Page 1 2011 SERVICE MANUAL FZ8NA FZ8SA 1BD-28197-E0...
Page 2 EAS20040 FZ8NA FZ8SA SERVICE MANUAL ©2010 by Yamaha Motor Co., Ltd. First edition, May 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4: How To Use This Manual
EAS20091 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 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
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: Table Of Contents
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-4 INSTRUMENT FUNCTIONS ..............1-5 OUTLINE OF THE ABS ................1-8 ABS COMPONENT FUNCTIONS ............1-14 ABS OPERATION .................1-19 ABS SELF-DIAGNOSIS FUNCTION ............1-22 ABS WARNING LIGHT AND OPERATION...........1-25 IMPORTANT INFORMATION ..............1-26 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-26...
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: Outline Of The Fi System
FEATURES EAS20170 FEATURES EAS39P1101 OUTLINE OF THE 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 10.Battery 11.Atmospheric pressure sensor 12.Relay unit (fuel pump relay) 13.Lean angle sensor 14.Catalytic converter 15.O sensor 16.Fuel hose 17.Fuel injector 18.Crankshaft position sensor 19.Coolant temperature sensor 20.Spark plug 21.Ignition coil 22.Cylinder identification sensor 23.Air cut-off valve A. FZ8NA B. FZ8SA...
Page 13: Fi System
FEATURES EAS39P1102 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remain open.
Page 14: Instrument Functions
FEATURES EAS39P1103 Tachometer INSTRUMENT FUNCTIONS Multi-function meter unit 1. Tachometer 2. Tachometer red zone 1. Fuel meter The electric tachometer allows the rider to 2. Coolant temperature display monitor the engine speed and keep it within 3. Speedometer the ideal power range. 4.
Page 15 3 seconds. If this flashing, and the odometer display will auto- occurs, have a Yamaha dealer check the elec- matically change to the fuel reserve tripmeter trical circuit.
Page 16 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 17: Outline Of The Abs
EAS4B56001 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
Page 18 FEATURES The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a front brake lever for operating the front brake and a rear brake pedal for operating the rear brake. When wheel lock is detected during emergency braking, hydraulic control is performed by the hydraulic system on the front and rear brakes independently.
Page 19 FEATURES Brake force and vehicle stability When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and the road surface and brake force is generated. The limit of this brake force is determined by the friction force between the tire and the road surface and is closely related to wheel slippage.
Page 20 FEATURES 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. The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip.
Page 21 FEATURES ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the ABS has been designed to gener- ate a reaction-force pulsating action in the front brake lever and rear brake pedal independently.
Page 22 FEATURES 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 23: Abs Component Functions
FEATURES EAS4B56009 ABS COMPONENT FUNCTIONS Wheel sensors and wheel sensor rotors Wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the ABS ECU. Each wheel sensor contains a Hall IC. The wheel sensors are installed in the sensor housing for each wheel.
Page 24 FEATURES 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 25 FEATURES 2. When the ABS is activated, the inlet solenoid valve “1” closes and the outlet solenoid valve “2” opens using the power supplied from the ABS ECU signals. This reduces the hydraulic pres- sure. 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2”...
Page 26 FEATURES ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. 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. 17.Front brake outlet solenoid 1.
Page 27 FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.
Page 28: Abs Operation
FEATURES EAS4B56010 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following describes the system for the front wheel only. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
Page 29 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressuriza- tion” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve com- presses the spring and closes the brake line from the brake master cylinder.
Page 30 FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.
Page 31: Abs Self-Diagnosis Function
FEATURES EAS4B56011 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. It is located in the meter assembly. 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 32 FEATURES 3. The ABS warning light comes on while riding. If the ABS warning light comes on while riding, a malfunction has been detected in the ABS. The ABS hydraulic control will not be performed. The ABS will have recourse to manual braking if this occurs.
Page 33 FEATURES 1-24...
Page 34: Abs Warning Light And Operation
FEATURES EAS4B56012 ABS WARNING LIGHT AND OPERATION ABS warning light • When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • The ABS warning light comes on while the start switch is being pushed. •...
Page 35: 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 36: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20231 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
Page 37: Basic Service Information
BASIC SERVICE INFORMATION EAS30380 Screw type BASIC SERVICE INFORMATION 1. Remove: • Quick fastener EAS30390 QUICK FASTENERS To remove the quick fastener, loosen the screw Rivet type with a screwdriver, then pull the fastener out. 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out.
Page 38 BASIC SERVICE INFORMATION ECA16770 ECA16750 When connecting the battery leads to the When disconnecting the battery leads from battery, be sure to connect the positive bat- the battery, be sure to disconnect the nega- tery lead first, then the negative battery tive battery lead first, then the positive bat- lead.
Page 39 BASIC SERVICE INFORMATION ECA16630 ECA14371 Electrical components are very sensitive to Never insert the tester probes into the cou- and can be damaged by static electricity. pler terminal slots. Always insert the Therefore, never touch the terminals and be probes from the opposite end “a” of the sure to keep the contacts clean.
Page 40 BASIC SERVICE INFORMATION Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • Lead • Coupler • Connector ECA16780 • When disconnecting a coupler, release the coupler lock, hold both sections of 3. Check: the coupler securely, and then disconnect •...
Page 41 BASIC SERVICE INFORMATION 5. Check: • Continuity (with the pocket tester) Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3). • As a quick remedy, use a contact revitalizer available at most part stores.
Page 42: 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 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-25 90890-01426 YU-38411 Rod holder 4-71, 4-76 90890-01434 Damper rod holder double ended YM-01434 Rod puller attachment (M10) 4-75, 4-76 90890-01436 Universal damping rod bleeding tool set YM-A8703 Rod puller 4-75, 4-76 90890-01437 Universal damping rod bleeding tool set...
Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 Compression gauge 90890-03081 Engine compression tester YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 Pocket tester 1-32, 8-183, 8- 90890-03112 184, 8-185, 8- Analog pocket tester 189, 8-190, 8- YU-03112-C 191, 8-192, 8-...
Page 45 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 5-43, 7-12, 8- 90890-03174 173, 8-195, 8- Model 88 Multimeter with tachometer 196, 8-201, 8- YU-A1927 Fuel pressure adapter 90890-03176 YM-03176 Thickness gauge 3-6, 5-21, 5-51 90890-03180 Feeler gauge set YU-26900-9 Test harness- speed sensor (3P) 8-201...
Page 46 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-25, 5-31 90890-04019 YM-04019 Middle driven shaft bearing driver 6-13 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Mechanical seal installer 6-13 90890-04078 Water pump seal installer YM-33221-A Universal clutch holder 5-49, 5-53...
Page 47 Valve guide reamer (ø4) 5-27 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Extension 90890-04136 Camshaft wrench 5-13, 5-17 90890-04162 YM-04162 Ignition checker 8-193 90890-06754 Oppama pet-4000 spark checker YM-34487 Yamaha bond No.1215 5-19, 5-34, 5-67 (Three bond No.1215®) 90890-85505 1-38...
Page 48 SPECIAL TOOLS 1-39...
Page 49 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-19 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE ....................2-23 CHASSIS ....................2-25 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-27 ENGINE OIL LUBRICATION CHART ...........2-27 LUBRICATION DIAGRAMS ..............2-29 COOLING SYSTEM DIAGRAMS ...............2-39...
Page 50 FZ8SA 1BD1 Dimensions Overall length 2140 mm (84.3 in) Overall width 770 mm (30.3 in) Overall height FZ8NA 1065 mm (41.9 in) FZ8SA 1225 mm (48.2 in) Seat height 815 mm (32.1 in) Wheelbase 1460 mm (57.5 in) Ground clearance 140 mm (5.51 in)
Page 51 ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 779 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 68.0 × 53.6 mm (2.68 × 2.11 in) Compression ratio 12.00 :1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (14.8 kgf/cm²/350 r/min, 210.5 psi/350 r/min) Minimum–Maximum...
Page 52 ENGINE SPECIFICATIONS Radiator core Width 222.6 mm (8.76 in) Height 360.0 mm (14.17 in) Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump 65/43 × 25/32 (1.181) Reduction ratio Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug(s) Manufacturer/model NGK/CR9E...
