 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...

Page 18: ...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...

Page 19: ...el 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 th...

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...

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...

Page 22: ...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 id...

Page 23: ...te 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 rota...

Page 24: ...ulic 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...

Page 25: ...tlet 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 t...

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...

Page 27: ...e 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...

Page 28: ...essure 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 nati...

Page 29: ...r 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 chambe...

Page 30: ...olenoid 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 switc...

Page 31: ...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...

Page 32: ...lashes 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 th...

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

Page 34: ...heels 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 clo...

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...

Page 36: ...d 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 ch...

Page 37: ...to 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 t...

Page 38: ...ter 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 le...

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...

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 di...

Page 41: ...h 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 Pock...

Page 42: ...d 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 0...

Page 43: ...1436 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...

Page 44: ...94 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 pres...

Page 45: ...3180 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...

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 compresso...

Page 47: ...m 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 121...

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

Page 49: ...ORQUES 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 LUBRICATIO...

Page 50: ...n 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 30...

Page 51: ...l 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 fil...

Page 52: ...tem 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...

Page 53: ...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 Val...

Page 54: ...m 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...

Page 55: ...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...

Page 56: ...ess 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...

Page 57: ...n Solenoid resistance 18 22 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 tem...

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 Load...

Page 59: ...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 absorb...

Page 60: ...e 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...

Page 61: ...t 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...

Page 62: ...um amperage 3 0 A Coil resistance 1 066 1 114 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...

Page 63: ...l 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 specif...

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 hous...

Page 65: ...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...

Page 66: ...h 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 lb...

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 Low...

Page 69: ...6 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 r...

Page 70: ...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 Sidestan...

Page 71: ...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...

Page 72: ...p 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 thrus...

Page 73: ...N 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...

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...

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: ...p 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 coole...

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: ...he 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 le...

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

Page 95: ...ead 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...

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

Page 97: ...e 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 come...

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

Page 99: ...gh 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 th...

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

Page 101: ...n 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...

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...

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

Page 105: ...e 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 t...

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 t...

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

Page 109: ...oolant 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 come...

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 rig...

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

Page 113: ...n 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 o...

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

Page 115: ...ont 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...

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 bra...

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

Page 119: ...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 rea...

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

Page 121: ...l 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 t...

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

Page 123: ...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...

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

Page 125: ...servoir 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 1...

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

Page 127: ...C 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 TIRE...

Page 128: ...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...

Page 129: ......

Page 130: ...ead 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 t...

Page 131: ...ck 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 1...

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...

Page 133: ...lowing 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 F...

Page 134: ...o 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 CHASS...

Page 135: ...ylinders 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...

Page 136: ...he 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 Exam...

Page 137: ...eed 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 se...

Page 138: ...e 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...

Page 139: ...tle 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...

Page 140: ...rease 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 butt...

Page 141: ...ly 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 EAS2096...

Page 142: ...vent 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 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...

Page 144: ...0 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 pad...

Page 145: ...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...

Page 146: ...o 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...

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...

Page 148: ...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 operat...

Page 149: ...he 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 us...

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...

Page 151: ...ust 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...

Page 152: ...he 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 EWA1...

Page 153: ...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...

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 u...

Page 155: ...e 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 LE...

Page 156: ...ay 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...

Page 157: ...onnect 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 a...

Page 158: ...age 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 ligh...

Page 159: ...he 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 t...

Page 160: ...ght 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 advers...

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 h...

Page 162: ...ly 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 p...

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: ...AR 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 M...

Page 166: ...PES 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...

Page 167: ...GARM 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...

Page 168: ...at 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 Ba...

Page 169: ...ight 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...

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...

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...

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 Rect...

Page 173: ...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...

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 Righ...

Page 175: ...wling 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 hos...

Page 176: ...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 in...

Page 177: ...g 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 projec...

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 ca...

Page 179: ...der 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 Fr...

Page 180: ...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...

Page 181: ...urface 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 pa...

Page 182: ...r 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 I...

