Yamaha 2007 FZ6-NA Service Manual

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2007

FZ6-N/S

FZ6-NA/SA

FZ6-NHG(W)

FZ6-SHG(W)

FZ6-NAHG/SAHG

SERVICE MANUAL

4S8-28197-E0

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Yamaha 2007 FZ6-NA

Page 1 2007 FZ6-N/S FZ6-NA/SA FZ6-NHG(W) FZ6-SHG(W) FZ6-NAHG/SAHG SERVICE MANUAL 4S8-28197-E0...
Page 2 EAS20040 FZ6-N/S FZ6-NA/SA FZ6-NHG(W)/SHG(W) FZ6-NAHG/SAHG SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, August 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4: How To Use This Manual
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6.
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 INSTRUMENT FUNCTIONS ..............1-4 OUTLINE OF THE ABS ................1-9 ABS COMPONENT FUNCTIONS ............1-13 ABS OPERATION .................1-19 ABS SELF-DIAGNOSIS FUNCTION ............1-23 ABS WARNING LIGHT AND OPERATION...........1-26 IMPORTANT INFORMATION ..............1-28 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-28 REPLACEMENT PARTS...............1-28...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS4S81003 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
Page 12: Fi System
FEATURES EAS4S81004 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kPa (2.5 kg/cm ). Accordingly, when the energiz- ing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Instrument Functions
FEATURES EAS4S81005 • a tachometer (which shows engine speed) INSTRUMENT FUNCTIONS • an odometer (which shows the total distance Multi-function meter unit traveled) • two tripmeters (which show the distance trav- eled since they were last set to zero) • a fuel reserve tripmeter (which shows the distance traveled since the left segment of the fuel meter started flashing) •...
Page 14 FEATURES 3 When the hour digits start flashing, push the B. FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/ FZ6-SAHG “RESET” button to set the hours. 1. Tachometer 4 Push the “SELECT” button, and the minute 2. Tachometer red zone. digits will start flashing. The electric tachometer allows the rider to 5 Push the “RESET”...
Page 15 “ ” will flash eight times, then go traveling 5 km (3 mi). off for approximately 3 seconds. If this occurs, have a Yamaha dealer check the electrical cir- cuit.
Page 16 FEATURES Coolant temperature mode (FZ6-NHG(W)/FZ6- The air intake temperature display indicates NAHG/FZ6-SHG(W)/FZ6-SAHG) the temperature of the air drawn into the air fil- ter case. Push the “RESET” button to switch the coolant temperature display to the air intake temperature display. NOTE: •...
Page 17 3 If one or both of the standard keys do not start the engine, take the vehicle, the code re-registering key and both standard keys to a Yamaha dealer and have the standard keys re-registered. If the display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle.
Page 18: Outline Of The Abs
10.Front wheel sensor rotor 5. Rear brake caliper The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
Page 19 FEATURES • Brake force: The force applied by braking to reduce the wheel speed. • Wheel lock: A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle continues to travel. • Side force: The force on the tires which supports the vehicle when cornering.
Page 20 FEATURES f. Controlling zone g. Slippery road surface Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
Page 21 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem condition and allows normal braking even if the ABS is not operating properly.
Page 22: Abs Component Functions
FEATURES ABS block diagram 8. Rear brake caliper 1. Rear brake master cylinder 9. Front brake caliper 2. Hydraulic unit 10.ABS ECU 3. Hydraulic pump 11.Rear wheel sensor 4. ABS motor 12.Front wheel sensor 5. Buffer chamber 13.ABS warning light 6.
Page 23 FEATURES 7. Wheel sensor rotor 4. At low speed 8. Voltage 5. At high speed 9. Time 6. Wheel sensor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is oper- ating properly.
Page 24 FEATURES Hydraulic unit The hydraulic unit “1” is composed of three hydraulic control valves (each with a solenoid valve and flow control valve), two buffer chambers, two hydraulic pumps, and an ABS motor. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
Page 25 FEATURES 3. Spool 1. Orifice 4. Flow control valve 2. Solenoid valve • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1. Buffer chamber (pressurized) 2. Buffer chamber (depressurized) 3. Raised piston 1-16...
Page 26 FEATURES ABS ECU (electronic control unit) The ABS ECU “1” controls the ABS and is installed under the fuel tank. To protect the ABS ECU from water damage, it is protected by a cover “2”. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits.
Page 27 FEATURES 13.Rectifier/regulator 22.ABS warning light 14.ABS fuse 23.ABS motor relay 15.ABS motor fuse 24.Signal fuse 16.ABS test coupler 25.Ignition fuse 17.ABS ECU 26.Hydraulic unit 18.Rear brake light switch 27.ABS motor 19.Front brake light switch 28.Front brake solenoid 20.Tail/brake light 29.Rear brake solenoid 21.Meter assembly The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit and ABS motor relay.
Page 28: Abs Operation
FEATURES Composition and operation The ABS motor relay is activated by signals transmitted from the ABS ECU and operates simulta- neously when the ABS starts to reduce the hydraulic pressure of the brake fluid. If the solenoid relay is turned off, the ABS motor relay is also deactivated and the motor stops operating if there is a mal- function.
Page 29 FEATURES Therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper via port A “7” and port B “9”. At this time, the inlet and outlet check valves of the pump close the lines and brake fluid is not sent. As a result, the brake master cylinder directly pressurizes the brake caliper during normal braking.
Page 30 FEATURES 17.Brake fluid pressure 18.Time 19.Repressurizing Emergency braking (ABS activated) 1.Depressurized state When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the spool of the flow control valve compresses the return spring and closes port B “9”.
Page 31 FEATURES 1. Brake master cylinder 11.Port D 2. Brake light switch 12.Solenoid valve 3. ABS motor 13.Port C 4. Hydraulic pump 14.Brake caliper 5. Buffer chamber 15.ABS ECU 6. Flow control valve 16.ABS warning light 7. Port A 17.Brake fluid pressure 8.
Page 32: Abs Self-Diagnosis Function
FEATURES 12.Solenoid valve 1. Brake master cylinder 13.Port C 2. Brake light switch 14.Brake caliper 3. ABS motor 15.ABS ECU 4. Hydraulic pump 5. Buffer chamber 16.ABS warning light 6. Flow control valve 17.Brake fluid pressure 7. Port A 18.Time 8.
Page 33 FEATURES Instances when the ABS warning light comes on 1.The ABS warning light comes on when the main switch is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
Page 34 FEATURES c. Goes off a. ABS warning light d. Preparation b. Comes on 4.The ABS warning light “1” flashes and a malfunction code “2” is indicated on the multi-function dis- play when the test coupler adapter “3” is connected to the ABS test coupler “4” for troubleshooting the ABS.
Page 35: Abs Warning Light And Operation
FEATURES • Diagnosis indication The place where the ABS diagnosis code is displayed is also used for the indication of the FI diag- nosis code, odometer, trip meter and fuel trip. As the priority level of indication, the diagnosis code for FI is the first and the diagnosis code for ABS is the second.
Page 36 FEATURES • The braking of the vehicle, even in the worst case, is principally executed when the vehicle is advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of the tires. Even vehicles equipped with ABS cannot be prevented from falling over if braked suddenly. •...
Page 37: Important Information
EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 38: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate.
Page 39: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
Page 40: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
Page 41 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-29, 4-74 90890-01403 Spanner wrench YU-33975 Damper rod holder 4-66, 4-68 90890-01294 Damping rod holder set YM-01300 T-handle 4-66, 4-68 90890-01326 YM-01326 Oil filter wrench 3-15 90890-01426 YU-38411 Fork seal driver weight 4-68, 4-69 90890-01367 Replacement hammer...
Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pocket tester 1-30, 5-38, 8- 90890-03112 111, 8-112, 8- Analog pocket tester 113, 8-114, 8- YU-03112-C 117, 8-118, 8- 119, 8-120, 8- 121, 8-122, 8- 123, 8-124, 8- 125, 8-126, 8- 127, 8-128, 8- 129, 8-130 Pressure gauge 3-16, 7-6...
Page 43 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-23 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Ignition checker 8-122 90890-06754 Opama pet-4000 spark checker YM-34487 Yamaha bond No. 1215 5-32, 5-35, 5- (Three bond No.1215®) 58, 6-12 90890-85505 1-34...
Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Test coupler adapter 1-25, 4-57, 4-58 90890-03149 Thickness gauge 4-21 90890-03079 Narrow gauge set YM-34483 1-35...
Page 45: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-15 ENGINE TIGHTENING TORQUES ............2-16 CHASSIS TIGHTENING TORQUES ............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE ....................2-23 CHASSIS ....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ...............2-39...
Page 46: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 1B3D (Europe) FZ6-N (Standard) 5S31 (Europe) FZ6-NA (ABS) 5S51 (Europe) FZ6-NHG (High-grade) 5S52 (Aus) FZ6-NHGW (High-grade) 5S41 (Europe) FZ6-NAHG (High-grade+ABS) 5VXL (Europe) FZ6-S (Standard) 4P53 (Europe) FZ6-SA (ABS) 4P54 (Europe) FZ6-SA (ABS) 4S81 (Europe) FZ6-SHG (High-grade) 4S85 (Aus) FZ6-SHGW (High-grade) 5S21 (Europe) FZ6-SAHG (High-grade+ABS) Dimensions...
Page 47: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 600.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) Compression ratio 12.20:1 Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min) Minimum–maximum...
Page 48 ENGINE SPECIFICATIONS Cooling system Radiator capacity (including all routes) 2.00 L (2.11 US qt) (1.76 Imp.qt) Radiator capacity 0.60 L (0.63 US qt) (0.53 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 93–123 kPa (13.2–17.5 psi) (0.93–1.23 kgf/ cm²)
Page 49 ENGINE SPECIFICATIONS Camshaft runout limit 0.060 mm (0.0024 in) Timing chain Model/number of links 92RH2015/120 Tensioning system Automatic Valve clearance (cold) Intake 0.13–0.20 mm (0.0051–0.0079 in) Exhaust 0.23–0.30 mm (0.0091–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake)
Page 50 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.040 mm (0.0016 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust)
Page 51 ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Limit 0.05 mm (0.0020 in) Diameter D 65.475–65.490 mm (2.5778–2.5783 in) Height H 4.0 mm (0.16 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) Limit 16.043 mm (0.6316 in)
Page 52 ENGINE SPECIFICATIONS Oil ring Dimensions (B × T) 1.50 × 2.00 mm (0.06 × 0.08 in) End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) Connecting rod Oil clearance (using plastigauge®) 0.028–0.052 mm (0.0011–0.0020 in) Limit 0.08 mm (0.0032 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green Crankshaft Width A...
Page 53 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 6-speed Primary reduction system Spur gear Primary reduction ratio 86/44 (1.955) Secondary reduction system Chain drive Secondary reduction ratio 46/16 (2.875) Operation Left foot operation Gear ratio 37/13 (2.846) 37/19 (1.947) 28/18 (1.556) 32/24 (1.333) 25/21 (1.190) 26/24 (1.083)
Page 54: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 25.00 ° Caster angle Trail 97.5 mm (3.84 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 55 CHASSIS SPECIFICATIONS 6.0 mm (0.24 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6- Limit 0.5 mm (0.02 in) (FZ6-SHG(W)/FZ6-SAHG/ FZ6-NHG(W)/FZ6-NAHG) 0.8 mm (0.03 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6- Brake pad lining thickness (outer) 4.5 mm (0.18 in) (FZ6-SHG(W)/FZ6-SAHG/ FZ6-NHG(W)/FZ6-NAHG) 6.0 mm (0.24 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6- Limit 0.5 mm (0.02 in) (FZ6-SHG(W)/FZ6-SAHG/ FZ6-NHG(W)/FZ6-NAHG) 0.8 mm (0.03 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6- Master cylinder inside diameter...
Page 56 CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (monocross) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 185.0 mm (7.28 in) Installed length 172.0 mm (6.77 in) Spring rate K1 127.40 N/mm (727.45 lb/in) (12.99 kgf/mm) Spring stroke K1 0.0–50.0 mm (0.00–1.97 in) Optional spring available...
Page 57: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Ignition system type DC. TCI Advancer type Digital 5.0 °/1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer FUA0015/MITSUBISHI (FZ6-SHG(W)/FZ6- NHG(W)) FUA0018/MITSUBISHI (FZ6-NAHG/FZ6- SAHG) FUA0019/MITSUBISHI (FZ6-SA/FZ6-NA) FUA0020/MITSUBISHI (FZ6-S/FZ6-N)
Page 58 ELECTRICAL SPECIFICATIONS 12 V, 5.0 W × 2 (FZ6-S/FZ6-SA/FZ6-SHG(W)/ FZ6-SAHG) 12 V, 5.0 W/21.0 W × 1 Tail/brake light 12 V, 10.0 W × 2 Front turn signal light 12 V, 10.0 W × 2 Rear turn signal light 12 V, 5.0 W × 1 License plate light Meter lighting LED (FZ6-SHG(W)/FZ6-SAHG/FZ6-NHG(W)/...
Page 59 ELECTRICAL SPECIFICATIONS Fuel gauge Model/manufacturer 5VX/DENSO 19.0–21.0 Ω Sender unit resistance (full) 139.0–141.0 Ω Sender unit resistance (empty) Starting circuit cut-off relay Model/manufacturer G8R-30Y-V3/OMRON 162–198 Ω Coil resistance Radiator fan motor relay Model/manufacturer ACM33211M05/MATSUSHITA 86.4–105.6 Ω Coil resistance Headlight relay Model/manufacturer ACM33211M05/MATSUSHITA 86.4–105.6 Ω...
Page 60: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 61: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plugs 18 Nm (1.8 m·kg, 13 ft·lb) Cylinder head bolt See NOTE Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft caps bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap oil check bolt...
Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Catalyst pipe and catalyst pipe 20 Nm (2.0 m·kg, 14 ft·lb) stay bolt Muffler joint bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE Catalyst joint bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE Exhaust pipe stay bolt 20 Nm (2.0 m·kg, 14 ft·lb)
Page 63 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size sensor 45 Nm (4.5 m·kg, 33 ft·lb) Shift shaft spring stopper screw 22 Nm (2.2 m·kg, 16 ft·lb) Left Shift rod nut 7 Nm (0.7 m·kg, 5.0 ft·lb) thread Shift rod nut 7 Nm (0.7 m·kg, 5.0 ft·lb) Shift rod joint 10 Nm (1.0 m·kg, 7.2 ft·lb)