Page 53 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.17 mm (0.0039–0.0067 in) Exhaust 0.25–0.29 mm (0.0098–0.0114 in) Valve dimensions Valve head diameter A (intake) 25.90–26.10 mm (1.0197–1.0276 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake) 1.210–2.490 mm (0.0476–0.0980 in) Valve face width B (exhaust)
Page 54 ENGINE SPECIFICATIONS Free length (exhaust) 38.62 mm (1.52 in) Limit 36.69 mm (1.44 in) Installed length (intake) 33.00 mm (1.30 in) Installed length (exhaust) 33.00 mm (1.30 in) Spring rate K1 (intake) 24.99 N/mm (2.55 kgf/mm, 142.69 lb/in) Spring rate K2 (intake) 37.28 N/mm (3.80 kgf/mm, 212.87 lb/in) Spring rate K1 (exhaust) 24.99 N/mm (2.55 kgf/mm, 142.69 lb/in)
Page 55 ENGINE SPECIFICATIONS End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) Limit 0.60 mm (0.0236 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit...
Page 56 ENGINE SPECIFICATIONS Clutch spring free length 52.50 mm (2.07 in) Limit 49.88 mm (1.96 in) Spring quantity 6 pcs Transmission Transmission type Constant mesh 6-speed Primary reduction system Spur gear Primary reduction ratio 65/43 (1.512) Secondary reduction system Chain drive Secondary reduction ratio 46/16 (2.875) Operation...
Page 57 ENGINE SPECIFICATIONS Air induction system Reed valve bending limit 0.4 mm (0.016 in) 18–22 Ω at 20 °C (68 °F) Solenoid resistance Idling condition Engine idling speed 1150–1250 r/min 4.0–5.0 % Intake vacuum 30.0 kPa (225 mmHg, 8.9 inHg) 90.0–110.0 °C (194.00–230.00 °F) Water temperature 75.0–95.0 °C (167.00–203.00 °F) Oil temperature...
Page 58 Front 250 kPa (2.50 kgf/cm², 36 psi) Rear 290 kPa (2.90 kgf/cm², 42 psi) Loading condition FZ8NA 90–194 kg (198–428 lb) FZ8SA 90–190 kg (198–419 lb) Front 250 kPa (2.50 kgf/cm², 36 psi) Rear 290 kPa (2.90 kgf/cm², 42 psi)
Page 59 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.20 mm (1.19 in) 27.00 mm (1.06 in) Recommended fluid...
Page 60 CHASSIS SPECIFICATIONS Spring rate K1 78.40 N/mm (7.99 kgf/mm, 447.66 lb/in) Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (12.0 kgf/cm², 170.7 psi) Spring preload adjusting positions Minimum Standard Maximum Drive chain Type/manufacturer 525V10/DAIDO Number of links...
Page 61 Bulb voltage, wattage × quantity 12 V, 60 W/55 W × 1 Headlight FZ8SA 12 V, 55 W × 1 FZ8NA 12 V, 5.0 W × 1 Auxiliary light FZ8SA 12 V, 5.0 W × 2 12 V, 5.0 W/21.0 W × 1 Tail/brake light 12 V, 10.0 W ×...
Page 62 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Power output 0.70 kW Armature coil 0.0100–0.2000 Ω at 20 °C (68 °F) Commutator resistance Above 1 MΩ at 20 °C (68 °F) Insulation resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force...
Page 63 TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 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 64 TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head nut See TIP. Cylinder head bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Cylinder head plug 42 Nm (4.2 m·kgf, 30 ft·lbf) Camshaft caps bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head cover bolt...
Page 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe and muffler bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe and exhaust pipe 20 Nm (2.0 m·kgf, 14 ft·lbf) bracket bolt Muffler and muffler bracket bolt 48 Nm (4.8 m·kgf, 35 ft·lbf) Crankcase stud bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Crankcase bolt (main journal)
Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift rod locknut (front) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Left Shift rod locknut (rear) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) thread Shift rod joint bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shift arm bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) Neutral switch...
Page 67 TIGHTENING TORQUES 2-18...
Page 68 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Front brake hose bracket and 7 Nm (0.7 m·kgf, 5.1 ft·lbf) front brake hose bolt Left rear view mirror (FZ8NA) 17 Nm (1.7 m·kgf, 12 ft·lbf) Left Right rear view mirror (FZ8NA) 17 Nm (1.7 m·kgf, 12 ft·lbf)
Page 69 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Right front engine mounting bolt 2 50 Nm (5.0 m·kgf, 36 ft·lbf) Left front engine mounting bolt 45 Nm (4.5 m·kgf, 33 ft·lbf) Upper self-locking nut 51 Nm (5.1 m·kgf, 37 ft·lbf) Lower self-locking nut 51 Nm (5.1 m·kgf, 37 ft·lbf) Engine mounting adjust bolt...
Page 70 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Battery box and rear frame bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rectifier/regulator bracket and 7 Nm (0.7 m·kgf, 5.1 ft·lbf) rear frame bolt Rectifier/regulator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Assist grip and rear frame bolt 19 Nm (1.9 m·kgf, 14 ft·lbf) (FZ8SA)
Page 71 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear wheel sensor lead stay bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear wheel sensor bracket and 7 Nm (0.7 m·kgf, 5.1 ft·lbf) rear wheel sensor housing Rear wheel sensor bracket and 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Page 72 Transmission gears (wheel and pinion) Main axle and drive axle Shift forks and shift fork guide bars Three bond Cylinder head cover mating surface No.1541C® Yamaha bond Cylinder head cover semicircular No.1215 (Three bond No.1215®) Yamaha bond Crankcase mating surface No.1215 (Three bond...
Page 73 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond Left crankcase cover (three mating surface) No.1215 (Three bond No.1215®) Yamaha bond Crankcase cover (lead grommet) No.1215 (Three bond No.1215®) 2-24...
Page 74 LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings, seal lip and bearing lip Tube guide (throttle grip) inner surface and throttle cables Brake lever pivot bolt and metal-to-metal moving parts Clutch lever pivot bolt, metal-to-metal moving parts and clutch cable end Engine mount bolts (rear upper and lower) Engine mount bolts (front left and right) Relay arm, connecting rod and rear shock absorber collar...
Page 75 LUBRICATION POINTS AND LUBRICANT TYPES 2-26...
Page 76: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27...
Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.AC magneto axle 13.Crankshaft 14.Piston cooler...
Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-29...
Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Oil level switch 3. Oil filter cartridge 4. Crankshaft 2-30...
Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump 2-32...
Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler 2-34...
Page 84 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 85 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pipe 3. Drive axle 2-36...
Page 86 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 87 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Main gallery 5. Crankshaft 2-38...
Page 88: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-39...
Page 89 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Water pump 3. Radiator 4. Radiator fan 5. Oil cooler 2-40...
Page 90 COOLING SYSTEM DIAGRAMS 2-41...
Page 91 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-42...
Page 92 CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (front view) FZ8NA 2-43...
Page 93 CABLE ROUTING 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Lower headlight stay 7. Front wheel sensor lead 8. Throttle cable (return side) 9. Throttle cable (pull side) 10.Brake hose 11.Wire harness 12.Right handlebar switch lead 13.Throttle cables...
Page 94 CABLE ROUTING Handlebar (front view) FZ8SA 2-45...
Page 95 CABLE ROUTING 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Horn bracket 7. Front wheel sensor lead 8. Throttle cable (return side) 9. Throttle cable (pull side) 10.Brake hose 11.Right handlebar switch lead 12.Throttle cables A.
Page 96 CABLE ROUTING Handlebar (right side view) 2-47...
Page 97 CABLE ROUTING 1. Wire harness 2. Throttle cable 3. Front wheel sensor lead 4. Radiator inlet hose 5. Right radiator fan motor lead 6. Coolant reservoir hose 7. Right handlebar switch lead 8. Throttle cables 9. Throttle cable (return side) 10.Throttle cable (pull side) 11.Radiator stay 12.Clutch cable...
Page 98 CABLE ROUTING Engine (right side view) 2-49...
Page 99 CABLE ROUTING 1. Cable guide 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Brake fluid reservoir hose 5. Rear wheel sensor lead 6. AC magneto lead 7. Rectifier/regulator lead 8. Rear brake light switch lead 9. Frame 10.Rear brake light switch stay 11.Rear brake light switch A.
Page 100 CABLE ROUTING Handlebar (left side view) 2-51...
Page 101 CABLE ROUTING 1. Immobilizer lead 2. Main switch lead 3. Left handlebar switch lead 4. Clutch cable 5. Clutch cable swaging metal 6. Left radiator fan motor lead 7. Water pump breather hose 8. Radiator stay 9. Horn 10.Right handlebar switch lead 11.Meter bracket 12.Brake hose 13.Throttle cables...
Page 102 CABLE ROUTING Engine (left side view) 2-53...
Page 103 CABLE ROUTING Q. Route the coolant reservoir tank drain hose 1. Water pump breather hose further to the rear of the vehicle than other 2. Oil level switch lead hoses and leads. 3. Sidestand switch lead R. Back of the vehicle 4.