Page 183: ...ke 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 du...

Page 184: ...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 be...

Page 185: ...P 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 pos...

Page 186: ...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 Oi...

Page 187: ...ace 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 bra...

Page 188: ...nsor 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 adjusti...

Page 189: ...rocket 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...

Page 190: ...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 p...

Page 191: ...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 Che...

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 magne...

Page 193: ...r 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 surf...

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 t...

Page 195: ...o 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...

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 chai...

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...

Page 198: ...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...

Page 199: ...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 c...

Page 200: ...marks 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...

Page 201: ...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...

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...

Page 203: ...er 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 pa...

Page 204: ...e 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...

Page 205: ...ls 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 b...

Page 206: ...ype 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 th...

Page 207: ...sed 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...

Page 208: ...arts 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...

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: ...ar 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...

Page 211: ...EL 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 reserv...

Page 212: ...RAKE 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 proc...

Page 213: ...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 r...

Page 214: ...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...

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...

Page 216: ...o 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 CHECK...

Page 217: ...o 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...

Page 218: ...r 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...

Page 219: ...nternal 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...

Page 220: ...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 BR...

Page 221: ...efore 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 EAS...

Page 222: ...nificantly 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 imme...

Page 223: ...er 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 res...

Page 224: ...nect 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 u...

Page 225: ...or 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 brak...

Page 226: ...aulic 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...

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 th...

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...

Page 229: ...ond 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 o...

Page 230: ...d 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 corr...

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 Dis...

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: ...andle 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 fall...

Page 234: ...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 do...

Page 235: ...here 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 i...

Page 236: ...he 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 Loose...

Page 237: ...e 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...

Page 238: ...ONT 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 compres...

Page 239: ...empt 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...

Page 240: ...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 inn...

Page 241: ...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 us...

Page 242: ...d 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...

Page 243: ...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...

Page 244: ...d 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 su...

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 couple...

Page 246: ...b 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 Lowe...

Page 247: ...o 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 Disconne...

Page 248: ...b 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 Lowe...

Page 249: ...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 stee...

Page 250: ...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...

Page 251: ...over 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...

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...

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 r...

Page 254: ...t 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 2...

Page 255: ...efer 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...

Page 256: ...lay 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 d...

Page 257: ...s 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 A...

Page 258: ...IVE 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 pr...

Page 259: ...h 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 for...

Page 260: ...wise 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 driv...

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

Page 263: ...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 CHE...

Page 264: ...VER 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 DELIVER...

Page 265: ...HECKING 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 TRANSMISSIO...

Page 266: ...P1501 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 exce...

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: ...ts 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...

Page 269: ...e 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 Muff...

Page 270: ...ge 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...

Page 271: ...rts 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 connec...

Page 272: ...ve 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 Loo...

Page 273: ...unting 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...

Page 274: ...e 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 ada...

Page 275: ...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...

Page 276: ...o 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 coup...

Page 277: ...ngine 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...

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...

Page 279: ...nstall 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...

Page 280: ...870 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...

Page 281: ...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 tensio...

Page 282: ...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 TI...

Page 283: ...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 chai...

Page 284: ...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 Ti...

Page 285: ...AL 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...

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...

Page 287: ...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 Exhaus...

Page 288: ...gs 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 Int...

Page 289: ...ove 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...

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 pr...

Page 291: ...uide 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 wit...

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...

Page 293: ...g 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 lappin...

Page 294: ...lve 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 followi...

Page 295: ...h 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...

Page 296: ...ve 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 smoothl...

Page 297: ...ERAL 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...

Page 298: ...oving 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...

Page 299: ...y 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...

Page 300: ...or 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 f...

Page 301: ...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 as...

Page 302: ...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 S...

Page 303: ...h 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 as...

Page 304: ...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 coupl...

Page 305: ...t 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 c...

Page 306: ...arks 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 307: ...mbly 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...

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 bru...

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 co...

Page 310: ...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 c...

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...

Page 312: ...ssure 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...