Page 64 TIGHTENING TORQUES Cylinder head tightening sequence. Crankcase tightening sequence. 2-19...
Page 65: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 30 Nm (3.0 m·kg, 22 ft·lb) Steering stem nut 110 Nm (11 m·kg, 80 ft·lb) Upper bracket and upper handle- 23 Nm (2.3 m·kg, 17 ft·lb) bar holder Lower bracket pinch bolt –...
Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Seat lock and frame 7 Nm (0.7 m·kg, 5.0 ft·lb) Licence plate light screw 4 Nm (0.4 m·kg, 2.9 ft·lb) Rear reflector bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Flap and bracket 6 7 Nm (0.7 m·kg, 5.0 ft·lb) Bracket 6 and rear frame 19 Nm (1.9 m·kg, 14 ft·lb)
Page 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Hydraulic unit bracket 1 and stay 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt (with ABS) Rear wheel sensor rotor bolt (with 6 Nm (0.6 m·kg, 4.3 ft·lb) ABS) Stay and frame bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Hydraulic unit and brake hose 30 Nm (3.0 m·kg, 22 ft·lb)
Page 68: Lubrication Points And Lubricant Types
Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Cylinder head cover semicircular No.1215 Yamaha bond Crankcase mating surface No.1215...
Page 69: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point...
Page 70: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main axle 7. Mission cooler 8. Drive axle 9. Main gallery 10.Piston cooler 11.Intake camshaft 12.Exhaust camshaft 2-26...
Page 72: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil cooler 3. Relief valve 2-28...
Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer 2-30...
Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil strainer 3. Oil level switch 4. Oil pump 2-32...
Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Relief valve 2-34...
Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 2-36...
Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 2-38...
Page 84: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-39...
Page 85 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Oil cooler 2-40...
Page 86 COOLING SYSTEM DIAGRAMS 2-41...
Page 87 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Oil cooler 3. Radiator 2-42...
Page 88 COOLING SYSTEM DIAGRAMS 2-43...
Page 89 COOLING SYSTEM DIAGRAMS 1. Oil cooler 2. Water pump 2-44...
Page 90 COOLING SYSTEM DIAGRAMS 2-45...
Page 91 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Thermostat 2-46...
Page 92: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG 2-47...
Page 93 CABLE ROUTING FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG 1. Left handlebar switch lead 2. Main switch and immobilizer lead 3. Clutch cable 4. Throttle cables 5. Right handlebar switch lead A. Clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of the handlebar.
Page 94 CABLE ROUTING FZ6-N/FZ6-NA 2-49...
Page 95 CABLE ROUTING FZ6-N/FZ6-NA 1. Left handlebar switch lead 2. Main switch and immobilizer lead 3. Clutch cable 4. Throttle cables 5. Right handlebar switch lead 6. Handlebar 7. Headlight stay A. Clamp the right handlebar switch lead and handlebars. Point the tip of the clamp downward in front of the handlebar.
Page 96 CABLE ROUTING FZ6-NHG(W)/FZ6-NAHG 2-51...
Page 97 CABLE ROUTING FZ6-NHG(W)/FZ6-NAHG 1. Left handlebar switch lead 2. Main switch and immobilizer lead 3. Clutch cable 4. Wire harness 5. Throttle cables 6. Right handlebar switch lead 7. Handlebar 8. Headlight stay A. Clamp the right handlebar switch lead and handlebars.
Page 98 CABLE ROUTING FZ6-S/FZ6-SHG(W) 2-53...
Page 99 CABLE ROUTING FZ6-S/FZ6-SHG(W) 1. Rear brake light switch lead 2. Neutral switch lead 3. Fuel tank breather hose 4. Crankshaft position sensor lead 5. Right handlebar switch lead 6. O sensor lead 7. Bracket 8. Fuel tank drain hose 9. Rear brake reservoir hose A.
Page 100 CABLE ROUTING FZ6-SA/FZ6-SAHG 2-55...
Page 101 CABLE ROUTING FZ6-SA/FZ6-SAHG P. Clamping position should be at the center 1. Rear brake light switch lead of bend-R as shown in the illustration for the rear brake reservoir tank hose. 2. Rear wheel sensor lead Q. Insert the front wheel sensor lead between 3.
Page 102 CABLE ROUTING FZ6-N/FZ6-NHG(W) 2-57...
Page 103 CABLE ROUTING FZ6-N/FZ6-NHG(W) Q. Clamping position should be at the center 1. Rear brake light switch lead of bend-R as shown in the illustration for the rear brake reservoir tank hose. 2. Neutral switch lead R. Pass the fuel tank breather hose, fuel tank 3.
Page 104 CABLE ROUTING FZ6-NA/FZ6-NAHG 2-59...
Page 105 CABLE ROUTING FZ6-NA/FZ6-NAHG O. Pull down the mark-painted sections of the 1. Rear brake light switch lead fuel tank breather hose and fuel tank drain hose to be lower than the clamp position of 2. Rear wheel sensor lead the muffler stay. Any order to take out the 3.
Page 106 CABLE ROUTING FZ6-S/FZ6-SHG(W) 2-61...
Page 107 CABLE ROUTING FZ6-S/FZ6-SHG(W) M. Clamp the rear turn signal light lead and 1. Main switch and immobilizer lead license plate light lead to the frame. Cut the tip of the clamp to be between 1 and 5 mm 2. Stay assembly (0.04 and 0.20 in).
Page 108 CABLE ROUTING FZ6-SA/FZ6-SAHG 2-63...
Page 109 CABLE ROUTING FZ6-SA/FZ6-SAHG M. Clamp the rear turn signal lead and license 1. Main switch and immobilizer lead plate light lead to the frame. Hook the clamp to the bracket. Pull out the lead suffi- 2. Stay assembly ciently to the frame side and route it along 3.
Page 110 CABLE ROUTING FZ6-N/FZ6-NHG(W) 2-65...
Page 111 CABLE ROUTING FZ6-N/FZ6-NHG(W) N. Clamp the rear turn signal light lead and 1. Main switch and immobilizer lead license plate light lead to the frame. Cut the tip of the clamp to be between 1 and 5 mm 2. Meter and left handlebar switch lead (0.04 and 0.20 in).
Page 112 CABLE ROUTING FZ6-NA/FZ6-NAHG 2-67...
Page 113 CABLE ROUTING FZ6-NA/FZ6-NAHG N. Clamp the rear turn signal lead and license 1. Main switch and immobilizer lead plate light lead to the frame. Hook the clamp to the bracket. Pull out the lead suffi- 2. Meter and left handlebar switch lead ciently to the frame side and route it along 3.
Page 114 CABLE ROUTING FZ6-S/FZ6-SHG(W) 2-69...
Page 115 CABLE ROUTING FZ6-S/FZ6-SHG(W) Q. Clamp the neutral switch lead, tail/brake 1. Right handlebar switch lead light lead and O sensor lead. Point the clamp opening to the rear side. 2. Throttle cables R. Push the wire harness in the groove of the 3.
Page 116 CABLE ROUTING FZ6-SA/FZ6-SAHG 2-71...
Page 117 CABLE ROUTING FZ6-SA/FZ6-SAHG M. To the neutral switch. Place the neutral 1. Right handlebar switch lead switch lead coupler under other leads so that it is not seen through the frame open- 2. Throttle cables ings. 3. Battery positive lead N.
Page 118 CABLE ROUTING 2-73...
Page 119 CABLE ROUTING AS.Route the spark plug lead #3 under the air cut-off valve hose. AT. Route the spark plug lead #2 behind the air cut-off valve hose. AU.Route the spark plug lead #4 by the front side of the spark plug leads #2 and #3. AV.Route the spark plug leads #2 and #3 behind the air cut-off valve hose.
Page 120 CABLE ROUTING FZ6-N/FZ6-NHG(W) 2-75...
Page 121 CABLE ROUTING FZ6-N/FZ6-NHG(W) P. Clamp the neutral switch lead, tail/brake 1. Right handlebar switch lead light lead and O sensor lead. Point the clamp opening to the rear side. 2. Throttle cables Q. Push the wire harness in the groove of the 3.
Page 122 CABLE ROUTING 2-77...
Page 123 CABLE ROUTING AV.Route the spark plug lead #4 behind the air cut-off valve hose. AW.Point the spark plug caps of #1 to #4 to the direction as shown in the illustration. AX.Route the spark plug lead #3 under the air cut-off valve hose.
Page 124 CABLE ROUTING FZ6-NA/FZ6-NAHG 2-79...
Page 125 CABLE ROUTING FZ6-NA/FZ6-NAHG L. To the neutral switch. Place the neutral 1. Right handlebar switch lead switch lead coupler under other leads so that it is not seen through the frame open- 2. Throttle cables ings. 3. Battery positive lead M.
Page 126 CABLE ROUTING 2-81...
Page 127 CABLE ROUTING AR.Route the throttle cables behind the #1 and #4 spark plug lead. AS.Pass the spark plug leads #1 and #4 through the slit of the cover 2. AT. Route the throttle cables by the front side of the #2 and #3 spark plug lead. AU.Route the throttle cables under the vent hose of the air-cut valve.
Page 128 CABLE ROUTING 2-83...
Page 129 CABLE ROUTING 1. Fuel pump assembly 2. Fuel tank breather hose 3. Fuel tank drain hose 4. Fuel hose 5. Clip 6. Clamp 7. Fuel tank protector A. Air opening. B. Install the O-ring with its lip pointed upward. C. Fuel tank breather hose has a white point mark.
Page 130 CABLE ROUTING 2-85...
Page 131: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-6 ADJUSTING THE EXHAUST GAS VOLUME (STANDARD) ....3-8 ADJUSTING THE EXHAUST GAS VOLUME (HIGH-GRADE) ....3-8 ADJUSTING THE ENGINE IDLING SPEED ..........3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-10 CHECKING THE SPARK PLUGS............3-11 MEASURING THE COMPRESSION PRESSURE .......3-12...
Page 132 ELECTRICAL SYSTEM................3-35 REPLACING THE HEADLIGHT BULBS..........3-35 ADJUSTING THE HEADLIGHT BEAMS ..........3-35...
Page 134: Periodic Maintenance
• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READ-...
Page 135 PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 • Check chain slack, alignment and condition. Every 1000 km and after wash- Drive chain • Adjust and lubricate chain with a ing the vehicle or riding in the special O-ring chain lubricant thor- rain...
Page 136 PERIODIC MAINTENANCE NOTE: • Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Page 137: Engine
ENGINE EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead 4.
Page 138 ENGINE • When removing the timing chain and cam- Valve clearance measuring sequence shafts, fasten the timing chain with a wire to Cylinder #1 → #2 → #4 → #3 retrieve it if it falls into the crankcase. 6. Adjust: •...
Page 139: Synchronizing The Throttle Bodies
ENGINE • Since valve pads of various sizes are origi- • Lubricate the valve lifter with molybdenum nally installed, the valve pad number must be disulfide oil. rounded in order to reach the closest equiva- • The valve lifter must turn smoothly when lent to the original.
Page 140 ENGINE • Air filter case ECA14900 CAUTION: Refer to "GENERAL CHASSIS" on page 4- Do not use the throttle valve adjusting 3. Install: screws to adjust the throttle body syncroni- • Vacuum gauge “1” zation. (onto the synchronizing hose “2”) Vacuum gauge Vacuum gauge 90890-03094...
Page 141: Adjusting The Exhaust Gas Volume (Standard)
ENGINE NOTE: Throttle cable free play The selected cylinder number appears on the 3.0–5.0 mm (0.12–0.20 in) clock LCD. • To decrease the selected cylinder number, 11. Install: press the “RESET” button. • Fuel tank • To increase the selected cylinder number, Refer to "FUEL TANK"...
Page 142: Adjusting The Engine Idling Speed
ENGINE 2. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: “dI” appears on the clock LCD. 5. After selecting the cylinder, simultaneously press the “SELECT”...
Page 143: Adjusting The Throttle Cable Free Play
ENGINE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to "GENERAL CHASSIS" on page 4- a. Turn the idle adjusting screw “1” in direction “a” or “b” until the specified engine idling • Fuel tank speed is obtained. Refer to "FUEL TANK" on page 7-1. • Air filter case Direction “a”...
Page 144: Checking The Spark Plugs
ENGINE b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. c. Tighten the locknut ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 145: Measuring The Compression Pressure
ENGINE Normal color is medium-to-light tan. 2. Start the engine, warm it up for several 6. Clean: minutes, and then turn it off. • Spark plug 3. Remove: (with a spark plug cleaner or wire brush) • Seat 7. Measure: Refer to "GENERAL CHASSIS"...
Page 146: Checking The Engine Oil Level
ENGINE Out of specification → Refer to steps (c) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ and (d). 8. Install: • Spark plugs Standard compression pres- sure (at sea level) Spark plug 1550 kPa/400 r/min (220.5 psi/ 18 Nm (1.8 m·kg, 13 ft·lb) 400 r/min) (15.5 kgf/cm²/400 r/ 9.
Page 147: Changing The Engine Oil
ENGINE NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 148: Measuring The Engine Oil Pressure
ENGINE Oil filter wrench Engine oil quantity 90890-01426 Total amount YU-38411 3.40 L (3.59 US qt) (2.99 Imp.qt) Without filter cartridge replacement 2.50 L (2.64 US qt) (2.20 Imp.qt) With oil filter cartridge replace- ment 2.80 L (2.96 US qt) (2.46 Imp.qt) 9.
Page 149: Adjusting The Clutch Cable Free Play
ENGINE Engine oil pressure Possible causes • Leaking oil passage • Faulty oil filter Above specification • Oil viscosity too high 6. Install: • Main gallery bolt “1” Main gallery bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) 4. Install: • Oil pressure gauge “1” •...
Page 150: Cleaning The Air Filter Element
ENGINE Refer to "FUEL TANK" on page 7-1. Direction “a” 2. Remove: Clutch cable free play is increased. • Air filter case cover “1” Direction “b” • Air filter element “2” Clutch cable free play is decreased. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side.
Page 151: Checking The Throttle Body Joints
ENGINE Refer to "GENERAL CHASSIS" on page 4- ECA14940 CAUTION: Make sure the fuel tank breather hose is EAS21010 routed correctly. CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1.
Page 152: Checking The Exhaust System
ENGINE • Seat Refer to "GENERAL CHASSIS" on page 4- EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • Radiator Refer to "RADIATOR" on page 6-1. 2. Check: • Exhaust pipe “1” •...
Page 153: Checking The Cooling System
ENGINE 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: • Coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles. EAS21130 CHANGING THE COOLANT 1. Remove: EAS21120 CHECKING THE COOLING SYSTEM •...
Page 154 ENGINE EWA13030 • Cooling system WARNING (with the specified amount of the recom- mended coolant) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the Recommended antifreeze engine is hot. Scalding hot fluid and steam High-quality ethylene glycol...
Page 155 ENGINE 12. Install: • Coolant reservoir cap 13. Start the engine, warm it up for several minutes, and then stop it. 14. Check: • Coolant level Refer to "CHECKING THE COOLANT LEVEL" on page 3-19. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled.
Page 156: Chassis
CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Check: • Brake pedal position EAS21160 ADJUSTING THE FRONT DISC BRAKE (distance “a” from the top of the rider foot- 1. Adjust: rest to the top of the brake pedal) •...
Page 157: Checking The Brake Fluid Level
CHASSIS Locknut 18 Nm (1.8 m·kg, 13 ft·lb) EWA4S81005 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system.
Page 158: Checking The Rear Brake Pads
CHASSIS EAS21290 CHECKING THE REAR BRAKE HOSE 1. Check: • Brake hose Cracks/damage/wear → Replace. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: 2. Check: • Rear brake pad •...
Page 159: Bleeding The Hydraulic Brake System
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21340 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. A. Front •...
Page 160 CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Bleeding the ABS brake EWA14010 WARNING Bleed the ABS whenever: • the system is disassembled. A. Front • a brake hose is loosened, disconnected B. Rear or replaced.
Page 161: Adjusting The Shift Pedal
CHASSIS EWA14020 EAS21390 ADJUSTING THE DRIVE CHAIN SLACK WARNING NOTE: After bleeding the ABS, check the brake The drive chain slack must be checked at the operation. tightest point on the chain. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ECA13550 CAUTION: EAS21370 ADJUSTING THE SHIFT PEDAL A drive chain that is too tight will overload 1.
Page 162: Lubricating The Drive Chain
CHASSIS EAS21500 Direction “a” CHECKING AND ADJUSTING THE STEER- Drive chain is tightened. ING HEAD Direction “b” 1. Stand the vehicle on a level surface. Drive chain is loosened. EWA13120 WARNING NOTE: Securely support the vehicle so that there To maintain the proper wheel alignment, adjust is no danger of it falling over.
Page 163: Checking The Front Fork
CHASSIS c. Loosen the lower ring nut “4” completely • Steering head tension and then tighten it to specification with a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ steering nut wrench. NOTE: EWA13140 Make sure all of the cables and wires are prop- WARNING erly routed. Do not overtighten the lower ring nut.
Page 164: Adjusting The Rear Shock Absorber Assembly
CHASSIS EWA13120 Spring preload WARNING ECA13590 CAUTION: Securely support the vehicle so that there is no danger of it falling over. Never go beyond the maximum or minimum adjustment positions. 2. Check: • Inner tube “1” 1. Adjust: Damage/scratches → Replace. •...
Page 165 CHASSIS Tire air pressure (measured on cold tires) Loading condition* 0–90 kg (0–198 lb) Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) EWA13180 Loading condition* WARNING 90–185 kg (198–408 lb) (FZ6- •...
Page 166 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. 1. Tire tread depth 2. Side wall Front tire 3.
Page 167: Checking The Wheels
CHASSIS EAS21670 EAS21710 CHECKING THE WHEELS LUBRICATING THE PEDAL The following procedure applies to both of the Lubricate the pivoting point and metal-to-metal wheels. moving parts of the pedal. 1. Check: Recommended lubricant • Wheel Damage/out-of-round → Replace. Lithium-soap-based grease EWA13260 WARNING EAS21720...
Page 168 ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: • Headlight coupler “1” 2. Remove: • Headlight bulb cover “2” A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
Page 169 ELECTRICAL SYSTEM A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left.
Page 170 ELECTRICAL SYSTEM 3-37...
Page 171 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-7 REMOVING THE FRONT WHEEL ............4-10 CHECKING THE FRONT WHEEL............4-10 [D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR .................4-11 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-13 INSTALLING THE FRONT WHEEL ............4-14 REAR WHEEL ....................4-15 REMOVING THE REAR WHEEL ............4-19 CHECKING THE REAR WHEEL ............4-19 CHECKING THE REAR WHEEL DRIVE HUB ........4-19...
Page 172 ABS (ANTI-LOCK BRAKE SYSTEM) ............4-53 [D-5] MAINTENANCE OF THE HYDRAULIC UNIT......4-55 HYDRAULIC UNIT OPERATION TEST ..........4-56 [D-6-5] TRIAL RUN ................4-59 HANDLEBAR....................4-60 REMOVING THE HANDLEBARS ............4-61 CHECKING THE HANDLEBAR............4-61 INSTALLING THE HANDLEBAR ............4-61 FRONT FORK.....................4-64 REMOVING THE FRONT FORK LEGS ..........4-66 DISASSEMBLING THE FRONT FORK LEGS ........4-66 CHECKING THE FRONT FORK LEGS..........4-67 ASSEMBLING THE FRONT FORK LEGS ...........4-68...
Page 174: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat Order Job/Parts to remove Q’ty Remarks Seat For installation, reverse the removal proce- dure.
Page 175 GENERAL CHASSIS Removing the cowlings (FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG) Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Side cover Rear cowling For installation, reverse the removal proce- dure.
Page 176 GENERAL CHASSIS Removing the cowlings (FZ6-S/FZ6-SA) Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Right front cowling inner panel (with cowling) Front turn signal light coupler Disconnect. Front cowling Rear view mirrors Windshield...
Page 177 GENERAL CHASSIS Removing the cowlings (FZ6-SHG(W)/FZ6-SAHG) Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Right front cowling inner panel (with cowling) Front turn signal light coupler Disconnect. Front cowling Front cowling inner panel (center) Rear view mirrors...
Page 178 GENERAL CHASSIS Removing the air filter case and battery Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 179 GENERAL CHASSIS Removing the battery box Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 180: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel and brake discs (FZ6-N/FZ6-NHG(W)/FZ6-S/FZ6-SHG(W)) Order Job/Parts to remove Q’ty Remarks Brake hose holder Brake hose holder Front brake caliper Front wheel axle pinch bolt Loosen. Front wheel axle Collar Front wheel Front brake disc For installation, reverse the removal proce- dure.
Page 181 FRONT WHEEL Removing the front wheel sensor and sensor rotor (FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6-SAHG) Order Job/Parts to remove Q’ty Remarks Brake hose holder Brake hose holder Front brake caliper Front wheel sensor Front wheel axle pinch bolt Loosen. Front wheel axle Collar Sensor housing Front wheel Front brake disc Clamp...
Page 182 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.
Page 183: Removing The Front Wheel
FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 184: [D-3] Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL Keep them away from dirt and do not sub- ject them to shocks. • The ABS wheel sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. Removing the front wheel sensor 1.
Page 185 FRONT WHEEL 2. Check: 2. Install: • Front wheel sensor rotor “2” • Front wheel sensor “1” Cracks/damage → Replace the front wheel assembly. Front wheel sensor bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) NOTE: The wheel sensor rotor of the vehicle is •...
Page 186: Adjusting The Front Wheel Static Balance
FRONT WHEEL c. Turn the front wheel 90° so that the “X ” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X ” mark at the bottom of the wheel. A. FZ6-NA/FZ6-SA B.
Page 187: Installing The Front Wheel
FRONT WHEEL c. If the heavy spot does not stay in that posi- Wheel axle nut tion, install a heavier weight. 72 Nm (7.2 m·kg, 52 ft·lb) d. Repeat steps (b) and (c) until the front wheel is balanced. • Wheel axle pinch bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 188: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel (FZ6-N/FZ6-NHG(W)/FZ6-S/FZ6-SHG(W)) Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut Loosen. Adjusting nut Loosen. Rear wheel axle nut Washer Rear wheel axle Washer Drive chain puller Rear wheel Rear brake caliper bracket For installation, reverse the removal proce- dure.
Page 189 REAR WHEEL Removing the rear wheel sensor and sensor rotor (FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6-SAHG) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor Rear brake caliper Lock nut Loosen. Adjusting nut Loosen. Wheel axle nut Washer Rear wheel axle Washer Drive chain puller Rear wheel Rear brake caliper bracket Sensor rotor...
Page 190 REAR WHEEL Removing the rear brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
Page 191 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-18...
Page 192: Removing The Rear Wheel
REAR WHEEL EAS22040 • Rear wheel drive hub “2” REMOVING THE REAR WHEEL • Rear wheel drive hub damper 1. Stand the vehicle on a level surface. • Right collar EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 193: Checking And Replacing The Rear Wheel Sprocket
REAR WHEEL EAS22120 EAS22200 CHECKING AND REPLACING THE REAR [D-4] MAINTENANCE OF THE REAR WHEEL SPROCKET WHEEL SENSOR AND SENSOR ROTOR 1. Check: ECA4S81012 CAUTION: • Rear wheel sprocket More than 1/4 tooth “a” wear → Replace • Be sure not to contact the sensor elec- the rear wheel sprocket.
Page 194 REAR WHEEL • Rear wheel damage to the inner sensor rotor and wheel Refer to "REMOVING THE REAR WHEEL" sensor. on page 4-19. 3. Install: 5. Remove: • Rear wheel sensor “2” • Sensor rotor “5” Rear wheel sensor bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) NOTE: When installing the rear wheel sensor, check...
Page 195: Adjusting The Rear Wheel Static Balance
REAR WHEEL • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: • Rear wheel static balance Refer to "ADJUSTING THE FRONT WHEEL STATIC BALANCE" on page 4-13. EAS22160 INSTALLING THE REAR WHEEL 1.
Page 196: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads (FZ6-N/FZ6-NA/FZ6-S/FZ6-SA) Order Job/Parts to remove Q’ty Remarks Front brake caliper Brake pad Brake pad spring Bleed screw For installation, reverse the removal proce- dure. 4-23...
Page 197 FRONT BRAKE Removing the front brake pads (FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-SAHG) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw Clamp For installation, reverse the removal proce- dure.
Page 198 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake lever Front brake light switch lead coupler Disconnect.
Page 199 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod For assembly, reverse the disassembly pro- cedure. 4-26...
Page 200 FRONT BRAKE Removing the front brake calipers (FZ6-N/FZ6-NA/FZ6-S/FZ6-SA) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Union bolt Copper washer Brake hose Brake caliper Brake pad Brake caliper bracket For installation, reverse the removal proce- dure.
Page 201 FRONT BRAKE Removing the front brake calipers (FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-SAHG) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Union bolt Copper washer Brake hose Brake caliper Clamp Brake hose holder For installation, reverse the removal proce- dure.
Page 202 FRONT BRAKE Disassembling the front brake calipers (FZ6-N/FZ6-NA/FZ6-S/FZ6-SA) Order Job/Parts to remove Q’ty Remarks Brake pad Brake caliper piston Brake caliper piston seal Brake pad spring Bleed screw For assembly, reverse the disassembly pro- cedure. 4-29...
Page 203 FRONT BRAKE Disassembling the front brake calipers (FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-SAHG) Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 204: Introduction
FRONT BRAKE EAS22220 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INTRODUCTION a. Place the vehicle on a suitable stand so EWA14100 that the front wheel is elevated. WARNING b. Before measuring the front brake disc Disc brake components rarely require dis- deflection, turn the handlebar to the left or assembly.
Page 205: Replacing The Front Brake Pads
FRONT BRAKE • Brake pads Brake disc bolt NOTE: 18 Nm (1.8 m·kg, 13 ft·lb) Always install new brake pads, brake pad LOCTITE® shims, and a brake pad spring as a set. d. Measure the brake disc deflection. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ e. If out of specification, repeat the adjust- a.
Page 206 FRONT BRAKE 5. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6- SAHG 1. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake b.
Page 207: Removing The Front Brake Calipers
FRONT BRAKE B. FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/ FZ6-SAHG NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 5. Check: FZ6-N/FZ6-NA/FZ6-S/FZ6-SA •...
Page 208: Checking The Front Brake Calipers
FRONT BRAKE FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6- Recommended brake component replace- SAHG ment schedule 1. Remove: Brake hoses Every four years • Brake caliper pistons “1” Every two years and • Brake caliper piston seals “2” Brake fluid whenever the brake is disassembled 1. Check: •...
Page 209: Assembling The Front Brake Calipers
FRONT BRAKE EAS22410 EWA13530 ASSEMBLING THE FRONT BRAKE CALI- WARNING PERS Proper brake hose routing is essential to EWA13620 insure safe vehicle operation. Refer to WARNING "CABLE ROUTING" on page 2-47. • Before installation, all internal brake com- ECA14170 ponents should be cleaned and lubricated CAUTION: with clean or new brake fluid.
Page 210 FRONT BRAKE • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. 4. Check: • Brake fluid level Below the minimum level mark “c” → Add the recommended brake fluid to the proper level. Refer to "CHECKING THE BRAKE FLUID LEVEL"...
Page 211: Removing The Front Brake Master Cylinder
FRONT BRAKE EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder “1” Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 5. Check: • Brake lever operation Soft or spongy feeling →...
Page 212: Assembling The Front Brake Master Cylinder
FRONT BRAKE EAS22520 EWA13530 ASSEMBLING THE FRONT BRAKE MAS- WARNING TER CYLINDER Proper brake hose routing is essential to EWA13520 insure safe vehicle operation. Refer to WARNING "CABLE ROUTING" on page 2-47. • Before installation, all internal brake com- ECA4S81013 ponents should be cleaned and lubricated CAUTION: with clean or new brake fluid.
Page 213 FRONT BRAKE boiling point of the brake fluid and could cause vapor lock. ECA13540 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM"...
Page 214: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Brake screw Brake pad spring For installation, reverse the removal proce- dure.
Page 215 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Union bolt...
Page 216 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Spring Brake master cylinder body For installation, reverse the removal proce- dure. 4-43...
Page 217 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-26. Union bolt Copper washer Brake hose Rear brake caliper For installation, reverse the removal proce- dure.