Page 104 CABLE ROUTING Rear frame (left side view) 2-55...
Page 105 CABLE ROUTING 1. Wire harness 2. Starter motor lead 3. Battery negative lead 4. Seat lock cable 5. Ground lead 6. Fuel tank drain hose 7. Fuel tank breather hose 8. AC magneto lead 9. Rectifier/regulator lead 10.Rear brake light switch lead 11.Coolant reservoir tank drain hose A.
Page 106 CABLE ROUTING Frame (top view) 2-57...
Page 107 CABLE ROUTING I. Connect the left handlebar switch lead cou- 1. Throttle cable pler and then put the rubber cover of the 2. Right handlebar switch lead wire harness. 3. Wire harness J. Route the main switch lead coupler 4. Front wheel sensor lead between outside of ECU (engine control 5.
Page 108 CABLE ROUTING Frame (top view) 2-59...
Page 109 CABLE ROUTING K. Insert the main fuse to the battery band. 1. Air filter case drain hose Soapy water can be spread. 2. Pickup coil lead L. Route the battery positive lead from inside 3. Right radiator fan motor lead of the vehicle to under the wire harness.
Page 110 CABLE ROUTING Frame (top view) 2-61...
Page 111 CABLE ROUTING K. The ABS check coupler should not cover 1. Atmospheric pressure sensor the top of the bolt. 2. Battery positive lead L. Route the tail/brake light lead and rear left 3. Radiator fan motor relay turn signal light lead between the ribs of 4.
Page 112 CABLE ROUTING Fuel tank (left and bottom view) 2-63...
Page 113 CABLE ROUTING 1. Frame 2. Fuel tank cover 3. Fuel tank breather hose 4. Fuel tank drain hose 5. Fuel tank 6. Fuel pump 7. Clip 8. Fuel hose 9. Fuel hose connector cover A. Install the fuel tank drain hose with the white paint marks facing to the left of the vehicle.
Page 114 CABLE ROUTING Front brake (right side view) 2-65...
Page 115 (hydraulic unit to front brake calipers), pushing projection to the stopper. F. Align the notch of the horn with the projec- tion of the lower headlight stay (FZ8NA) or horn bracket (FZ8SA). G. Install the brake hose (hydraulic unit to...
Page 116 CABLE ROUTING Front brake (left side) 2-67...
Page 117 CABLE ROUTING 1. Front fork 2. Horn 3. Under bracket 4. Brake hose holder A. Install the clamp so that the distance from the clamp upper surface to the end of the brake hose protector may be 0–10 mm (0– 0.39 in).
Page 118 CABLE ROUTING Rear brake 2-69...
Page 119 CABLE ROUTING 1. Brake hose (hydraulic unit to rear brake caliper) 2. Rear wheel sensor lead 3. Rear wheel sensor 4. Clamp 5. Swingarm 6. Rear fender A. Install the clip knob so that it faces to the outside of the vehicle as shown in the illus- tration.
Page 120 CABLE ROUTING Hydraulic unit (top view) 2-71...
Page 121 CABLE ROUTING 1. Brake pipe/joint assembly (front brake master cylinder to hydraulic unit) 2. Brake pipe/joint assembly (hydraulic unit to front brake calipers) 3. Rear frame 4. Damper 5. Upper hydraulic unit bracket 6. Grommet 7. Hydraulic unit 8. Lower hydraulic unit bracket 9.
Page 122 CABLE ROUTING Hydraulic unit (front view) 2-73...
Page 123 CABLE ROUTING 1. Fuse box 2 2. Waterproof coupler 3. Brake hose (hydraulic unit to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Rear wheel sensor lead 6. Rear brake hose holder 7. Rear brake hose guide 8.
Page 124 CABLE ROUTING Hydraulic unit (left side view) 2-75...
Page 125 CABLE ROUTING 1. Brake pipe/joint assembly (front brake master cylinder to hydraulic unit) 2. Brake pipe/joint assembly (hydraulic unit to front brake calipers) 3. Brake fluid reservoir tank stay 4. Rear frame 5. Battery box 6. Upper hydraulic unit bracket 7.
Page 126 CABLE ROUTING 2-77...
Page 127 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .....3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 ADJUSTING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODIES ........3-9 CHECKING THE THROTTLE BODY JOINTS ........3-10 ADJUSTING THE EXHAUST GAS VOLUME ........3-11...
Page 128 CHECKING AND LUBRICATING THE CABLES ........3-29 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-30 CHECKING AND CHARGING THE BATTERY........3-30 CHECKING THE FUSES..............3-30 REPLACING THE HEADLIGHT BULB (FZ8NA) ........3-30 REPLACING THE HEADLIGHT BULBS (FZ8SA) ........3-32 ADJUSTING THE HEADLIGHT BEAM (FZ8NA)........3-33 ADJUSTING THE HEADLIGHT BEAMS (FZ8SA)........3-33...
Page 130 UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 131: General Maintenance And Lubrication Chart
PERIODIC MAINTENANCE EAS39P1302 GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) √ Air filter element •...
Page 132 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Engine oil filter √ √ √ • Replace. cartridge • Check coolant level and vehi- √...
Page 133 4-1. Refer to “GENERAL CHASSIS” on page • Fuel tank 4-1. Refer to “FUEL TANK” on page 7-1. • Radiator upper cover (FZ8NA) 2. Check: • Radiator upper panel (FZ8SA) • Fuel hose “1” • Radiator upper bolt • Vacuum hose “2”...
Page 134 3. Remove: • Pickup rotor cover “1” 8. Install: • Radiator upper bolt • Radiator lower bolt • Radiator upper cover (FZ8NA) • Radiator upper panel (FZ8SA) Refer to “RADIATOR” on page 6-1. • Inner panel/side panel/front cowling side panel (FZ8SA) Refer to “GENERAL CHASSIS”...
Page 135 PERIODIC MAINTENANCE A. Front d. To measure the valve clearances of the TDC on the compression stroke can be found other cylinders, starting with cylinder #1 at when the camshaft lobes are turned away from TDC, turn the crankshaft clockwise as each other.
Page 136 PERIODIC MAINTENANCE Example: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve If the valve pad is marked “158”, the pad pad “2” with a valve lapper “3”. thickness is 1.58 mm (0.062 in). d. Calculate the sum of the values obtained in Valve lapper steps (b) and (c) to determine the required 90890-04101...
Page 137 PERIODIC MAINTENANCE • Lubricate the valve lifter (Outer side) with be clean, and the engine should have ade- engine oil. quate compression. • Install the valve lifter and the valve pad in the 1. Start the engine and let it warm up for sev- correct place.
Page 138 PERIODIC MAINTENANCE • Fuel tank Refer to “FUEL TANK” on page 7-1. • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 3. Remove: • Synchronizing hoses “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
Page 139 PERIODIC MAINTENANCE • If a bypass air screw was removed, turn in Engine idling speed the screw fully and be sure to synchronize 1150–1250 r/min the throttle bodies. • If the throttle body synchronization can not b. Check the vacuum pressure. adjusted by the bypass air screw, clean or replace the throttle bodies.
Page 140 PERIODIC MAINTENANCE 4. After selecting “CO”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection. 5. Press the “SELECT” and “RESET” buttons to select a cylinder. The selected cylinder number appears on the clock LCD.
Page 141 PERIODIC MAINTENANCE Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe and muffler bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe and exhaust pipe bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler and rear footrest bolt 48 Nm (4.8 m·kgf, 35 ft·lbf) 3.
Page 142 PERIODIC MAINTENANCE Clutch cable free play • Replace the air filter element every 40000 10.0–15.0 mm (0.39–0.59 in) km (24000 mi) of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Page 143 PERIODIC MAINTENANCE Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. c. Tighten the locknut “1”. Locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. Front brake EAS39P1307 CHECKING THE BRAKE OPERATION B. Rear brake 1.
Page 144 PERIODIC MAINTENANCE EAS21160 EAS21250 ADJUSTING THE FRONT DISC BRAKE CHECKING THE FRONT BRAKE PADS 1. Adjust: The following procedure applies to all of the • Brake lever position brake pads. (distance “a” from the throttle grip to the 1. Operate the brake. brake lever) 2.
Page 145 PERIODIC MAINTENANCE • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre- caution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure.
Page 146 PERIODIC MAINTENANCE f. Fully pull the brake lever or fully press down the brake pedal and hold it in posi- tion. g. Loosen the bleed screw. Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend.