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: ...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...

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 thi...

Page 316: ...ge 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...

Page 317: ...lutch 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 wa...

Page 318: ...te 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...

Page 319: ...ll 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...

Page 320: ...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...

Page 321: ...HIFT 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 stoppe...

Page 322: ...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 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 wate...

Page 324: ...ng 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 t...

Page 325: ...l 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...

Page 326: ...amage 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 Rep...

Page 327: ...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 O...

Page 328: ...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 driv...

Page 329: ...2820 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...

Page 330: ...MOVAL 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...

Page 331: ...g 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...

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...

Page 333: ...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 M...

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...

Page 335: ...o 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...

Page 336: ...eplace 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 measuri...

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 r...

Page 338: ...s 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 a...

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...

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 clearanc...

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...

Page 342: ...tive 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 poin...

Page 343: ...e 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...

Page 344: ...he 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 tou...

Page 345: ...RANKCASE 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...

Page 346: ...rankshaft 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 correc...

Page 347: ...s 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 jour...

Page 348: ...per 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 c...

Page 349: ...e 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...

Page 350: ...SION 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 pro...

Page 351: ...r 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...

Page 352: ...her 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...

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 CHECK...

Page 355: ...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 Meas...

Page 356: ...ner 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 washe...

Page 357: ...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...

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

Page 359: ...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...

Page 360: ...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 p...

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 pip...

Page 362: ...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 cool...

Page 363: ...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...

Page 364: ...fer 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...

Page 365: ...oap 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...

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...

Page 367: ...RMOSTAT 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 ced...

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...

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 o...

Page 370: ...emove 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...

Page 371: ...ewdriver 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...

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...

Page 373: ...KING 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 AN...

Page 374: ...o 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...

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...

Page 376: ...33 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...

Page 377: ...P1702 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 fue...

Page 378: ...ge 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 Di...

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 re...

Page 380: ...se 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 A...

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 s...

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 e...

Page 383: ...he 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 su...

Page 384: ...LE 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 c...

Page 385: ...NSOR 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 replac...

Page 386: ...n 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...

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: ...NK 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 ho...

Page 391: ...he 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 be...

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 k...

Page 393: ...ALING 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...

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 CHECKIN...

Page 395: ......

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

Page 397: ...ut 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...

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

Page 399: ...ut 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...

Page 400: ...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 condition...

Page 401: ...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...

Page 402: ...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...

Page 403: ...ch 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...

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: ...und 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 Engin...

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

Page 409: ...und 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 Engin...

Page 410: ...sed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from op...

Page 411: ...TAND 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...

Page 412: ...use 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...

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 sidest...

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: ...HECKING 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 co...

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

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

Page 421: ...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 Licens...

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 lo...

Page 424: ...E 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...

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 lig...

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

Page 427: ...ction 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...

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

Page 429: ...ction 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...

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 t...

Page 431: ...ly 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 li...

Page 432: ...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 H...

Page 433: ...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 assem...

Page 434: ...t 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...

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

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

Page 437: ...ne 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...

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

Page 439: ...ne 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...

Page 440: ...e 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 SWIT...

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: ...trol 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 thro...

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

Page 445: ...trol 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 thro...

Page 446: ...played 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 followin...

Page 447: ...g 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 specifie...

Page 448: ...ory 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 TROUBLESHOOTI...

Page 449: ...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...

Page 450: ...pler 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...

Page 451: ...ck 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 we...

Page 452: ...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 t...

Page 453: ...uit 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...

Page 454: ...e 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...

Page 455: ...d 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 F...

Page 456: ...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 C...

Page 457: ...n 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...

Page 458: ...or 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 POSITIO...

Page 459: ...ection 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...

Page 460: ...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...

Page 461: ...ed 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 Repl...

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 rep...

Page 463: ...e 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...

Page 464: ...ndicated 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 wea...

Page 465: ...eter 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 Sen...

Page 466: ...icated 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...

Page 467: ...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 malfunctio...