Page 218 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 219: Introduction
REAR BRAKE EAS22560 4. Adjust: INTRODUCTION • Brake disc deflection EWA14100 Refer to "CHECKING THE FRONT BRAKE WARNING DISCS" on page 4-31. Disc brake components rarely require dis- assembly. Therefore, always follow these Brake disc bolt 30 Nm (3.0 m·kg, 22 ft·lb) preventive measures: LOCTITE®...
Page 220: Removing The Rear Brake Caliper
REAR BRAKE b. Loosen the bleed screw and push the 5. Check: brake caliper pistons into the brake caliper • Brake pedal operation with your finger. Soft or spongy feeling → Bleed the brake c. Tighten the bleed screw. system. Refer to "BLEEDING THE HYDRAULIC Bleed screw BRAKE SYSTEM"...
Page 221: Checking The Rear Brake Caliper
REAR BRAKE Scratches/wear → Replace the brake cali- per assembly. • Brake caliper body “3” Cracks/damage → Replace the brake cali- per assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a”...
Page 222: Installing The Rear Brake Caliper
REAR BRAKE 1. Install: • Brake pad shims (on to the brake pads) • Brake pads • Brake caliper seals • Brake caliper • Brake caliper piston Brake caliper bolt (front side) EAS22670 27 Nm (2.7 m·kg, 20 ft·lb) INSTALLING THE REAR BRAKE CALIPER Brake caliper bolt (rear side) 1.
Page 223: Removing The Rear Brake Master Cylinder
REAR BRAKE EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder “1” Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 7. Check: • Brake pedal operation Soft or spongy feeling →...
Page 224: Assembling The Rear Brake Master Cylinder
REAR BRAKE EAS22730 ASSEMBLING THE REAR BRAKE MASTER Recommended fluid CYLINDER DOT 4 EWA13520 WARNING EWA13090 WARNING • Before installation, all internal brake com- • Use only the designated brake fluid. ponents should be cleaned and lubricated Other brake fluids may cause the rubber with clean or new brake fluid.
Page 225 REAR BRAKE Brake pedal position 25.8 mm (1.02 in) 6. Adjust: • Rear brake light operation timing Refer to "ADJUSTING THE REAR BRAKE LIGHT SWITCH" on page 3-25. 4-52...
Page 226: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Refer to "ABS ECU AND ABS MOTOR ABS ECU RELAY"...
Page 227 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit Order Job/Parts to remove Q’ty Remarks Brake hose (hydraulic unit to front brake cali- pers) Union bolt Copper washer Brake hose (rear brake master cylinder to hydraulic unit) Union bolt Copper washer Brake hose (hydraulic unit to rear brake caliper) Hydraulic unit Hydraulic unit bracket 1...
Page 228: [D-5] Maintenance Of The Hydraulic Unit
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22770 • Brake hose “3” (from the rear brake master [D-5] MAINTENANCE OF THE HYDRAULIC cylinder) UNIT • Brake hose “4” (to the rear brake caliper) ECA15060 CAUTION: Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve.
Page 229: Hydraulic Unit Operation Test
ABS (ANTI-LOCK BRAKE SYSTEM) Installing the hydraulic unit EWA13940 Proceed in the reverse order of disassembly. WARNING Pay attention to the following items. The brake hoses to the front and rear brake 1. Install: calipers can be distinguished by the rubber •...
Page 230 ABS (ANTI-LOCK BRAKE SYSTEM) • Hydraulic unit operation test 1: this test gen- Test coupler adapter erates the same reaction-force pulsating 90890-03149 action that is generated in the brake lever and brake pedal when the ABS is activated. • Hydraulic unit operation test 2: this test checks the function of the ABS after the sys- tem was disassembled, adjusted, or ser- viced.
Page 231 ABS (ANTI-LOCK BRAKE SYSTEM) Refer to "GENERAL CHASSIS" on page 4- • Fuel tank Refer to "FUEL TANK" on page 7-1. 4. Check: • Battery voltage Battery voltage Higher than 12.8 V a. ABS warning light b. Main switch “ON” Lower than 12.8 V →...
Page 232: [D-6-5] Trial Run
ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: NOTE: After setting the main switch to “ON”, wait Be sure to continue to operate the brake lever (approximately 2 seconds) until the ABS warn- and brake pedal even after the pulsating action ing light goes off. has stopped.
Page 233: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Grip end Handlebar grip Clutch switch connector Disconnect. Left handlebar switch Clutch cable Clutch lever Right handlebar switch Throttle grip Throttle cable Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder Upper handlebar holder...
Page 234: Removing The Handlebars
HANDLEBAR EAS22860 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: Blow compressed air between the left handle- EAS22880 CHECKING THE HANDLEBAR bar and the handlebar grip, and gradually push...
Page 235 HANDLEBAR 2. Install: • Handlebar “1” • Upper handlebar holders “2” • Upper handlebar holder caps “3” (Stan- dard) Upper handlebar holder bolt 23 Nm (2.3 m·kg, 17 ft·lb) 3. Install: • Throttle cables • Right handlebar switch “1” • Throttle grip “2” NOTE: Align the projections “a”...
Page 236 HANDLEBAR • Clutch cable Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" on page 3-10. NOTE: Align the slit on the clutch lever holder with the Throttle cable free play punch mark “a” on the handlebar. 3.0–5.0 mm (0.12–0.20 in) 9.
Page 237: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-7. Front brake calipers Refer to "FRONT BRAKE" on page 4-23. Front fender Cap bolt Loosen. Upper bracket pinch bolt Loosen.
Page 238 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Spacer Washer Front fork spring Dust seal Oil seal clip Damper rod assembly bolt Copper washer Damper rod assembly Oil seal Washer Inner tube Outer tube bushing Inner tube bushing Oil flow stopper...
Page 239: Removing The Front Fork Legs
FRONT FORK EAS22970 (with a flat-head screwdriver) REMOVING THE FRONT FORK LEGS ECA14180 The following procedure applies to both of the CAUTION: front fork legs. Do not scratch the inner tube. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 240: Checking The Front Fork Legs
FRONT FORK ECA14190 CAUTION: • Excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. • Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. 3.
Page 241: Assembling The Front Fork Legs
FRONT FORK Recommended lubricant Suspension oil 01 or equiva- lent 3. Tighten: • Damper rod assembly bolt “1” Damper rod assembly bolt 23 Nm (2.3 m·kg, 17 ft·lb) LOCTITE® EAS23020 ASSEMBLING THE FRONT FORK LEGS NOTE: The following procedure applies to both of the While holding the damper rod assembly with front fork legs.
Page 242 FRONT FORK NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 5. Install: • Washer • Oil seal “1” (with the fork seal driver and adapter) 7. Install: ECA14220 CAUTION: • Dust seal “1” (with the fork seal driver weight) Make sure the numbered side of the oil seal faces up.
Page 243: Installing The Front Fork Legs
FRONT FORK 9. Measure: • Front fork leg oil level “a” Out of specification → Correct. Level 134.0 mm (5.28 in) NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil.
Page 244 FRONT FORK 4-71...
Page 245: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-7. Front fender Refer to "FRONT FORK" on page 4-64. Front fork Refer to "FRONT FORK" on page 4-64. Handlebar Refer to "HANDLEBAR"...
Page 246 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race For installation, reverse the removal proce- dure. 4-73...
Page 247: Removing The Lower Bracket
STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Steering stem nut • Washer 3. Replace: •...
Page 248: Installing The Steering Head
STEERING HEAD • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: • Lower bracket •...
Page 249: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Side cover Refer to "GENERAL CHASSIS" on page 4-1. Rear brake caliper Refer to "REAR BRAKE"...
Page 250: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23180 • Seat HANDLING THE REAR SHOCK ABSORBER • Side cover EWA13740 Refer to "GENERAL CHASSIS" on page 4- WARNING This rear shock absorber contains highly • Rear wheel compressed nitrogen gas. Before handling Refer to "REAR WHEEL" on page 4-15. the rear shock absorber, read and make 3.
Page 251: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY • Bushings Damage/wear → Replace. • Dust seals Damage/wear → Replace. • Bolts Bends/damage/wear → Replace. 4. Install: EAS23300 • Rear wheel INSTALLING THE REAR SHOCK Refer to "REAR WHEEL" on page 4-15. ABSORBER ASSEMBLY 5. Adjust: 1.
Page 252: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Muffler assembly Refer to "ENGINE REMOVAL" on page 5-1. Catalyst assembly Refer to "ENGINE REMOVAL" on page 5-1. Exhaust pipe assembly Refer to "ENGINE REMOVAL" on page 5-1. Rear brake caliper Refer to "REAR BRAKE"...
Page 253 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 4-80...
Page 254: Removing The Swingarm
SWINGARM EAS23340 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.
Page 255: Installing The Swingarm
SWINGARM EAS23380 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacers • Dust covers • Pivot shaft “1” Recommended lubricant Lithium-soap-based grease 2. Install: • Swingarm • Pivot shaft nut “2” Pivot shaft nut 120 Nm (12.0 m·kg, 87 ft·lb) 3.
Page 256: Chain Drive
CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to "ENGINE REMOVAL" on page 5-1. Refer to "REMOVING THE SWINGARM" on Swingarm page 4-81. Rear fender Drive chain Chain protector For installation, reverse the removal proce- dure.
Page 257: Removing The Drive Chain
CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2. Check: Place the vehicle on a suitable stand so that •...
Page 258: Checking The Drive Sprocket
CHAIN DRIVE More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to "CHECKING AND REPLACING THE REAR WHEEL SPROCKET"...
Page 259: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-6 CAMSHAFTS....................5-8 REMOVING THE CAMSHAFTS ............5-10 CHECKING THE CAMSHAFTS ............5-11 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-12 CHECKING THE TIMING CHAIN GUIDES ..........5-12 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS ............5-13 CYLINDER HEAD..................5-16 REMOVING THE CYLINDER HEAD ............5-17 CHECKING THE CYLINDER HEAD ............5-17...
Page 260 CHECKING THE OIL NOZZLES ............5-44 ASSEMBLING THE OIL PUMP ............5-44 INSTALLING THE OIL PUMP ...............5-45 INSTALLING THE OIL STRAINER ............5-45 INSTALLING THE OIL PAN ..............5-45 CLUTCH......................5-46 REMOVING THE CLUTCH..............5-49 CHECKING THE FRICTION PLATES ..........5-49 CHECKING THE CLUTCH PLATES.............5-50 CHECKING THE CLUTCH SPRINGS ..........5-50 CHECKING THE CLUTCH HOUSING ..........5-50 CHECKING THE CLUTCH BOSS ............5-50 CHECKING THE PRESSURE PLATE ..........5-51...
Page 262 ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Loosen Drive chain Refer to "ADJUSTING THE SHIFT PEDAL" on page 3-28. Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket For installation, reverse the removal proce- dure.
Page 263 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks Exhaust pipe assembly Exhaust pipe gasket Catalytic converter pipe Muffler cover Muffler For installation, reverse the removal proce- dure.
Page 264 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 265 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Stator coil assembly coupler Disconnect. Oil level switch connector Disconnect. Neutral switch coupler Disconnect. Speed sensor coupler Disconnect. For assembly, reverse the removal proce- dure.
Page 266 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Right front engine mounting bolt Left front engine mounting bolt Self-locking nut Rear engine mounting bolt Engine For installation, reverse the removal proce- dure.
Page 267: Engine Removal
ENGINE REMOVAL EAS23720 NOTE: INSTALLING THE ENGINE First tighten the lower self-locking nut. 1. Install: • Rear engine mounting bolts “1” NOTE: Lubricate the rear engine mounting bolt threads with engine oil. 4. Tighten: • Left front engine mounting bolts “5” Left front engine mounting bolt 55 Nm (5.5 m·kg, 40 ft·lb) 2.
Page 268 ENGINE REMOVAL NOTE: • Before installing, make sure to align the punch mark “a” of the shift shaft with the punch mark “b” of the shift arm. • Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket.
Page 269: Camshafts
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Battery Refer to "GENERAL CHASSIS" on page 4-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Battery box Refer to "FUEL TANK" on page 7-1. Battery box bracket Refer to "GENERAL CHASSIS"...
Page 270 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup rotor cover Refer to "PICKUP ROTOR" on page 5-33. Camshaft sprocket bolt Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft...
Page 271: Removing The Camshafts
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "PICKUP ROTOR" on page 5-33. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.
Page 272: Checking The Camshafts
CAMSHAFTS 8. Remove: • Camshaft sprockets EAS23850 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 3. Measure: • Camshaft lobe dimensions “a” and “b” • Camshaft runout Out of specification → Replace the cam- Out of specification →...
Page 273: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFTS NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clear- ance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) EAS23870 d.
Page 274: Checking The Timing Chain Tensioner
CAMSHAFTS Damage/wear → Replace the defective part(s). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: EAS23970 CHECKING THE TIMING CHAIN TEN- • Timing chain tensioner cap bolt SIONER • Aluminum washer 1. Check: • Gasket • Timing chain tensioner Damage/wear → Replace the defective Cracks/damage → Replace. part(s).
Page 275 CAMSHAFTS NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. ECA4S81016 CAUTION: • Lubricate the camshaft cap bolts with the engine oil. • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, 3.
Page 276 CAMSHAFTS 10. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Valve clearance 7. Turn: Out of specification → Adjust. • Crankshaft Refer to "ADJUSTING THE VALVE (several full turns clockwise) CLEARANCE" on page 3-4. 8. Check: • “T” mark “a” Make sure the “T” mark on the pickup rotor is aligned with the crankcase mating sure face “b”.
Page 277: Cylinder Head
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Intake camshaft Refer to "CAMSHAFTS" on page 5-8. Exhaust camshaft Refer to "CAMSHAFTS" on page 5-8. Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal proce- dure.