Page 147 Rear 290 kPa (2.90 kgf/cm², 42 psi) EAS21650 Maximum load CHECKING THE TIRES 194 kg (428 lb) (FZ8NA) The following procedure applies to both of the 190 kg (419 lb) (FZ8SA) tires. 1. Check: * Total weight of rider, passenger, cargo •...
Page 148 The following procedure applies to all of the given if a tire combination other than one wheel bearings. approved by Yamaha is used on this vehi- 1. Check: cle. • Wheel bearings Refer to “CHECKING THE FRONT Front tire WHEEL”...
Page 149 PERIODIC MAINTENANCE Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Move the rear wheel several times and find the tightest position of drive chain. 3. Check: • Drive chain slack “a” Out of specification → Adjust. •...
Page 150 PERIODIC MAINTENANCE EAS21510 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 151 PERIODIC MAINTENANCE 2. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Installed shift rod length 5. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Upper bracket a. Loosen both locknuts “1”. Refer to “HANDLEBAR” on page 4-64. b. Turn the shift rod “2” in direction “a” or “b” to EAS39P1303 obtain the correct shift pedal position.
Page 152 PERIODIC MAINTENANCE EAS21531 EAS21590 CHECKING THE FRONT FORK ADJUSTING THE REAR SHOCK 1. Stand the vehicle on a level surface. ABSORBER ASSEMBLY EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there Securely support the vehicle so that there is no danger of it falling over.
Page 153 PERIODIC MAINTENANCE Recommended brand YAMALUBE Type SAE 10W-30, SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS39P1312 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to “CHECKING THE CONNECTING ARM AND RELAY ARM”...
Page 154 PERIODIC MAINTENANCE c. Tighten the new oil filter cartridge to speci- fication with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Engine oil drain bolt (along with the gasket Engine oil drain bolt 4.
Page 155 PERIODIC MAINTENANCE EAS20820 MEASURING THE ENGINE OIL PRESSURE 1. Check: • Engine oil level Below the minimum level mark “a” → Add the recommended engine oil to the proper level. 5. Measure: • Engine oil pressure (at the following conditions) Oil pressure 230.0 kPa/5000 r/min (2.30 kgf/ cm²/5000 r/min, 33.4 psi/5000...
Page 156 PERIODIC MAINTENANCE 2. Check: • Water pump outlet pipe “10” Cracks/damage → Replace. • Coolant level The coolant level should be between the Refer to “RADIATOR” on page 6-1, “OIL maximum level mark “a” and minimum COOLER” on page 6-5, “THERMOSTAT” level mark “b”.
Page 157 PERIODIC MAINTENANCE 3. Remove: 8. Drain: • Coolant reservoir tank • Coolant 4. Disconnect: (from the engine and radiator) • Coolant reservoir hose 9. Install: 5. Drain: • Coolant drain bolt • Coolant (along with the copper washer (from the coolant reservoir) 6.
Page 158 PERIODIC MAINTENANCE • Use only distilled water. However, if dis- EAS21330 ADJUSTING THE REAR BRAKE LIGHT tilled water is not available, soft water SWITCH may be used. • If coolant comes into contact with painted The rear brake light switch is operated by surfaces, immediately wash them with movement of the brake pedal.
Page 159 EAS21770 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8- 185. EAS21790 REPLACING THE HEADLIGHT BULB (FZ8NA) 1. Remove: • Headlight top cover bolts “1” • Headlight top cover “2” 2. Adjust: • Throttle cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 160 PERIODIC MAINTENANCE 2. Remove: 6. Remove: • Headlight bolt “1” • Headlight bulb holder “1” EWA13320 3. Remove: WARNING • Headlight bolts “2” Since the headlight bulb gets extremely • Headlight unit “3” hot, keep flammable products and your hands away from the bulb until it has cooled down.
Page 161 PERIODIC MAINTENANCE 12. Install: 3. Remove: • Headlight bolts • Headlight bulb cover “1” Headlight bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 13. Install: • Headlight side covers • Headlight side cover bolts Headlight side cover bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 14.
Page 162 ADJUSTING THE HEADLIGHT BEAMS 4-1. (FZ8SA) EAS21810 The following procedure applies to both of the ADJUSTING THE HEADLIGHT BEAM headlights. (FZ8NA) 1. Adjust: 1. Adjust: • Headlight beam (vertically) • Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a”...
Page 163 PERIODIC MAINTENANCE Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-34...
Page 164 PERIODIC MAINTENANCE 3-35...
Page 165 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE INNER PANEL (FZ8SA) ..........4-9 INSTALLING THE INNER PANEL (FZ8SA) ..........4-9 REMOVING THE SIDE PANEL (FZ8SA) ..........4-9 INSTALLING THE SIDE PANEL (FZ8SA)..........4-9 REMOVING THE FRONT COWLING SIDE PANEL (FZ8SA)....4-10 INSTALLING THE FRONT COWLING SIDE PANEL (FZ8SA) .....4-10 INSTALLING THE HEADLIGHT ASSEMBLY (FZ8SA) ......4-11 FRONT WHEEL ..................4-12 REMOVING THE FRONT WHEEL ............4-14...
Page 166 REAR BRAKE ....................4-43 INTRODUCTION ..................4-49 CHECKING THE REAR BRAKE DISC ..........4-49 REPLACING THE REAR BRAKE PADS ..........4-49 REMOVING THE REAR BRAKE CALIPER..........4-51 DISASSEMBLING THE REAR BRAKE CALIPER........4-51 CHECKING THE REAR BRAKE CALIPER ..........4-51 ASSEMBLING THE REAR BRAKE CALIPER........4-52 INSTALLING THE REAR BRAKE CALIPER.........4-52 REMOVING THE REAR BRAKE MASTER CYLINDER .......4-53 CHECKING THE REAR BRAKE MASTER CYLINDER .......4-54 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ....4-54...
Page 167 SWINGARM ....................4-88 REMOVING THE SWINGARM .............4-89 CHECKING THE SWINGARM .............4-89 INSTALLING THE SWINGARM ............4-90 CHAIN DRIVE .....................4-91 REMOVING THE DRIVE CHAIN ............4-92 CHECKING THE DRIVE CHAIN ............4-92 CHECKING THE DRIVE SPROCKET ..........4-93 CHECKING THE REAR WHEEL SPROCKET ........4-93 CHECKING THE REAR WHEEL DRIVE HUB ........4-93 INSTALLING THE DRIVE CHAIN ............4-94...
Page 168 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Passenger seat Rider seat Tool kit Battery negative lead Battery positive lead Main fuse Battery band Battery Battery seat For installation, reverse the removal proce- dure.
Page 169 GENERAL CHASSIS Removing the headlight and meter assembly (FZ8NA) Order Job/Parts to remove Q’ty Remarks Headlight top cover Left headlight side panel Right headlight side panel Headlight assembly Headlight sub-wire harness coupler Disconnect. Left turn signal light lead connector Disconnect.
Page 170 GENERAL CHASSIS Removing the front cowling assembly (FZ8SA) Order Job/Parts to remove Q’ty Remarks Right inner panel Left inner panel Headlight sub-wire harness coupler Disconnect. Left turn signal light lead connector Disconnect. Right turn signal light lead connector Disconnect. Left side panel Right side panel Front cowling assembly Front cowling bracket...
Page 171 GENERAL CHASSIS Disassembling the front cowling assembly (FZ8SA) Order Job/Parts to remove Q’ty Remarks Inner panel bracket Front cowling side panel Windshield Rear view mirror Auxiliary light lead coupler Disconnect. Ground lead Disconnect. Front cowling stay Meter coupler Disconnect. Meter assembly Headlight coupler Disconnect.
Page 172 GENERAL CHASSIS Removing the under cowling Order Job/Parts to remove Q’ty Remarks Left bottom cowling Left bottom cowling bracket Right bottom cowling Rectifier/regulator coupler Disconnect. Rectifier/regulator Right bottom cowling bracket Rectifier/regulator bracket For installation, reverse the removal proce- dure.
Page 173: General Chassis
GENERAL CHASSIS Removing the rear cover (FZ8NA) Order Job/Parts to remove Q’ty Remarks Passenger seat/rider seat Refer to “GENERAL CHASSIS” on page 4-1. Left side cover Right side cover Tail/brake light lead coupler Disconnect. Upper tail cover Tail/brake light bracket...
Page 174 GENERAL CHASSIS Removing the rear cover (FZ8SA) Order Job/Parts to remove Q’ty Remarks Passenger seat/rider seat Refer to “GENERAL CHASSIS” on page 4-1. Left side cover Right side cover Assist grip Tail/brake light lead coupler Disconnect. Upper tail cover Tail/brake light bracket Tail/brake light assembly Left turn signal light lead connector Disconnect.