Page 468: ...ault 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...

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 un...

Page 470: ...l 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 C...

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 inst...

Page 472: ...ed 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 cou...

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 insta...

Page 474: ...ed 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 cou...

Page 475: ...een 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 i...

Page 476: ...ed 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 cou...

Page 477: ...een 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 ins...

Page 478: ...e 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 o...

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...

Page 480: ...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...

Page 481: ...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 th...

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...

Page 483: ...ult 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 sens...

Page 484: ...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...

Page 485: ...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 Rec...

Page 486: ...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 E...

Page 487: ...lace 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...

Page 488: ...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 w...

Page 489: ...ion 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...

Page 490: ...t 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...

Page 491: ...or 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 ma...

Page 492: ...G 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...

Page 493: ...le 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 t...

Page 494: ...i 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 positio...

Page 495: ...sition 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 se...

Page 496: ...ive 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...

Page 497: ...on 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 pos...

Page 498: ...ation 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 eac...

Page 499: ...on 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 p...

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...

Page 501: ...red 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...

Page 502: ...arning 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 Illumina...

Page 503: ...esponding 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 co...

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

Page 505: ...n 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 handleba...

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

Page 507: ...n 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 handleba...

Page 508: ...r 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 Chec...

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: ...h 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 lig...

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

Page 513: ...h 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 lig...

Page 514: ...gistered 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...

Page 515: ...g 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...

Page 516: ...g 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 act...

Page 517: ...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 I...

Page 518: ...attery 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...

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 IMMOBILI...

Page 520: ...5 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 i...

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 Ta...

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 Ta...

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

Page 527: ...TI 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...

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: ...on 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 i...

Page 531: ...ng 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...

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...

Page 534: ...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 conditi...

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 li...

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 bet...

Page 537: ...S_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 contin...

Page 538: ...CU 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 locki...

Page 539: ...S_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 mo...

Page 540: ...ff 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 comp...

Page 541: ...g 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...

Page 542: ...t 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...

Page 543: ...f 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 Def...

Page 544: ...e 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 bl...

Page 545: ...el 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...

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...

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...

Page 548: ...g 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...

Page 549: ...or 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...

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...

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 pu...

Page 552: ...ement 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 Pe...

Page 553: ...r 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 couple...

Page 554: ...ble 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 l...

Page 555: ...s 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...

Page 556: ...raulic 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...

Page 557: ...ponding 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 t...

Page 558: ...raulic 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 p...

Page 559: ...ns 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 1...

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 R...

Page 561: ...or 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 SEN...

Page 562: ...ff 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 coup...

Page 563: ...ome 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 conn...

Page 564: ...ause 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 AB...

Page 565: ...tive 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 se...

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...

Page 567: ...splay 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...

Page 568: ...e 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...

Page 569: ...el 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 hyd...

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

Page 571: ...itch 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 Recti...

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

Page 573: ...ssure 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...

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

Page 575: ...ch 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 switc...

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

Page 577: ...ch 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 switc...

Page 578: ...e 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 mai...

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 do...

Page 580: ...t tester to the fuse and check the continuity TIP Set the pocket tester selector to 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a ne...

Page 581: ...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 Le...

Page 582: ...ry 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 s...

Page 583: ...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 minut...

Page 584: ...g is incor rect replace the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester 1 and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specifica...

Page 585: ...minal 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...

Page 586: ...ain 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...

Page 587: ...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...

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 t...

Page 589: ...tion 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...

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...

Page 591: ...ital 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 swit...

Page 592: ...tion 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 a...

Page 593: ...hocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester 1 k 100 to the coolant temperature...

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 th...

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 1 to the air induction system...

Page 596: ...S28411 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 p...

Page 597: ...ester 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...

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

Page 599: ...DIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY F...

Page 600: ...mp 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 i...

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...

Page 602: ...RCOOLING 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 F...

Page 603: ...rcuit 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 t...

Page 604: ...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 lef...

Page 605: ...witch 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...

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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