Page 278: Removing The Cylinder Head
CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head bolts NOTE: • Loosen the bolts in the proper sequence as shown. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Loosen each bolts 1/2 of a turn at a time. a. Place a straightedge “1” and a thickness After all of the bolts are fully loosened, gauge “2”...
Page 279 CYLINDER HEAD NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: • Cylinder head bolts “1” – “10” Cylinder head bolt (1st) 19 Nm (1.9 m·kg, 14 ft·lb) Cylinder head bolt (2nd) 50 Nm (5.0 m·kg, 36 ft·lb) •...
Page 280 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to "CYLINDER HEAD" on page 5-16. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner Intake valve stem seal...
Page 281: Valves And Valve Springs
VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-20...
Page 282: Removing The Valves
VALVES AND VALVE SPRINGS EAS24280 • Valve cotters “1” REMOVING THE VALVES NOTE: The following procedure applies to all of the Remove the valve cotters by compressing the valves and related components. valve springs with the valve spring compressor NOTE: “2”...
Page 283: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS EAS24290 NOTE: CHECKING THE VALVES AND VALVE To ease valve guide removal and installation, GUIDES and to maintain the correct fit, heat the cylinder The following procedure applies to all of the head to 100°C (212°F) in an oven. valves and valve guides.
Page 284: Checking The Valve Seats
VALVES AND VALVE SPRINGS Out of specification → Replace the valve. Valve guide remover (ø4) NOTE: 90890-04111 • When installing a new valve, always replace Valve guide remover (4.0 mm) the valve guide. YM-04111 • If the valve is removed or replaced, always Valve guide installer (ø4) replace the oil seal.
Page 285 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Apply molybdenum disulfide oil onto the a. Apply Mechanic’s blueing dye (Dykem) “b” valve stem. onto the valve face. c. Install the valve into the cylinder head. b. Install the valve into the cylinder head. d.
Page 286: Checking The Valve Springs
VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: i. Press the valve through the valve guide • Compressed valve spring force “a” and onto the valve seat to make a clear Out of specification → Replace the valve impression.
Page 287: Checking The Valve Lifters
VALVES AND VALVE SPRINGS EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • Valve stem end (with an oil stone) 3. Measure: • Valve spring tilt “a” Out of specification → Replace the valve spring.
Page 288 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad “1” •...
Page 289: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS4S81014 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Drain Coolant Refer to "CHANGING THE COOLANT"...
Page 290 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch Order Job/Parts to remove Q’ty Remarks Idler gear shaft Idler gear Starter clutch drive gear For installation, reverse the removal proce- dure. 5-29...
Page 291: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 ECA13880 REMOVING THE GENERATOR CAUTION: 1. Remove: To protect the end of the crankshaft, place • Seat an appropriate sized socket between the Refer to "GENERAL CHASSIS" on page 4- flywheel puller set’s center bolt and the crankshaft.
Page 292: Checking The Starter Clutch
GENERATOR AND STARTER CLUTCH otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. EAS24570 CHECKING THE STARTER CLUTCH 1.
Page 293: Installing The Generator
GENERATOR AND STARTER CLUTCH Yamaha bond No. 1215 ® (Three bond No.1215 90890-85505 EAS24500 INSTALLING THE GENERATOR 1. Install: • Generator rotor • Washer • Generator rotor bolt 4. Install: NOTE: • Stator coil • Clean the tapered portion of the crankshaft 5.
Page 294: Pickup Rotor
PICKUP ROTOR EAS4S81015 PICKUP ROTOR Removing the pickup rotor Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 295: Removing The Pickup Rotor
PICKUP ROTOR EAS4S81041 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor cover “1” NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS4S81042 INSTALLING THE PICKUP ROTOR 1.
Page 296 PICKUP ROTOR 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 ® (Three Bond No.1215 90890-85505 4. Install: • Pickup rotor cover gasket • Pickup rotor cover NOTE: • When installing the pickup rotor cover, align the timing chain guide (intake side) pin “1”...
Page 297: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 298 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set O-ring Brush holder Armature assembly Starter motor yoke O-ring For assembly, reverse the disassembly pro- cedure.
Page 299: Checking The Starter Motor
ELECTRIC STARTER EAS24790 a. Measure the armature assembly resis- CHECKING THE STARTER MOTOR tances with the pocket tester. 1. Check: • Commutator Pocket tester Dirt → Clean with 600 grit sandpaper. 90890-03112 2. Measure: Analog pocket tester • Commutator diameter “a” YU-03112-C Out of specification →...
Page 300: Assembling The Starter Motor
ELECTRIC STARTER NOTE: Align the match marks “a” on the starter motor yoke with the match marks “b” on the starter motor front and rear covers. 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing •...
Page 301: Oil Pump
OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-14. Drain. Coolant Refer to "CHANGING THE COOLANT" on page 3-20. Exhaust pipe assembly Refer to "ENGINE REMOVAL"...
Page 302 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Relief valve assembly For installation, reverse the removal proce- dure. 5-41...
Page 303 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump rotor housing Oil pump driven sprocket For assembly, reverse the removal proce- dure. 5-42...
Page 304: Removing The Oil Pan
OIL PUMP EAS24930 REMOVING THE OIL PAN Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil level switch “1” 0.030–0.090 (0.0012– • Oil pan “2” 0.0035 in) • Oil pan gasket Limit • Dowel pins 0.15 mm (0.0059 in) Outer-rotor-to-oil-pump-hous- NOTE: ing clearance Loosen each bolt 1/4 of a turn at a time, in 0.030–0.080 (0.0012–...
Page 305: Checking The Oil Delivery Pipes
OIL PUMP Damage/wear → Replace. • Oil nozzle passage Obstruction → Blow out with compressed air. EAS24980 CHECKING THE OIL DELIVERY PIPES 1. Check: • Oil delivery pipe “1” • Oil pipe “2” EAS25010 Damage → Replace. ASSEMBLING THE OIL PUMP Obstruction →...
Page 306: Installing The Oil Pump
OIL PUMP EAS25050 INSTALLING THE OIL PAN 1. Install: • Oil pipe • Oil delivery pipe 2. Install: • Dowel pins • Gasket • Oil pan “1” Oil pan bolt 3. Check: 12 Nm (1.2 m·kg, 8.7 ft·lb) • Oil pump operation •...
Page 307: Clutch
3-14. Drain Coolant Refer to "CHANGING THE COOLANT" on page 3-20. Coolant hose Clutch cable Clutch cable holder Clutch cover Clutch cover gasket Dowel pin For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three Bond No.1215®) 5-46...
Page 308 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer For installation, reverse the removal proce- dure. 5-47...
Page 309 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch boss nut Lock washer Clutch boss Thrust plate For assembly, reverse the removal proce- dure.
Page 310: Removing The Clutch
CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch cable holder “1” • Clutch cover “2” • Gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 311: Checking The Clutch Plates
CLUTCH Clutch spring free length 55.00 mm (2.17 in) Minimum length 54.00 mm (2.13 in) Limit 52.3 mm (2.06 in) EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • Clutch plate Damage →...
Page 312: Checking The Pressure Plate
CLUTCH EAS25270 NOTE: INSTALLING THE CLUTCH Pitting on the clutch boss splines will cause 1. Install: erratic clutch operation. • Thrust plate “1” • Clutch boss “2” • Lock washer “3” • Clutch boss nut “4” EAS25170 CHECKING THE PRESSURE PLATE 1.
Page 313 CLUTCH 5. Install: NOTE: • Friction plates Tighten the clutch spring bolts in stages and in • Clutch plates a crisscross pattern. NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
Page 314: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to "ENGINE REMOVAL" on page 5-1. Shift shaft cover Shift shaft cover gasket Dowel pin Oil seal Shift shaft Shift shaft spring Collar Stopper lever spring...
Page 315: Checking The Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” Damage/wear → Replace. 2. Install: • Shift shaft cover NOTE: Lubricate the oil seal lips with lithium-soap- based grease. EAS25430 CHECKING THE STOPPER LEVER 1.
Page 316: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to "ENGINE REMOVAL" on page 5-1. Cylinder head Refer to "CYLINDER HEAD" on page 5-16. Refer to "GENERATOR AND STARTER Generator CLUTCH" on page 5-28. Refer to "GENERATOR AND STARTER Starter clutch CLUTCH"...
Page 317 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Plate For installation, reverse the removal proce- dure. 5-56...
Page 318: Disassembling The Crankcase
CRANKCASE EAS25550 NOTE: DISASSEMBLING THE CRANKCASE Identify the position of each crankshaft journal 1. Place the engine upside down. lower bearing so that it can be reinstalled in its 2. Remove: original place. • Crankcase bolts NOTE: EAS25580 • Loosen each bolt 1/4 of a turn at a time, in CHECKING THE CRANKCASE stages and in a crisscross pattern.
Page 319: Assembling The Crankcase
Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) 6. Install: • Crankcase bolts Yamaha bond No. 1215 ® (Three bond No.1215 NOTE: • Lubricate the bolt threads with engine oil. 90890-85505 • Install a washer on bolts “1”–”10”...
Page 320 CRANKCASE 5-59...
Page 321: Crankshaft
CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-55. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring...
Page 322 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to "CRANKCASE" on page 5-55. Connecting rods caps Refer to "CRANKSHAFT" on page 5-60. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal proce- dure.
Page 323: Removing The Connecting Rods And Pistons
CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • Connecting rod cap “1” • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 324: Checking The Cylinder And Piston
CRANKSHAFT EAS24390 CHECKING THE CYLINDER AND PISTON Piston size “P” 1. Check: Standard • Piston wall 65.475–65.490 mm (2.5778– • Cylinder wall 2.5783 in) Vertical scratches → Replace the cylinder, and replace the piston and piston rings as a set. 2.
Page 325: Checking The Piston Pins
CRANKSHAFT Top ring Top ring Ring side clearance End gap (installed) 0.030–0.065 (0.0012– 0.25–0.35 mm (0.0098–0.0138 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.60 mm (0.0236 in) 2nd ring 2nd ring Ring side clearance End gap (installed) 0.030–0.065 (0.0012– 0.70–0.80 mm (0.0276–0.0315 0.0026 in) Limit...
Page 326: Checking The Big End Bearings
CRANKSHAFT end bearings must be installed in their orig- Piston pin bore inside diameter inal positions. 16.002–16.013 mm (0.6300– a. Clean the big end bearings, crankshaft 0.6304 in) pins, and the inside of the connecting rod Limit halves. 16.043 mm (0.6316 in) b.
Page 327 CRANKSHAFT j. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. k. Tighten the connecting rod bolts. Connecting rod bolt 15 Nm (1.5 m·kg, 11 ft·lb) + 120°...
Page 328 CRANKSHAFT If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. p. After the installation, check that the section show “a” is flush with each other by touch- ing the surface. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Side machined face “a” 2.
Page 329: Installing The Connecting Rod And Piston
CRANKSHAFT • Make sure that the “Y” mark “a” on the con- necting rod faces left when the arrow mark “b” on the piston is pointing up as shown. • Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4).
Page 330 CRANKSHAFT 6. Install: • Big end bearings • Connecting rod cap (onto the connecting rod) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • Make sure that the characters “a” on both the connecting rod and connecting rod cap are aligned.
Page 331: Checking The Crankshaft
CRANKSHAFT 9. Tighten: a. Side machined face • Connecting rod bolts EWA13990 WARNING Connecting rod bolt • When the bolt is tightened more than the 15 Nm (1.5 m·kg, 11 ft·lb) + specified angle, do not loosen the bolt 120° and then retighten it.
Page 332 CRANKSHAFT Out of specification → Replace the crank- shaft journal bearings. Crankshaft-journal-to-crank- shaft journal bearing clearance 0.028–0.052 mm (0.0011–0.0020 in) ECA4S81028 CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft e. Install the crankshaft journal lower bear- journal- to-crankshaft-journal-bearing ings “1”...
Page 333: Installing The Crankshaft
CRANKSHAFT Refer to "CRANKCASE" on page 5-55. For example, if the crankcase “J ” and crankshaft web “J ” numbers are “6” and “2” respectively, than the bearing size for “J ” is: “J ” (crankcase) – “J ” (crankshaft web) – 1 = 6 –...
Page 334 CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place. 2. Install: • Crankshaft 3. Install: •...
Page 335: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5-55. Drive axle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar Spring Shift fork-L Shift fork-R...
Page 336 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For installation, reverse the removal proce-...
Page 337 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer 2nd wheel gear...
Page 338 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-77...
Page 339: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” (with the Torx® wrench) 2. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat sur- face. Bends → Replace. EWA12840 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a.
Page 340: Checking The Transmission
TRANSMISSION • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). EAS26300 CHECKING THE TRANSMISSION 1. Measure: 4. Check: • Main axle runout • Transmission gear engagement (with a centering device and dial gauge “1”) (each pinion gear to its respective wheel Out of specification →...
Page 341 TRANSMISSION Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 3. Install: • Shift fork-R “1” • Shift fork-L “2” • Drive axle “3” • Shift fork guide bar • Shift drum retainer Shift drum retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE®...
Page 342 TRANSMISSION 5-81...
Page 343: Cooling System
COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER..............6-5 INSTALLING THE OIL COOLER ............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT............6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP..........6-11 CHECKING THE WATER PUMP ............6-11 ASSEMBLING THE WATER PUMP............6-12 INSTALLING THE WATER PUMP ............6-13...
Page 344 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 345 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Coolant reservoir drain hose For installation, reverse the removal proce- dure.
Page 346: Checking The Radiator
RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
Page 347: Oil Cooler
OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Radiator assembly Refer to "RADIATOR" on page 6-1. Coolant reservoir Refer to "RADIATOR" on page 6-1. Drain. Engine oil Refer to "CHANGING THE ENGINE OIL" on page 3-14.
Page 348: Checking The Oil Cooler
OIL COOLER EAS26420 (with the specified amount of the recom- CHECKING THE OIL COOLER mended coolant) 1. Check: Refer to "CHANGING THE COOLANT" on • Oil cooler page 3-20. Cracks/damage → Replace. • Crankcase (with the specified amount of the recom- mended engine oil) Refer to "CHANGING THE ENGINE OIL"...
Page 349: Thermostat
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling)+ Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 350: Checking The Thermostat
THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat housing cover “1” 1. Check: • Cracks/damage → Replace. • Thermostat “1” Does not open at 71–85°C (160–185°F) → Replace. EAS26490 INSTALLING THE THERMOSTAT ASSEM- 1. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Thermostat a. Suspend the thermostat “3” in a container NOTE: “4”...
Page 351 THERMOSTAT Refer to "CHECKING THE RADIATOR" on page 6-3.
Page 352: Water Pump
WATER PUMP EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Drain. Coolant Refer to "CHANGING THE COOLANT" on page 3-20.
Page 353 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump cover O-ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O-ring Copper washer For assembly, reverse the disassembly pro- cedure. 6-10...
Page 354: Disassembling The Water Pump
WATER PUMP EAS26510 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump cover • O-ring • Circlip • Impeller shaft 2. Remove: • Water pump seal “1” NOTE: 5. Remove: Remove the water pump seal from the inside • Rubber damper holder “5” of the water pump housing “2”.
Page 355: Assembling The Water Pump
CAUTION: • Before installing the water pump seal, apply Make sure the rubber damper and rubber Yamaha bond No.1215 or Quick Gasket “2” damper holder are flush with the impeller. to the water pump housing “3”. Impeller shaft tilt limit Mechanical seal installer 0.15 mm (0.006 in)
Page 356: Installing The Water Pump
WATER PUMP • Water pump outlet hose “2” • Copper washer NOTE: • Install the radiator outlet hose with white “a” mark positioned outside. • Install the hose clamp with its screw head pointed to the inner side. 1. Straightedge 2.
Page 357: Fuel System
FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK...............7-3 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS ...............7-6 CHECKING THE THROTTLE BODIES ..........7-6 CHECKING THE FUEL PRESSURE............7-6 ADJUSTING THE THROTTLE POSITION SENSOR ......7-6...
Page 358 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 359: Fuel Tank
FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Remove: Cracks/damage →...
Page 360: Installing The Fuel Tank
FUEL TANK EAS4S81001 INSTALLING THE FUEL TANK 1. Install: • Fuel hose ECA4S81001 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed.
Page 361: Throttle Bodies
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 362 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Throttle position sensor coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder #1 injector coupler Disconnect. Cylinder #2 injector coupler Disconnect. Cylinder #3 injector coupler Disconnect. Cylinder #4 injector coupler Disconnect.
Page 363: Checking The Injectors
THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 EAS26990 YM-03176 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2.
Page 364 THROTTLE BODIES • Positive tester probe Yellow “1” • Negative tester probe Black/Blue “2” Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 c. Measure the throttle position sensor volt- age. d. Adjust the throttle position sensor angle so that the voltage is within the specified range.
Page 365 THROTTLE BODIES...
Page 366: Air Induction System
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM...
Page 367 AIR INDUCTION SYSTEM 1. Air cut-off valve 2. Reed valve 3. To air filter case A. To cylinder #1 and #2 B. To cylinder #3 and #4 7-10...
Page 368 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS" on page 4-1. Right front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 369: Checking The Air Induction System
AIR INDUCTION SYSTEM EAS27060 CHECKING THE AIR INDUCTION SYSTEM A. From the air filter case B. To the reed valve Air injection The air induction system burns unburned 1. Check: exhaust gases by injecting fresh air (second- • Hoses ary air) into the exhaust port, reducing the Loose connections →...
Page 370 AIR INDUCTION SYSTEM 2. Install: • Reed valve cover 7-13...
Page 371: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM..............8-5 CIRCUIT DIAGRAM................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING ................8-8 CHARGING SYSTEM .................8-11 CIRCUIT DIAGRAM................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ...................8-15 CIRCUIT DIAGRAM................8-15 TROUBLESHOOTING ................8-17 SIGNALING SYSTEM.................8-19 CIRCUIT DIAGRAM................8-19 TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM................8-27 TROUBLESHOOTING ................8-29...
Page 372 ABS (ANTI-LOCK BRAKE SYSTEM) ............8-71 ABS CIRCUIT DIAGRAM ..............8-71 ABS COMPONENTS CHART...............8-73 ABS CONNECTOR LOCATION CHART ..........8-75 ABS ECU AND ABS MOTOR RELAY...........8-77 [D-1] MAINTENANCE OF THE ABS ECU ..........8-78 [D-2] MAINTENANCE OF THE ABS MOTOR RELAY ......8-78 ABS TROUBLESHOOTING OUTLINE ..........8-78 BASIC INSTRUCTION FOR TROUBLESHOOTING ......8-79 BASIC PROCESS FOR TROUBLESHOOTING ........8-81 [A] ABS MALFUNCTION CHECK USING THE ABS WARNING...
Page 373 CHECKING THE ENGINE OIL LEVEL GAUGE .........8-125 CHECKING THE FUEL SENDER ............8-126 CHECKING THE SPEED SENSOR ...........8-126 CHECKING THE RADIATOR FAN MOTOR........8-127 CHECKING THE COOLANT TEMPERATURE SENSOR ....8-127 CHECKING THE THROTTLE POSITION SENSOR......8-128 CHECKING THE FUEL PUMP ............8-128 CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....8-129 CHECKING THE INTAKE AIR PRESSURE SENSOR .......8-129 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-130...
Page 374: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 375 IGNITION SYSTEM 1. Main switch 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 12.Sidestand switch 13.Neutral switch 18.Lean angle sensor 19.Crankshaft position sensor 22.ECU (engine control unit) 29.Cylinder-#1/#4 ignition coil 30.Cylinder-#2/#3 ignition coil 31.Spark plugs 45.Engine stop switch 52.Ignition fuse 59.Clutch switch...
Page 376: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Side cowlings 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to "CHECKING THE FUSES"...
Page 377 IGNITION SYSTEM 8. Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-109. OK↓ NG→ 9. Check the neutral switch. Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-109. OK↓...
Page 378: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 379 ELECTRIC STARTING SYSTEM 1. Main switch 7. Main fuse 8. Starter relay 9. Starter motor 10.Battery 11.Starting circuit cut-off relay 12.Sidestand switch 13.Neutral switch 45.Engine stop switch 46.Start switch 52.Ignition fuse 59.Clutch switch...
Page 380: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 381: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Left side cover NG→ 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to "CHECKING THE FUSES"...
Page 382 ELECTRIC STARTING SYSTEM 8. Check the neutral switch. NG→ Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-109. OK↓ NG→ 9. Check the sidestand switch. Refer to "CHECKING THE Replace the sidestand switch. SWITCHES" on page 8-109. OK↓...
Page 383 ELECTRIC STARTING SYSTEM 8-10...
Page 384: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
Page 385 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 7. Main fuse 10.Battery 8-12...
Page 386: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to "CHECKING THE FUSES" on page 8-113. OK↓...
Page 387 CHARGING SYSTEM 8-14...
Page 388: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
Page 389 LIGHTING SYSTEM 1. Main switch 7. Main fuse 10.Battery 22.ECU (engine control unit) 38.High beam indicator light 51.Headlight fuse 53.Tail fuse 56.License plate light 57.Tail/brake light 60.Pass switch 61.Dimmer switch 66.Headlight relay 67.Auxiliary light 68.Headlight (high beam) 69.Headlight (low beam) 8-16...
Page 390: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Side cover 1. Check the each bulbs and bulb NG→...
Page 391 LIGHTING SYSTEM 8. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to "CIRCUIT DIAGRAM" on system’s wiring. page 8-1. OK↓ This circuit is OK. 8-18...
Page 392: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
Page 393 SIGNALING SYSTEM 1. Main switch 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 13.Neutral switch 14.Fuel pump 22.ECU (engine control unit) 30.ABS ECU 32.Rear wheel sensor 40.Fuel level warning light 41.Oil level warning light 42.Neutral indicator light 43.Tachometer 44.Multi-function meter 46.Coolant temperature warning light 48.Left turn signal indicator light 49.Right turn signal indicator light...
Page 394: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Side cover 1.
Page 395 SIGNALING SYSTEM 3. Check the entire signaling sys- NG→ tem’s wiring. Properly connect or repair the signal- Refer to "CIRCUIT DIAGRAM" on ing system’s wiring. page 8-1. OK↓ This circuit is OK. The tail/brake light fails to come on. 1. Check the tail/brake light bulb and NG→...
Page 396 SIGNALING SYSTEM 3. Check the hazard switch. NG→ Refer to "CHECKING THE Replace the left handlebar switch. SWITCHES" on page 8-109. OK↓ 4. Check the turn signal/hazard relay. NG→ The turn signal relay is faulty and must Refer to "CHECKING THE be replaced.
Page 397 SIGNALING SYSTEM 4. Check the entire signaling sys- NG→ tem’s wiring. Properly connect or repair the signal- Refer to "CIRCUIT DIAGRAM" on ing system’s wiring. page 8-1. OK↓ This circuit is OK. The oil level warning light fails to come. 1.
Page 398 SIGNALING SYSTEM 3. Check the entire signaling sys- NG→ tem’s wiring. Properly connect or repair the signal- Refer to "CIRCUIT DIAGRAM" on ing system’s wiring. page 8-1. OK↓ This circuit is OK. The speedometer fails to operate. 1. Check the speed sensor. NG→...
Page 399 SIGNALING SYSTEM 8-26...
Page 400: Cooling System
COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
Page 401 COOLING SYSTEM 1. Main switch 7. Main fuse 10.Battery 21.Coolant temperature sensor 22.ECU (engine control unit) 37.Multi-function meter 47.Radiator fan motor fuse 48.Radiator fan motor relay 49.Radiator fan motor 52.Ignition fuse 8-28...
Page 402: Troubleshooting
COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Side cover 1. Check the fuses. NG→ (Main, ignition and radiator fan motor) Replace the fuse(s). Refer to "CHECKING THE FUSES" on page 8-113. OK↓...
Page 403 COOLING SYSTEM 7. Check the entire cooling system’s NG→ wiring. Properly connect or repair the cooling Refer to "CIRCUIT DIAGRAM" on system’s wiring. page 8-1. OK↓ This circuit is OK. 8-30...
Page 404: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
Page 405 FUEL INJECTION SYSTEM 1. Main switch 3. Backup fuse 5. Fuel injection system fuse 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 12.Sidestand switch 13.Neutral switch 14.Fuel pump 15.Throttle position sensor 16.Intake air pressure sensor 17.O sensor 18.Lean angle sensor 19.Crankshaft position sensor 20.Intake air temperature sensor 21.Coolant temperature sensor...
Page 406: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 407: Fail-Safe Actions (Substitute Characteristics Operation Control)
FUEL INJECTION SYSTEM EAS27362 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
Page 408 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable to unable to code No. start drive Able Able Malfunction detected in the pri- (depending (depending Ignition coil (#2, #3) mary wire of the ignition coil (#2, on the num- on the num- (faulty ignition) #3).
Page 409: Troubleshooting Method
FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable to unable to code No. start drive ECU internal malfunc- Data from the ECU cannot be Er-3 tion Unable Unable received correctly. (output signal error) ECU internal malfunc- Non-registered data has been Er-4 tion Unable...
Page 410: Diagnostic Mode
FUEL INJECTION SYSTEM EAS27411 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
Page 411 FUEL INJECTION SYSTEM A. FZ6-N/FZ6-NA/FZ6-S/FZ6-SA B. FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/ FZ6-SAHG 8. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the trip LCD. • Actuator operation Set the engine stop switch to “ ”...
Page 412 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Intake air pressure sensor- pipe system malfunction • Intake air pressure sensor hose is (clogged or detached detached, clogged, kinked, or pinched. hose). • Malfunction in ECU. •...
Page 413 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. No normal signals are • Defective speed sensor. received from the speed • Malfunction in vehicle speed sensor sensor. detected unit.
Page 414 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Pressure difference Displays the intake air pres- Turn On the engine stop (intake air pressure) sure. switch, then operate the throttle while pressing the start switch. (If the display value changes, the perfor- mance is OK.) Intake air temperature...
Page 415 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code display • No history • History exists 12-50 (Fault detection code) • (If code numbers more than one are detected, the dis- — play alternates every two seconds to show all the detected code numbers.
Page 416: Troubleshooting Details
FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the injector #1/#4 Check the operating sound for five times every second. Injector #1/#4 of the injector #1/#4 five Illuminates the engine trou- times. ble warning light. Actuates the injector #2/#3 Check the operating sound for five times every second.
Page 417 FUEL INJECTION SYSTEM Diagnostic code number to be used when the diagnostic mode is operated. Refer to "DIAGNOSTIC MODE" on page 8-37. No normal signals are received from the crankshaft posi- Fault code No. 12 Symptom tion sensor. Diagnostic code No. Item/components and probable Reinstate- Order...
Page 418 FUEL INJECTION SYSTEM A. Intake air pressure sensor-pipe system malfunction (clogged or detached hose). Fault code No. 14 Symptom B. Intake air pressure sensor-open or short circuit detected. C. Stuck throttle position sensor detected. Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstate- Order...
Page 419 FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor-open or short circuit detected. Diagnostic code No. Throttle position sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method Installed condition of throttle position Check the installed area for Turning the sensor.
Page 420 FUEL INJECTION SYSTEM Open circuit is detected in the input line from the side- Fault code No. 19 Symptom stand switch to the ECU. Diagnostic code No. Sidestand switch Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector •...
Page 421 FUEL INJECTION SYSTEM Intake air temperature sensor-open or short circuit Fault code No. 22 Symptom detected. Diagnostic code No. Intake air temperature sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method Installed condition of intake air tem- Check the installed area for Turning the perature sensor...
Page 422 FUEL INJECTION SYSTEM Latch up detected. Fault code No. 30 Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Item/components and probable Reinstate- Order Check or maintenance job cause ment method The vehicle has overturned. Raise the vehicle upright.
Page 423 FUEL INJECTION SYSTEM Malfunction detected in the primary wire of the ignition Fault code No. 34 Symptom coil (#2/#3). Diagnostic code No. Ignition coil (#2/#3) Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector •...
Page 424 FUEL INJECTION SYSTEM A. No normal signals are received from the rear wheel Fault code No. 42 Symptom sensor. (with ABS) B. Open or short circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstate- Order...
Page 425 FUEL INJECTION SYSTEM A. No normal signals are received from the rear wheel Fault code No. 42 Symptom sensor. (with ABS) B. Open or short circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstate- Order...
Page 426 FUEL INJECTION SYSTEM An error is detected while reading or writing on EEPROM Fault code No. 44 Symptom (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Item/components and probable Reinstate- Order Check or maintenance job cause ment method Malfunction in ECU •...
Page 427 FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply to the FI system relay is not normal. Diagnostic monitor- — — ing code No. Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector. •...
Page 428 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector • Check the coupler for any pins Reinstated •...
Page 429 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Item/components and probable Reinstate- Order Check or maintenance job cause ment method Connected state of connector • Check the coupler for any pins Reinstated •...
Page 430: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-57...
Page 431 FUEL PUMP SYSTEM 1. Main switch 5. Fuel injection system fuse 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 14.Fuel pump 22.ECU (engine control unit) 56.Engine stop switch 64.Ignition fuse 8-58...
Page 432: Troubleshooting
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel3 3.Fuel tank 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s). Refer to "CHECKING THE FUSES"...
Page 433 FUEL PUMP SYSTEM 8-60...
Page 434: Immobilizer System
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-61...
Page 435 IMMOBILIZER SYSTEM 1. Main switch 4. Backup fuse 6. Immobilizer unit 7. Main fuse 10.Battery 22.ECU (engine control unit) 39.Immobilizer indicator light 44.Multi-function meter 64.Ignition fuse 8-62...
Page 436: General Information
IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
Page 437 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration Acces- immobilizer unit Standard requirement sory lock* Main Immobi- and key switch lizer unit √ Standard key is lost New standard key All keys have been Code re-registering √ √ √...
Page 438 IMMOBILIZER SYSTEM Standby mode: To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the immobilizer system is still enabled. Standby mode d.
Page 439 IMMOBILIZER SYSTEM Standard key registration h. Second standard key a. Main switch “ON” i. Registration mode b. Main switch “OFF” c. LED on A. Registration of the second standard key is complete. d. LED off B. Immobilizer system indicator light stops e.
Page 440: Troubleshooting
IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. NG→ (Main, ignition and backup) Replace the fuse(s). Refer to "CHECKING THE FUSES" on page 8-113. OK↓...
Page 441 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1.Signal received from 1.Place the immobi- UNIT key and immobilizer other transponder lizer unit at least unit do not match. (failed to recognize 50 mm away from code after ten consec- the transponder of utive attempts).
Page 442 IMMOBILIZER SYSTEM a. Light on b. Light off 8-69...
Page 443 IMMOBILIZER SYSTEM 8-70...
Page 444: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-71...
Page 445 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Main switch 7. Main fuse 8. Starter relay 9. Starter motor 10.Battery 11.Starting circuit cut-off relay 13.Neutral switch 22.ECU (engine control unit) 28.ABS motor fuse 29.ABS test coupler 30.ABS ECU 31.Front wheel sensor 32.Rear wheel sensor 33.ABS motor relay 34.Hydraulic unit 44.Multi-function meter...
Page 446: Abs Components Chart
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 8-73...
Page 447 ABS (ANTI-LOCK BRAKE SYSTEM) 1. ABS warning light 2. ABS test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. ABS ECU 9. ABS motor relay 10.Fuse box 8-74...
Page 448: Abs Connector Location Chart
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS CONNECTOR LOCATION CHART 8-75...
Page 449 ABS (ANTI-LOCK BRAKE SYSTEM) 1. ABS motor relay 2. ABS ECU coupler 3. Hydraulic unit coupler 4. Rear wheel sensor coupler 5. Front wheel sensor coupler 6. ABS test coupler 7. Multi-function coupler (FZ6-SA) 8. Multi-function coupler (FZ6-NA) 9. Multi-function coupler (FZ6-SAHG) 10.Multi-function coupler (FZ6-NAHG) 8-76...
Page 450: Abs Ecu And Abs Motor Relay
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27760 ABS ECU AND ABS MOTOR RELAY Removing the ABS ECU and ABS motor relay Order Job/Parts to remove Q’ty Remarks Seat Refer to "GENERAL CHASSIS" on page 4-1. Left front cowling inner panel (with cowling) Refer to "GENERAL CHASSIS"...
Page 451: [D-1] Maintenance Of The Abs Ecu
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 Checking the ABS ECU [D-1] MAINTENANCE OF THE ABS ECU 1. Check: • Terminals “1” of the ABS ECU Removing the ABS ECU Cracks/damages → Replace ABS ECU 1. Remove: • Terminals “2” of the ABS ECU coupler •...
Page 452: Basic Instruction For Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) (Refer to "[D-6] FINAL CHECK" on page 8-104.) ABS warning light goes on and the ABS condition 1.When the ABS warning light keeps going on → It works as a normal brake. • Detecting the malfunction by means of the ABS self diagnostic function. 2.Light goes on and off at the time of starting →...
Page 453 ABS (ANTI-LOCK BRAKE SYSTEM) [A] Malfunction check by the ABS warning light [B] Detail check of malfunction Results by self diagnosis are displayed by the multifunction display or a pocket tester according to the ECU’s operation. [C] Supposing the malfunction cause and position Find the malfunction cause by reasoning the place and situation where it occurred.
Page 454: Basic Process For Troubleshooting
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-81...
Page 455: [A] Abs Malfunction Check Using The Abs Warning Light
ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. EWA14050 WARNING Always execute the “final check” when the components related to ABS are checked and ser- viced.
Page 456: [B-3] The Abs Warning Light Flashes
ABS (ANTI-LOCK BRAKE SYSTEM) EAS4S81020 [B-3] THE ABS WARNING LIGHT FLASHES NOTE: Check the battery voltage before proceeding. Check the test coupler located in the left inner panel (front cowling). Is the T/C terminal ground? 1. Yes → Disconnect the grounding lead from the T/C terminal and install the protective cap onto the test coupler.
Page 457 ABS (ANTI-LOCK BRAKE SYSTEM) A. FZ6-N/FZ6-NA/FZ6-S/FZ6-SA B. FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/ FZ6-SAHG 2.ABS warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5] If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS).
Page 458: [B-5] Malfunction Check By The Abs Self Diagnosis (Present Malfunction)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS27870 [B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION) NOTE: Before proceeding to read the part of “Arrangement and the function of test coupler”. Remove the side cowling (right) and check the location of test coupler. Connect the test coupler adapter with the test coupler in order to ground the T/C terminal (sky-blue).
Page 459: [C] Determining The Cause And Location Of The Malfunction
ABS (ANTI-LOCK BRAKE SYSTEM) As an example, “10 digits/1 digit pattern” of tester reading is shown below. C. Time (second) A. This example is the pattern which shows malfunction code 12. B. This example is the pattern which shows malfunction code 21. EAS4S81021 [C] DETERMINING THE CAUSE AND LOCATION OF THE MALFUNCTION EAS4S81022...
Page 460: [C-3] Abs Warning Light Flashes
ABS (ANTI-LOCK BRAKE SYSTEM) 2. Check that the main switch coupler is securely connected. 3. Check that the meter assembly coupler is securely connected. (Refer to "ABS CONNECTOR LOCATION CHART" on page 8-75.) When these checks are finished, return to [A] and check the ABS again. EAS4S81024 [C-3] ABS WARNING LIGHT FLASHES 1.
Page 461 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Front wheel sensor signal is not • Installation of the front wheel Malfunction received properly. sensor code 11 • Front wheel sensor lead and cou- pler • ABS wire harness circuit •...
Page 462 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code At the beginning of running, there • Rear wheel was rotated with the Malfunction is no pulse from the front wheel vehicle on the centerstand. code 25 sensor. • Rear wheel was wheel-spin. •...
Page 463 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Disconnection is detected between • ABS harness circuit (from ABS Malfunction the ABS ECU and solenoid sys- ECU to the solenoid) code 35 tem. • Solenoid coupler Downstream side of the solenoid •...
Page 464 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Sensor power supply failure • Wire harness circuit Malfunction • Battery terminal is disconnected code 63 63 (front) • Replace the ABS ECU (front) and 64 64 (rear) (rear) Present ABS ECU may be malfunctioning •...
Page 465 ABS (ANTI-LOCK BRAKE SYSTEM) 2. ABS warning light goes on for 2 seconds then goes off. 1. With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is not a malfunction. 2. Signal is not generated at the rear wheel sensor. •...
Page 466 ABS (ANTI-LOCK BRAKE SYSTEM) 2. Check the appearance. 3. Check the wire harness. 1. Disconnection of the ABS ECU coupler terminal 2. Remove the ABS ECU coupler and wheel sensor coupler and check the conductivity, short- circuit to GND and short-circuit to SSR-VCC from the wire harness. •...
Page 467 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Front solenoid 1. ABS ECU 6. Rear solenoid 2. White 7. Green 3. Red 8. White/Blue 4. Red *Continuity between: “A”–“B”, “A”–“C”, “D”–“G”, “E”–“F” • Check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal. 4.
Page 468 ABS (ANTI-LOCK BRAKE SYSTEM) *Continuity between: “A”–“B” Malfunction code 25 (At the beginning of running, there is no pulse from the front wheel sen- sor.) • Rear wheel was rotated with the vehicle on the stand. • Rear wheel was wheel-spin. •...
Page 469 ABS (ANTI-LOCK BRAKE SYSTEM) 5. ABS ECU 1. Battery 6. White 2. Red 7. Red 3. Main switch 8. To HU 4. Brown/White *Continuity between: “A”–“C”, “B”–“C” 3. When the items 1 to 2 are normal, replace the ABS ECU. Malfunction code 33 (Defective operation of the ABS motor is detected.
Page 470 ABS (ANTI-LOCK BRAKE SYSTEM) • Check if the ABS motor coupler located under the fuel tank is connected properly. • Check the ABS motor for continuity. → [D-5] 2. Wire harness (ABS) • Remove the ABS motor coupler and check for continuity between the black terminal of the ABS motor coupler of the wire harness (ABS) and the negative battery terminal.
Page 471 ABS (ANTI-LOCK BRAKE SYSTEM) EWA4S81009 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the front brake caliper from the hydraulic unit are correct.
Page 472 EWA4S81011 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the rear brake caliper from the hydraulic unit are correct.
Page 473 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunction code 51 (Front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the ABS ECU to release the hydraulic state [when the battery voltage is low].) Check the following: 1.
Page 474: [D-6-4] Deleting The Malfunction Code
ABS (ANTI-LOCK BRAKE SYSTEM) Malfunction code 61 (front), 62 (rear) (Sensor power supply is low) 1. Battery voltage low Charge, check or replace the battery. 2. Battery terminal is disconnected. Malfunction code 63 (front), 64 (rear) (Sensor power supply failure) 1.
Page 475 ABS (ANTI-LOCK BRAKE SYSTEM) 2. Turn the main switch on. • The multi-function display indicates previously recorded malfunction codes. NOTE: The ABS error code is not displayed during the diagnosis of the fuel injection. 3. Turn the engine stop switch off. ECA4S81019 CAUTION: If the starter switch is pushed without turning the engine stop switch off, it may damage the...
Page 476: [D-6-6] Delete Function Test
ABS (ANTI-LOCK BRAKE SYSTEM) EAS4S81033 [D-6-6] DELETE FUNCTION TEST 1. Place the vehicle on the sidestand. 2. Set the main switch to “OFF”. 3. Connect the test coupler adapter to the test coupler. 4. Set the main switch to “ON”. 5.