Page 175 GENERAL CHASSIS Removing the air filter case 2.0 Nm (0.20 m kgf, 1.5 ft Ibf) Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. FZ8SA Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
Page 176 GENERAL CHASSIS EAS39P1404 d. Press the rear of the inner panel downward REMOVING THE INNER PANEL (FZ8SA) to engage projections “b”. 1. Remove: • Inner panel “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. First remove the right inner panel, and then remove the left inner panel. b.
Page 177 GENERAL CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Install the quick fastener and bolt. c. Connect the turn signal light connectors. EAS39P1409 d. Fasten headlight sub-wire harness “1” and INSTALLING THE FRONT COWLING SIDE left turn signal light lead connector “2” at PANEL (FZ8SA) clamp “3”...
Page 178 GENERAL CHASSIS EAS39P1410 INSTALLING THE HEADLIGHT ASSEMBLY (FZ8SA) 1. Install: • Headlight assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporarily tighten the screw “1”. b. Tighten the screw “2”. c. Tighten the screw “1”. d. Tighten the screws “3” not specified can be in any order. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 179 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel sensor Wheel axle pinch bolt Loosen. Wheel axle Collar Front wheel sensor housing Front wheel Front brake disc For installation, reverse the removal proce- dure.
Page 180 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-13...
Page 181: Front Wheel
FRONT WHEEL EAS21900 3. Measure: REMOVING THE FRONT WHEEL • Radial wheel runout “1” 1. Stand the vehicle on a level surface. • Lateral wheel runout “2” EWA13120 Over the specified limits → Replace. WARNING Radial wheel runout limit Securely support the vehicle so that there 1.0 mm (0.04 in) is no danger of it falling over.
Page 182 FRONT WHEEL b. Install the spacer. c. Install the new wheel bearing (left side). Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”.
Page 183 FRONT WHEEL • 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. Disconnect: • Front wheel sensor coupler “1” 2. Check: • Front wheel sensor rotor Cracks/damage →...
Page 184 FRONT WHEEL c. If the deflection is above specification, Distance “a” (between replace the wheel sensor. wheel sensor rotor and wheel Wheel sensor rotor bolt sensor housing) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 29.53–30.25 mm (1.16–1.19 in) LOCTITE® ECA4B56023 Replace the wheel sensor rotor bolts with new ones.
Page 185 FRONT WHEEL c. Turn the front wheel 90° so that the “X ” 4. Connect: mark is positioned as shown. • Front wheel sensor coupler “1” d. Release the front wheel. e. When the wheel stops, put an “X ” mark at the bottom of the wheel.
Page 186 FRONT WHEEL b. Turn the front wheel 90° so that the heavy spot is positioned as shown. 2. Check: c. If the heavy spot does not stay in that posi- • Front brake discs tion, install a heavier weight. Refer to “CHECKING THE FRONT d.
Page 187 FRONT WHEEL Check that wheel axle end “a” is flush with front folk surface “b” and then tighten the wheel axle pinch bolt. If end “a” is not flush with sur- face “b”, align the ends manually or with a plastic hammer.
Page 188 REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-43. Rear wheel sensor protector Rear wheel sensor Rear wheel sensor bracket Locknut Loosen. Adjusting bolt Loosen.
Page 189 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Collar Rear wheel sprocket Rear wheel drive hub Rear wheel drive hub damper Collar Oil seal Bearing Rear wheel For installation, reverse the removal proce- dure.
Page 190 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Rear wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-23...
Page 191 REAR WHEEL EAS22040 REMOVING THE REAR 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. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 192 REAR WHEEL EAS14B1003 CHECKING AND REPLACING THE REAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WHEEL SPROCKET 1. Check: EAS22140 • Rear wheel sprocket ASSEMBLING THE REAR WHEEL More than 1/4 tooth “a” wear → Replace 1. Install: the drive chain sprockets as a set. • Wheel bearings Bent teeth →...
Page 193 REAR WHEEL Removing the rear wheel sensor Checking the rear wheel sensor and sensor 1. Disconnect: rotor • Rear wheel sensor coupler “1” 1. Check: • Rear wheel sensor Cracks/bends/distortion → Replace. Iron powder/dust → Clean. 2. Check: • Rear wheel sensor rotor Cracks/damage →...
Page 194 REAR WHEEL ECA14470 ECA14500 Make sure there are no foreign materials in To route the rear wheel sensor lead, refer to the wheel hub. Foreign materials cause “CABLE ROUTING” on page 2-43. damage to the inner sensor rotor and wheel sensor.
Page 195 REAR WHEEL EAS22150 3. Lubricate: ADJUSTING THE REAR WHEEL STATIC • Oil seal lips BALANCE Recommended lubricant Lithium-soap-based grease • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. 4. Install: • Adjust the rear wheel static balance with the •...
Page 196 REAR WHEEL 5. Install: • Rear brake caliper • Rear brake caliper retaining bolts 6. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-19. Drive chain slack 20.0–30.0 mm (0.79–1.18 in) 7. Tighten: • Wheel axle nut •...
Page 197 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw For installation, reverse the removal proce-...
Page 198: Front Brake
FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks FZ8NA Right rear view mirror Refer to “HANDLEBAR” on page 4-64. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. Brake master cylinder reservoir cap...
Page 199 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32...
Page 200 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. Brake hose union bolt Brake hose gasket Brake hose Front brake caliper...
Page 201 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...
Page 202 FRONT BRAKE EAS22220 d. Hold the dial gauge at a right angle against INTRODUCTION the brake disc surface. EWA14100 e. Measure the deflection 1.5 mm (0.06 in) WARNING below the edge of the brake disc. Disc brake components rarely require dis- assembly.
Page 203 FRONT BRAKE 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake lining thickness d. Measure the brake disc deflection. (outer) e.
Page 204 FRONT BRAKE EAS22300 REMOVING THE FRONT BRAKE CALIPERS The arrow mark “a” on the brake pad spring The following procedure applies to both of the must point in the direction of disc rotation. brake calipers. Before removing the brake caliper, drain the brake fluid from the entire brake system.
Page 205 FRONT BRAKE EWA39P1401 EWA13611 WARNING WARNING • Never try to pry out the brake caliper pis- Whenever a brake caliper is disassembled, tons. replace the brake caliper piston dust seals • Do not loosen the bolts “4”. and brake caliper piston seals. c.
Page 206 FRONT BRAKE EWA13530 EWA13090 WARNING WARNING Proper brake hose routing is essential to • Use only the designated brake fluid. insure safe vehicle operation. Refer to Other brake fluids may cause the rubber “CABLE ROUTING” on page 2-43. seals to deteriorate, causing leakage and poor brake performance.
Page 207 FRONT BRAKE EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER Before removing the front brake master cylin- der, drain the brake fluid from the entire brake system. 1. Disconnect: • Brake light switch connectors (from the front brake light switch) 4. Check: 2.
Page 208 FRONT BRAKE • Align the end of the front brake master cylin- der holder with the punch mark “b” on the handlebar. • First, tighten the upper bolt, then the lower bolt. • There should be more than 11 mm (0.43 in) for clearance between the right handlebar switch and the front brake master cylinder holder.
Page 209 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-16. 4-42...
Page 210 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 Brake pad shim Brake pad insulator Brake pad spring Bleed screw For installation, reverse the removal proce- dure.
Page 211: Rear Brake
REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. FZ8SA Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Right side cover Refer to “GENERAL CHASSIS”...
Page 212 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Rear brake light switch Rear brake master cylinder assembly For installation, reverse the removal proce- dure. 4-45...
Page 213 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-46...
Page 214 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake hose union bolt Brake hose gasket Brake hose Rear brake caliper For installation, reverse the removal proce- dure. 4-47...
Page 215 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 insulator Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 216 REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-35. •...
Page 217 REAR BRAKE 2. Install: • Brake pad insulators • Brake pad shims (onto the brake pads) • Brake pad spring (into the rear brake caliper) • Brake pads Always install new brake pads, brake pad insu- lators, brake pad shims, and brake pad spring as a set.
Page 218 REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose 6. Check: joint opening “a” to force out the piston from • Brake pedal operation the brake caliper. Soft or spongy feeling → Bleed the brake EWA13550 system. WARNING Refer to “BLEEDING THE HYDRAULIC •...
Page 219 REAR BRAKE 1. Check: • Whenever a brake caliper is disassem- • Brake caliper piston “1” bled, replace the brake caliper piston dust Rust/scratches/wear → Replace the seal and brake caliper piston seal. brake caliper piston. • Brake caliper cylinder “2” Recommended fluid Scratches/wear →...