Page 477: [D-6] Final Check
ABS (ANTI-LOCK BRAKE SYSTEM) 8. If the above-mentioned check are within specification, replace the ECU. EAS4S81028 [D-6] FINAL CHECK Checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir. Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-24. 2.
Page 478: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-105...
Page 479 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Starter relay 4. Battery 5. ABS motor relay (FZ6-NA/FZ6-NAHG/FZ6- SA/FZ6-SAHG) 6. Fuse box 7. Rear brake light switch 8. Neutral switch 9. Sidestand switch 10.Oil level switch 11.Radiator fan motor 12.Horn 13.Ignition coil 8-106...
Page 480 ELECTRICAL COMPONENTS 8-107...
Page 481 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air temperature sensor 4. Fuel pump 5. Intake air pressure sensor 6. ECU (engine control unit) 7. ABS ECU (FZ6-NA/FZ6-NAHG/FZ6-SA/ FZ6-SAHG) 8. Lean angle sensor 9. Starting circuit cut-off relay 10.Rear wheel sensor 11.Dimmer relay 12.Radiator fan motor relay...
Page 482: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-109...
Page 483 ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Dimmer switch (FZ6-S/FZ6-NA/FZ6-SA/ FZ6-SHG(W)/FZ6-SAHG) 4. Dimmer switch (FZ6-N/FZ6-NHG(W)/FZ6- NAHG) 5. Pass switch (FZ6-S/FZ6-NA/FZ6-SA/FZ6- SHG(W)/FZ6-SAHG) 6. Pass switch (FZ6-N/FZ6-NHG(W)/FZ6- NAHG) 7. Turn signal switch 8. Hazard switch 9. Clutch switch 10.Sidestand switch 11.Engine stop switch 12.Front brake light switch 13.Start switch...
Page 484 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 485: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS EAS27990 Checking the condition of the bulbs CHECKING THE BULBS AND BULB SOCK- The following procedure applies to all of the bulbs. Check each bulb and bulb socket for damage 1. Remove: or wear, proper connections, and also for conti- •...
Page 486: Checking The Leds
ELECTRICAL COMPONENTS b. Connect the positive tester probe to termi- b. Connect two jumper leads “1” from the bat- nal “1” and the negative tester probe to ter- tery terminals to the respective coupler ter- minal “3”, and check the continuity. minal as shown.
Page 487: Checking And Charging The Battery
ELECTRICAL COMPONENTS EAS28030 Pocket tester CHECKING AND CHARGING THE BATTERY 90890-03112 EWA13290 WARNING Analog pocket tester YU-03112-C Batteries generate explosive hydrogen gas and contain electrolyte which is made of b. If the pocket tester indicates “∞”, replace poisonous and highly caustic sulfuric acid. the fuse.
Page 488 ELECTRICAL COMPONENTS NOTE: Example Since MF batteries are sealed, it is not possi- Open-circuit voltage = 12.0 V ble to check the charge state of the battery by Charging time = 6.5 hours measuring the specific gravity of the electro- Charge of the battery = 20–30% lyte.
Page 489 ELECTRICAL COMPONENTS minutes after charging is completed 12.8 V or more --- Charging is complete. before measuring the open-circuit volt- 12.7 V or less --- Recharging is required. age. Under 12.0 V --- Replace the battery. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Charging method using a variable-current ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 490: Checking The Relays
ELECTRICAL COMPONENTS Relay operation Continuity/No continuity (between “3” to “4”) Relay unit (starting circuit cut-off relay) 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 1. Positive battery terminal 9. Lubricate: 2. Negative battery terminal •...
Page 491: Checking The Abs Motor Relay
ELECTRICAL COMPONENTS Headlight relay Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Tester positive probe →Terminal “2” • Tester negative probe → Terminal “1” Tester reading is “∞”. → Replace the ABS motor relay. ECA4S81021 CAUTION: 1. Positive battery terminal Do not reverse the connections.
Page 492: Checking The Solenoid Valves And Motor
ELECTRICAL COMPONENTS EAS4S81031 CHECKING THE SOLENOID VALVES AND Pocket tester MOTOR 90890-03112 Analog pocket tester ECA4S81023 CAUTION: YU-03112-C When check the hydraulic unit solenoid • Positive tester probe → relay and ABS motor, do not remove the terminal “3” brake hoses. •...
Page 493: Checking The Turn Signal/Hazard Relay
ELECTRICAL COMPONENTS EAS4S81032 CHECKING THE TURN SIGNAL/HAZARD Pocket tester RELAY 90890-03112 1. Check: Analog pocket tester • Turn signal/hazard relay input voltage YU-03112-C Out of specification → The wiring circuit • Positive tester probe → from the main switch to the turn signal/haz- ard relay coupler is faulty and must be Brown/White “1”...
Page 494: Checking The Spark Plug Caps
ELECTRICAL COMPONENTS a. Disconnect the relay unit coupler from the Continuity wire harness. Positive tester probe → Sky b. Connect the pocket tester (Ω × 1) to the blue “1” relay unit terminal as shown. → Negative tester probe c. Check the relay unit (diode) for continuity. Black/Yellow “2”...
Page 495: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the pocket tester (Ω × 1) to the ignition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C c. Measure the secondary coil resistance. •...
Page 496: Checking The Lean Angle Sensor
ELECTRICAL COMPONENTS 2. Check: Pocket tester • Crankshaft position sensor resistance 90890-03112 Out of specification → Replace the crank- Analog pocket tester shaft position sensor. YU-03112-C Crankshaft position sensor 248–372 Ω at 20°C (68°F) • Positive tester probe Yellow/Green “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 497: Checking The Startor Motor Operation
ELECTRICAL COMPONENTS Out of specification → Replace the stator coil. EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) b. Turn the main switch to “ON”. 2. Check: c. Elevate the front wheel and slowly rotate it. •...
Page 498: Checking The Horn
ELECTRICAL COMPONENTS Out of specification → Replace the rectifier/ Pocket tester regulator. 90890-03112 Analog pocket tester Charging voltage YU-03112-C above 14 V at 5000 r/min ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe a. Set the engine tachometer to the ignition Horn terminal “1” coil of cylinder #1.
Page 499: Checking The Fuel Sender
ELECTRICAL COMPONENTS (from the fuel tank) Engine oil level gauge 4. Check: Maximum level position resis- • Fuel sender resistance tance Out of specification → Replace the fuel 114–126 Ω at 20°C (68°F) pump assembly. Minimum level position resis- tance Fuel sender resistance (full) 484–536 Ω...
Page 500: Checking The Radiator Fan Motor
ELECTRICAL COMPONENTS EWA14130 • Positive tester probe WARNING White/Yellow “1” • Handle the coolant temperature sensor • Negative tester probe with special care. Black/Blue “2” • Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2.
Page 501: Checking The Throttle Position Sensor
ELECTRICAL COMPONENTS e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28300 CHECKING THE THROTTLE POSITION SENSOR d. While slowly turning the throttle position 1. Remove: sensor shaft, check that the throttle posi- •...
Page 502: Checking The Air Induction System Solenoid
ELECTRICAL COMPONENTS • Positive tester probe Fuel pump resistance Brown/Red “1” 0.2–3.0 Ω at 20°C (68°F) • Negative tester probe Red/White “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1) to the fuel pump coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C...
Page 503: Checking The Intake Air Temperature Sensor
ELECTRICAL COMPONENTS c. Measure the intake air pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28420 CHECKING THE INTAKE AIR TEMPERA- TURE SENSOR 1. Remove: • Intake air temperature sensor (from the air filter case.) EWA14110 WARNING • Handle the intake air temperature sensor with special care.
Page 504 ELECTRICAL COMPONENTS 8-131...
Page 505: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...
Page 506 TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.
Page 507 TROUBLESHOOTING • Improper throttle cable free play • Foreign object between transmission gears • Flooded throttle body • Improperly assembled transmission • Faulty air induction system EAS28550 JUMPS OUT OF GEAR Electrical system 1. Battery Shift shaft • Discharged battery •...
Page 508 TROUBLESHOOTING 2. Engine oil • Worn brake disc • Incorrect oil level • Air in hydraulic brake system • Incorrect oil viscosity • Leaking brake fluid • Inferior oil quality • Faulty brake caliper kit • Faulty brake caliper seal Cooling system •...
Page 509 TROUBLESHOOTING • Faulty rear shock absorber spring • Incorrect connection • Leaking oil or gas • Damaged or faulty wire harness 6. Tire(s) • Improperly grounded circuit • Uneven tire pressures (front and rear) • Faulty battery • Incorrect tire pressure •...
Page 510 TROUBLESHOOTING • Defective connection of the meter coupler ABS warning light continues to flashes • Brake light switch (front or rear) is defective • Brake light switch front or rear coupler has come off • Defective starter motor monitor • Other defective ABS warning light flashes every 0.5 sec- onds •...
Page 511 TROUBLESHOOTING...
Page 512: Wiring Diagram
EAS28740 58. Left handlebar switch Sb/W Sky blue/White WIRING DIAGRAM 59. Clutch switch White/Black 60. Pass switch FZ6-N 2007 White/Red 61. Dimmer switch 1. Main switch White/Yellow 62. Hazard switch 2. AC magneto Yellow/Black 63. Turn signal switch 3. Rectifier/regulator Yellow/Green 64.
Page 513 FZ6-NA 2007 60. Tail fuse Red/Black 61. Turn signal relay 1. Main switch Red/Green 62. Rear brake light switch 2. AC magneto Red/Blue 63. License plate light 3. Rectifier/regulator Red/White 64. Tail/brake light 4. Backup fuse Red/Yellow 65. Left handlebar switch 5.
Page 514 FZ6-NHG(W) 2007 59. Rear brake light switch Red/Blue 60. License plate light 1. Main switch Red/White 61. Tail/brake light 2. AC magneto Red/Yellow 62. Left handlebar switch 3. Rectifier/regulator Sb/W Sky blue/White 63. Clutch switch 4. Backup fuse White/Black 64. Pass switch 5.
Page 515 FZ6-NAHG 2007 59. Radiator fan motor relay Blue/Black 60. Radiator fan motor 1. Main switch Blue/Red 61. ABS fuse 2. AC magneto Blue/White 62. Signal fuse 3. Rectifier/regulator Blue/Yellow 63. Headlight fuse 4. Backup fuse Orange/Black 64. Ignition fuse 5. Fuel injection system fuse Pink/White 65.
Page 516 FZ6-S 2007 60. Pass switch White/Black 61. Dimmer switch 1. Main switch White/Red 62. Hazard switch 2. AC magneto White/Yellow 63. Turn signal switch 3. Rectifier/regulator Yellow/Black 64. Horn switch 4. Backup fuse Yellow/Green 65. Horn 5. Fuel injection system fuse Yellow/Blue 66.
Page 517 FZ6-SA 2007 60. Tail fuse Pink/White 61. Turn signal relay 1. Main switch Red/Black 62. Rear brake light switch 2. AC magneto Red/Green 63. License plate light 3. Rectifier/regulator Red/Blue 64. Tail/brake light 4. Backup fuse Red/White 65. Left handlebar switch 5.
Page 518 FZ6-SHG(W) 2007 59. Rear brake light switch Red/Green 60. License plate light 1. Main switch Red/Blue 61. Tail/brake light 2. AC magneto Red/White 62. Left handlebar switch 3. Rectifier/regulator Red/Yellow 63. Clutch switch 4. Backup fuse Sb/W Sky blue/White 64. Pass switch 5.
Page 519 FZ6-SAHG 2007 59. Radiator fan motor relay Blue/Black 60. Radiator fan motor 1. Main switch Blue/Red 61. ABS fuser 2. AC magneto Blue/White 62. Signal fuse 3. Rectifier/regulator Blue/Yellow 63. Headlight fuse 4. Backup fuse Orange/Black 64. Ignition fuse 5. Fuel injection system fuse Pink/White 65.
Page 522 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 523 FZ6-N 2007 FZ6-N 2007 FZ6-N 2007 FZ6-N 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-N 2007 Y/L G/L R/W Br/W G/W Br/W Y R/B R/L Dg Ch P/W B/L G/B L MAIN HARNESS WIRE SUB LEAD3 MAIN HARNESS WIRE SUB LEAD2 MAIN HARNESS...
Page 524 FZ6-NA 2007 FZ6-NA 2007 FZ6-NA 2007 FZ6-NA 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-NA 2007...
Page 525 FZ6-NHG(W) 2007 FZ6-NHG(W) 2007 FZ6-NHG(W) 2007 FZ6-NHG(W) 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-NHG(W) 2007 Br/W G/W Br/W Y R/B R/L Y/L G/L R/W Dg Ch P/W B/L G/B L MAIN HARNESS WIRE SUB LEAD3 MAIN HARNESS WIRE SUB LEAD2 MAIN HARNESS...
Page 526 FZ6-NAHG 2007 FZ6-NAHG 2007 FZ6-NAHG 2007 FZ6-NAHG 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-NAHG 2007...
Page 527 FZ6-S 2007 FZ6-S 2007 FZ6-S 2007 FZ6-S 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-S 2007 Y/L G/L R/W Br/W G/W Br/W Y R/B R/L G/L Y/L R/G R/W L/R Y B G P/W B/L G/B L Lg B/W G/W W Ch Dg...
Page 528 FZ6-SA 2007 FZ6-SA 2007 FZ6-SA 2007 FZ6-SA 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-SA 2007...
Page 529 FZ6-SHG(W) 2007 FZ6-SHG(W) 2007 FZ6-SHG(W) 2007 FZ6-SHG(W) 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-SHG(W) 2007 Br/W G/W Br/W Y R/B R/L G/L Y/L R/G R/W L/R Y B G P/W B/L G/B L Lg B/W Y/L G/L R/W G/W W Ch Dg...
Page 530 FZ6-SAHG 2007 FZ6-SAHG 2007 FZ6-SAHG 2007 FZ6-SAHG 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-SAHG 2007...
Page 531 FZ6-N 2007 FZ6-N 2007 FZ6-N 2007 FZ6-N 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-N 2007...
Page 532 FZ6-NA 2007 FZ6-NA 2007 FZ6-NA 2007 FZ6-NA 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-NA 2007...
Page 533 FZ6-NHG(W) 2007 FZ6-NHG(W) 2007 FZ6-NHG(W) 2007 FZ6-NHG(W) 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-NHG(W) 2007...
Page 534 FZ6-NAHG 2007 FZ6-NAHG 2007 FZ6-NAHG 2007 FZ6-NAHG 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-NAHG 2007...
Page 535 FZ6-S 2007 FZ6-S 2007 FZ6-S 2007 FZ6-S 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-S 2007...
Page 536 FZ6-SA 2007 FZ6-SA 2007 FZ6-SA 2007 FZ6-SA 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-SA 2007...
Page 537 FZ6-SHG(W) 2007 FZ6-SHG(W) 2007 FZ6-SHG(W) 2007 FZ6-SHG(W) 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-SHG(W) 2007...
Page 538 FZ6-SAHG 2007 FZ6-SAHG 2007 FZ6-SAHG 2007 FZ6-SAHG 2007 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ6-SAHG 2007...

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Yamaha 2007 FZ6-NA Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Abs (Anti-Lock Brake System)

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Pickup Rotor

Electric Starter

Oil Pump

Clutch

Shift Shaft

Crankcase

Crankshaft

Transmission

Cooling System

Oil Cooler

Thermostat

Water Pump

Fuel System

Fuel Tank

Throttle Bodies

Air Induction System

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Fuel Pump System

Immobilizer System

Abs (Anti-Lock Brake System)

Electrical Components

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha 2007 FZ6-NA