Page 220 REAR BRAKE 2. Remove: 5. Bleed: • Rear brake caliper • Brake system 3. Install: Refer to “BLEEDING THE HYDRAULIC • Brake pad insulators BRAKE SYSTEM” on page 3-16. • Brake pad shims 6. Check: (onto the brake pads) • Brake fluid level Below the minimum level mark “a”...
Page 221 REAR BRAKE EAS22720 • Never use solvents on internal brake CHECKING THE REAR BRAKE MASTER components. CYLINDER 1. Check: Recommended fluid • Brake master cylinder DOT 4 Damage/scratches/wear → Replace. • Brake fluid delivery passages 1. Install: (brake master cylinder body) •...
Page 222 REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.
Page 223 ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS”. Side cover Refer to “GENERAL CHASSIS”. Fuel tank Refer to “FUEL TANK”. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”.
Page 224 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly Order Job/Parts to remove Q’ty Remarks Brake pipe/joint assembly (hydraulic unit to rear Disconnect. brake caliper) Brake pipe/joint assembly (front brake master Disconnect. cylinder to hydraulic unit) Brake pipe/joint assembly (rear brake master Disconnect.
Page 225 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56004 2. Disconnect: REMOVING THE HYDRAULIC UNIT ASSEM- • ABS ECU coupler “1” ECA4B56013 Pull up the coupler ejection slider to discon- nect the ABS ECU coupler. Unless necessary, avoid removing and installing the brake pipes of the hydraulic unit assembly.
Page 226 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56006 4. Install: CHECKING THE BRAKE PIPES • Brake pipe/joint assemblies “1” The following procedure applies to all of the • Brake pipe/joint assembly flare nuts “2” brake pipes. 1. Check: Brake pipe/joint assembly flare • Brake pipe end (flare nut) Damage →...
Page 227 ABS (ANTI-LOCK BRAKE SYSTEM) • Hydraulic unit operation test 1: this test Recommended fluid checks the function of the ABS after the sys- DOT 4 tem was disassembled, adjusted, or ser- viced. EWA13090 • Hydraulic unit operation test 2: this test gen- WARNING erates the same reaction-force pulsating •...
Page 228 ABS (ANTI-LOCK BRAKE SYSTEM) ECA4B56019 • Check that the pulse is felt in the front brake lever, rear brake pedal, and again in the front brake lever, in this order. • If the pulse is felt in the rear brake pedal before it is felt in the front brake lever, check that the brake hoses and brake pipes are connected correctly to the...
Page 229 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Connect the test coupler adapter “1” to the 10. A reaction-force pulsating action is gener- ABS test coupler “2”. ated in the front brake lever “1” 0.5 second after the brake lever and brake pedal are Test coupler adapter operated simultaneously and continues for 90890-03149...
Page 230 ABS (ANTI-LOCK BRAKE SYSTEM) 12. After the pulsating action has stopped in the rear brake pedal, it is generated in the front brake lever 0.5 second later and con- tinues for approximately 1.5 seconds. The reaction-force pulsating action consists of quick pulses.
Page 231 Job/Parts to remove Q’ty Remarks FZ8SA Inner panel Refer to “GENERAL CHASSIS” on page 4-1. Rear view mirror FZ8NA Front brake light switch connector Disconnect. Front master cylinder holder Front brake master cylinder assembly Right handlebar switch Throttle cable housing Throttle cable Disconnect.
Page 232 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal proce- dure. 4-65...
Page 233 HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 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” Blow compressed air between the left handle- EAS22931 INSTALLING THE HANDLEBAR bar and the handlebar grip, and gradually push...
Page 234 HANDLEBAR 3. Tighten: 7. Install: • Lower handlebar holder nuts • Throttle cable clamp “1” Lower handlebar holder nut • Using side “a” of the master cylinder as a 32 Nm (3.2 m·kgf, 23 ft·lbf) guide, install the clamp between side “a” and protector “2”...
Page 235 HANDLEBAR 12. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto • Clutch cable free play the end of the left handlebar. Refer to “ADJUSTING THE CLUTCH b. Side the handlebar grip over the end of the CABLE FREE PLAY” on page 3-13. left handlebar.
Page 236 FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies both of the front fork legs. Front wheel Refer to “FRONT WHEEL” on page 4-12. Front fender Band Left side only. Upper bracket pinch bolt Loosen.
Page 237 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies both of the front fork legs. Cap bolt O-ring Spacer Fork spring Locknut Outer tube Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer Damper rod assembly...
Page 238 FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS Fork spring compressor The following procedure applies to both of the 90890-01441 front fork legs. YM-01441 1. Stand the vehicle on a level surface. Rod holder EWA13120 90890-01434 WARNING Damper rod holder double ended Securely support the vehicle so that there is no danger of it falling over.
Page 239 FRONT FORK ECA39P1404 EWA13650 WARNING Do not scratch the outer tube. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: 4. Remove: • Spring free length “a” • Damper rod assembly bolt Out of specification →...
Page 240 FRONT FORK EAS23031 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA39P1404 WARNING • Note that the amount of the fork oil is dif- ferent in the left and right front fork legs. Make sure to fill each of the left and right A.
Page 241 FRONT FORK ECA14B1007 Make sure the numbered side of the oil seal faces bottom side. • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. 8. Install: •...
Page 242 FRONT FORK • When disassembling and assembling the front fork leg, do not allow any foreign Be sure to bleed the front fork leg of any resid- material to enter the front fork. ual air. 10. Install: 13. Measure: • Rod puller “1” •...
Page 243 FRONT FORK c. Install the locknut all the way onto the h. Remove the rod puller and rod puller damper rod assembly. attachment. d. Install the spacer. Install the cap bolt all the way onto the e. Install the rod puller, rod puller attachment, damper rod assembly, and finger tighten it.
Page 244 FRONT FORK EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. Make sure the outer tube is flush with the top of the upper bracket.
Page 245 STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket (FZ8NA) Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Meter assembly Refer to “GENERAL CHASSIS” on page 4-1.
Page 246 STEERING HEAD Removing the lower bracket (FZ8NA) Order Job/Parts to remove Q’ty Remarks Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Lower bearing dust seal Upper bearing Lower bearing For installation, reverse the removal proce- dure.
Page 247 STEERING HEAD Removing the lower bracket (FZ8SA) Order Job/Parts to remove Q’ty Remarks Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Handlebar Refer to “HANDLEBAR”...
Page 248 STEERING HEAD Removing the lower bracket (FZ8SA) Order Job/Parts to remove Q’ty Remarks Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Bearing cover Lower bearing dust seal Upper bearing Lower bearing For installation, reverse the removal proce- dure.
Page 249 STEERING HEAD EAS23110 2. Check: REMOVING THE LOWER BRACKET • Bearings “1” 1. Stand the vehicle on a level surface. • Bearing races “2” EWA13120 Damage/pitting → Replace the bearings WARNING and bearing races as a set. Securely support the vehicle so that there is no danger of it falling over.
Page 250 STEERING HEAD Temporarily tighten the upper and lower bracket pinch bolts. 5. Tighten: • Steering stem nut Steering stem nut 115 Nm (11.5 m·kgf, 83 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage →...
Page 251 REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Left side cover Refer to “GENERAL CHASSIS” on page 4-1. Right side cover Refer to “GENERAL CHASSIS” on page 4-1. Brake fluid reservoir bolt Refer to “REAR BRAKE”...
Page 252 REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA13740 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Relay arm and swingarm bolt “1” the rear shock absorber, read and make •...
Page 253 REAR SHOCK ABSORBER ASSEMBLY EAS23261 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arm “1” • Relay arms “2” Damage/wear → Replace. 3. Frame 4. Swingarm A. Left side B. Right side 3. Install: 2. Check: • Rear shock absorber assembly •...
Page 254 REAR SHOCK ABSORBER ASSEMBLY 3. Frame 4. Swingarm A. Left side B. Right side 4. Tighten: • Rear shock absorber assembly upper nut • Rear shock absorber assembly lower nut • Frame and connecting arm nut • Relay arm and swingarm nut •...
Page 255 SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear brake caliper Refer to “REAR BRAKE” on page 4-43. Rear wheel Refer to “REAR WHEEL” on page 4-21. Refer to “REAR SHOCK ABSORBER Relay arm ASSEMBLY” on page 4-84. Chain Refer to “CHAIN DRIVE”...
Page 256 SWINGARM EAS23350 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. Place the vehicle on a suitable stand so that the rear wheel is elevated. 2.
Page 257 SWINGARM 4. Check: • Dust covers “1” • Spacer “2” • Oil seals “3” Damage/wear → Replace. • Collar “4” Damage/scratches → Replace. • Bearings “5” Damage/pitting → Replace. A. Left side B. Right side EAS23380 INSTALLING THE SWINGARM 3. Install: 1.
Page 258 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL” on page 5-3. Drive chain For installation, reverse the removal proce- dure. 4-91...
Page 259 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. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 260 CHAIN DRIVE ECA39P1403 • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pres- sure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings.
Page 261 CHAIN DRIVE EAS39P1403 3. Install: INSTALLING THE DRIVE CHAIN • Drive sprocket 1. Install: • Washer • Drive chain • Drive sprocket nut Refer to “ENGINE REMOVAL” on page 5- Install the drive chain joint with the drive chain cut & rivet tool. (Use goods on the market) Drive sprocket nut ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 262 CHAIN DRIVE 4-95...
Page 263 ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE .........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE ..............5-8 INSTALLING THE DRIVE SPROCKET ..........5-10 CAMSHAFTS....................5-11 REMOVING THE CAMSHAFTS ............5-13 CHECKING THE CAMSHAFTS ............5-14 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-15 CHECKING THE TIMING CHAIN GUIDES ..........5-15 CHECKING THE TIMING CHAIN TENSIONER ........5-16 INSTALLING THE CAMSHAFTS ............5-17 CYLINDER HEAD..................5-20...
Page 264 ELECTRIC STARTER.................5-41 CHECKING THE STARTER MOTOR ...........5-43 ASSEMBLING THE STARTER MOTOR ..........5-44 INSTALLING THE STARTER MOTOR..........5-44 CLUTCH......................5-45 REMOVING THE CLUTCH..............5-49 CHECKING THE FRICTION PLATES ..........5-50 CHECKING THE CLUTCH PLATES.............5-50 CHECKING THE CLUTCH SPRINGS ..........5-51 CHECKING THE CLUTCH HOUSING ..........5-51 CHECKING THE CLUTCH BOSS ............5-51 CHECKING THE PRESSURE PLATE ..........5-51 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-52 INSTALLING THE CLUTCH..............5-52...
Page 265 CRANKSHAFT ...................5-80 REMOVING THE CRANKSHAFT ASSEMBLY ........5-81 CHECKING THE OIL NOZZLES ............5-81 CHECKING THE CRANKSHAFT ............5-81 INSTALLING THE CRANKSHAFT............5-83 TRANSMISSION..................5-84 REMOVING THE TRANSMISSION ............5-89 CHECKING THE SHIFT FORKS ............5-89 CHECKING THE SHIFT DRUM ASSEMBLY........5-90 CHECKING THE TRANSMISSION ............5-90 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-91 INSTALLING THE TRANSMISSION.............5-91...
Page 266 ENGINE INSPECTION EAS14B1052 5. Measure: ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) EAS20710 and (d). MEASURING THE COMPRESSION PRES- SURE Standard compression pres- The following procedure applies to all of the sure (at sea level) cylinders.
Page 267 ENGINE INSPECTION 6. Install: • Spark plug Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 7. Install: • Ignition coils...
Page 268 ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Loosen. Drive chain Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-19. Locknut Shift rod Shift arm Joint Drive sprocket cover Plate Drive sprocket nut Washer Drive sprocket For installation, reverse the removal proce-...
Page 269 ENGINE REMOVAL Removing the muffler and exhaust pipe Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-3. sensor coupler Disconnect.
Page 270: Engine Removal
ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Thermostat assembly Refer to “THERMOSTAT” on page 6-7. Oil cooler Refer to “OIL COOLER”...
Page 271 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead coupler Disconnect. Crankshaft position sensor lead coupler Disconnect. Oil level switch lead coupler Disconnect. Neutral switch connector Disconnect. For installation, reverse the removal proce- dure.
Page 272 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Right front engine mounting bolt 1 Left front engine mounting bolt Upper engine mounting bolt/nut Lower engine mounting bolt/nut Engine mounting adjust bolt Loosen. Engine For installation, reverse the removal proce- dure.
Page 273 ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Right front engine mounting bolt 2 “1” Refer to “CYLINDER HEAD” on page 5- 6. Install: • Left front engine mounting bolt “1” (temporarily tighten) • Right front engine mounting bolt 1 “2” (temporarily tighten) 2.
Page 274 ENGINE REMOVAL Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter 90890-01476 9. Tighten: • Left front engine mounting bolt “1” • Right front engine mounting bolt 1 “2” Left front engine mounting bolt 45 Nm (4.5 m·kgf, 33 ft·lbf) Right front engine mounting bolt 1 45 Nm (4.5 m·kgf, 33 ft·lbf)
Page 275 ENGINE REMOVAL Align punch mark “a” of the shift arm “1” with alignment mark “b” of the crankcase. EAS39P1501 INSTALLING THE DRIVE SPROCKET 1. Install: • Drive sprocket • Washer • Drive sprocket nut “1” Drive sprocket nut 85 Nm (8.5 m·kgf, 61 ft·lbf) LOCTITE®...
Page 276 CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Refer to “AIR INDUCTION SYSTEM” on Air cut-off valve page 7-15.
Page 277 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT POSITION SEN- Pickup rotor cover SOR” on page 5-39. Disconnect. Clutch cable (engine side) Refer to “CLUTCH” on page 5-45. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft...
Page 278 CAMSHAFTS EAS23810 camshaft cap bolts in stages and in a criss- REMOVING THE CAMSHAFTS cross pattern, working from the outside in. 1. Remove: • Pickup rotor cover Refer to “CRANKSHAFT POSITION SENSOR” on page 5-39. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 279 CAMSHAFTS EAS23850 3. Measure: CHECKING THE CAMSHAFTS • Camshaft runout 1. Check: Out of specification → Replace. • Camshaft lobes Blue discoloration/pitting/scratches → Camshaft runout limit Replace the camshaft. 0.030 mm (0.0012 in) 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...
Page 280 CAMSHAFTS c. Install the dowel pins and camshaft caps. EAS23870 CHECKING THE TIMING CHAIN AND CAM- SHAFT SPROCKET • Tighten the camshaft cap bolts in stages and 1. Check: in a crisscross pattern, working from the • Timing chain inner caps out. Damage/stiffness →...
Page 281 CAMSHAFTS EAS23960 b. Squeeze the timing chain tensioner clip “2”, CHECKING THE TIMING CHAIN TEN- and then push the timing chain tensioner SIONER rod “3” into the timing chain tensioner hous- 1. Remove: ing. • Timing chain tensioner housing “1” •...
Page 282 CAMSHAFTS Camshaft wrench 90890-04162 YM-04162 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC, align the “T” mark “a”...
Page 283 CAMSHAFTS “EL”: Exhaust left side camshaft cap mark 7. Install: “ER”: Exhaust right side camshaft cap mark • Timing chain tensioner gasket • Make sure the arrow mark “a” on each cam- • Timing chain tensioner “1” shaft points towards the right side of the •...
Page 284 • Apply bond TB1541C® onto the mating sur- faces “a” of the cylinder head cover and cyl- inder head cover gasket. • Apply bond Yamaha bond No.1215 (Three bond No.1215®) onto the mating surfaces “b” of the cylinder head cover gasket and cylin- der head.
Page 285 CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Intake camshaft Refer to “CAMSHAFTS” on page 5-11. Exhaust camshaft Refer to “CAMSHAFTS” on page 5-11. Coolant pipe Fast idle plunger inlet hose Coolant temperature sensor Right front engine mounting bolt 2...
Page 286: Cylinder Head
CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-13. 2. Remove: • Cylinder head nuts • Cylinder head bolts • Loosen the nuts in the proper sequence as ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 287 CYLINDER HEAD 5. Install: 2. Install: • Exhaust camshaft • Intake camshaft • Cylinder head gasket “1” Refer to “INSTALLING THE CAM- • Dowel pins SHAFTS” on page 5-17. 3. Install: • Cylinder head • Washers • Cylinder head nuts •...
Page 288 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 5-20. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...
Page 289 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring Exhaust valve Exhaust valve stem seal Exhaust valve spring seat Exhaust valve guide For installation, reverse the removal proce- dure.
Page 290 VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
Page 291 VALVES AND VALVE SPRINGS Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1.
Page 292 VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the Valve margin thickness valve guide with the valve guide reamer “3” Valve margin thickness (intake) to obtain the proper valve-stem-to-valve- 0.50–0.90 mm (0.0197–0.0354 guide clearance. Valve margin thickness (exhaust) 0.50–0.90 mm (0.0197–0.0354 After replacing the valve guide, reface the...
Page 293 VALVES AND VALVE SPRINGS EAS24300 c. Press the valve through the valve guide CHECKING THE VALVE SEATS and onto the valve seat to make a clear The following procedure applies to all of the impression. valves and valve seats. d. Measure the valve seat width. 1.
Page 294 VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Valve spring free length Free length (intake) e.
Page 295 VALVES AND VALVE SPRINGS EAS24340 Installed compression spring INSTALLING THE VALVES force (intake) The following procedure applies to all of the 130.60–150.20 N (13.32–15.32 valves and related components. kgf, 29.36–33.76 lbf) 1. Deburr: Installed compression spring • Valve stem end force (exhaust) (with an oil stone) 130.60–150.20 N (13.32–15.32...
Page 296 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 Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad (with the recommended lubricant) b.
Page 297 GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Left side cover Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain.
Page 298 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Bearing housing Collar Bearing Starter clutch idler gear Idler gear shaft Bearing For installation, reverse the removal proce- dure. 5-33...
Page 299 • Generator rotor and starter clutch assem- bly “1” 3. Apply: • Sealant 3. Remove: (onto the stator coil lead grommet “1”) • Idle gear shaft bolt “1” Yamaha bond No.1215 • Washer (Three bond No.1215®) • Idle shaft 90890-85505 • Idle gear “2” 5-34...
Page 300 GENERATOR 4. Install: • Generator rotor cover gasket • Generator rotor cover “1” Generator rotor cover bolt (M8) 22 Nm (2.2 m·kgf, 16 ft·lbf) Generator rotor cover bolt (M6) 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • First tighten the M8 bolts and then tighten the M6 bolts.
Page 301 STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Spacer O-ring Washer Starter clutch drive gear Collar Washer Driven gear Damper Starter clutch assembly plate Starter clutch assembly Generator rotor For installation, reverse the removal proce- dure.
Page 302 STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer “1” • O-ring “2” • Washer “3” EAS5D01018 CHECKING THE DAMPER 1. Check: • Dampers “1” Damage/wear → Replace. 2. Remove: • Starter clutch drive gear “1” • Collar “2” •...
Page 303 STARTER CLUTCH 3. Check: 2. Install: • Starter clutch gear’s contacting surfaces • Generator rotor “1” Damage/pitting/wear → Replace the • Dampers “2” starter clutch gear. • Driven gear “3” 4. Check: • Starter clutch operation • Be sure to install the damper to the driven ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 304 CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-24.
Page 305 CRANKSHAFT POSITION SENSOR EAS24530 REMOVING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor • O-rings • Pickup rotor cover “1” Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
Page 306 ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle bodies Refer to “THROTTLE BODIES” on page 7-5. Right throttle body joint Refer to “THROTTLE BODIES”...
Page 307 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Starter motor yoke Armature assembly Gasket Brush holder set Rear cover For assembly, reverse the disassembly pro- cedure. * When replacing any of the front cover, starter motor yoke, armature assembly, and rear cover, replace the starter motor assembly.
Page 308 ELECTRIC STARTER EAS24791 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
Page 309 ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear → Replace the starter motor. 7. Check: • Bearing • Oil seal Damage/wear → Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush holder set 2. Install: • Rear cover “1” •...
Page 310 CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-24. Clutch cable Disconnect. Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce- dure.
Page 311 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal proce- dure. 5-46...
Page 312 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Green paint mark. Clutch plate 1 Friction plate 2 Purple paint mark. Clutch boss nut Washer Clutch boss Wire circlip Clutch plate 2 Friction plate 3 Clutch damper spring...
Page 313 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch housing Bearing For installation, reverse the removal proce- dure. 5-48...
Page 314 CLUTCH EAS30712 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Clutch cover “1” • Gasket 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 315 CLUTCH 7. Remove: EAS25100 CHECKING THE FRICTION PLATES • Clutch boss nut The following procedure applies to all of the • Washer friction plates. • Clutch boss assembly 1. Check: • Thrust plate • Friction plate 8. Remove: Damage/wear → Replace the friction •...
Page 316 CLUTCH 2. Measure: EAS25150 CHECKING THE CLUTCH HOUSING • Clutch plate warpage 1. Check: (with a surface plate and thickness gauge • Clutch housing dogs “1”) Damage/pitting/wear → Deburr the clutch Out of specification → Replace the clutch housing dogs or replace the clutch hous- plates as a set.
Page 317 CLUTCH 3. Install: EAS25220 CHECKING THE PULL LEVER SHAFT AND • Wire circlip “1” PULL ROD 1. Check: • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft as a set. 4.
Page 318 CLUTCH • Stake the clutch boss nut at a cutout “a” in 7. Install: the main axle. • Friction plate 1 “1” • While holding the clutch boss assembly “1” with the universal clutch holder “3”, tighten • Install the last friction plate shifting half the clutch boss nut.
Page 319 CLUTCH 9. Install: • Dowel pins • Clutch cover gasket • Clutch cover “1” Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Apply engine oil onto the bearing. • Apply locking agent (LOCTITE®) to the threads of only the clutch cover bolts “a” 11.
Page 320 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-45. Shift arm and shift rod Refer to “ENGINE REMOVAL” on page 5-3. Circlip Washer Shift shaft Washer Shift shaft spring...
Page 321: Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift shaft spring “2” • Collar “3” Damage/wear → Replace. 2. Install: • Bearing • Washer • Collar • Shift shaft spring “1” •...
Page 322 OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-3. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 323 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin...
Page 324 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Collar Oil pump housing Bearing Oil pump rotor assembly For assembly, reverse the disassembly pro- cedure. 5-59...
Page 325 OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1. Remove: 1. Check: • Oil level switch “1” • Oil pump driven gear “1” • Oil pan “2” • Oil pump housing “2” Cracks/damage/wear → Replace the •...
Page 326 OIL PUMP EAS24980 CHECKING THE OIL DELIVERY PIPES The following procedure applies to all of the oil delivery pipes. 1. Check: • Oil delivery pipe “1” • Oil pipe “2” Damage → Replace. Obstruction → Wash and blow out with compressed air.
Page 327 OIL PUMP EAS25010 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 4. Check: • Pin “1” • Oil pump operation • Inner rotor “2” Refer to “CHECKING THE OIL PUMP”...
Page 328 OIL PUMP Install the oil/water pump assembly drive chain “1” onto the oil/water pump assembly drive sprocket “2”. 5. Install: • Relief valve assembly “1” • O-ring • Oil strainer “2” • O-ring Oil strainer bolt 3. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) •...
Page 329 OIL PUMP • Oil level switch “2” Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Engine oil drain bolt “3” Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf) EWA12820 WARNING Always use new copper washers. •...
Page 330 Crankshaft position sensor SOR” on page 5-39. Oil/water pump assembly Refer to “OIL PUMP” on page 5-57. Refer to “ELECTRIC STARTER” on page 5- Starter motor Oil return pipe Blind plug Neutral switch * Yamaha bond No.1215 (Three bond No.1215®) 5-65...
Page 331 Separating the crankcase Order Job/Parts to remove Q’ty Remarks Crankcase breather hose Ventilation chamber cover Ventilation chamber cover gasket Left side cover O-ring Lower crankcase Dowel pin For installation, reverse the removal proce- dure. * Yamaha bond No.1215 (Three bond No.1215®) 5-66...
Page 332 Tap on one side of the crankcase with a bearings. soft-face hammer. Tap only on reinforced • For area “a”, apply Yamaha bond No.1215 portions of the crankcase, not on the (Three Bond No.1215®) twice. For shaded crankcase mating surfaces. Work slowly area “b”, degrease the area and then apply...
Page 333 CRANKCASE 3. Install: Crankcase bolt “1”–“10” • Dowel pins 1st: 20 Nm (2.0 m·kgf, 14 ft·lbf) 4. Set the shift drum assembly and transmis- 2nd*: 20 Nm (2.0 m·kgf, 14 sion gears in the neutral position. ft·lbf) 5. Install: 3rd: 56°–61° •...
Page 334 CONNECTING RODS AND PISTONS EAS39P1503 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-65. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston...
Page 335 CONNECTING RODS AND PISTONS 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” • Connecting rod • Big end bearings • Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 336 CONNECTING RODS AND PISTONS 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the mea- surements.
Page 337 CONNECTING RODS AND PISTONS Piston ring side clearance Piston ring end gap Top ring Top ring 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 0.020–0.055 (0.0008– 0.35–0.50 mm (0.0138–0.0197 0.0022 in) Limit Limit...
Page 338 CONNECTING RODS AND PISTONS EAS39P1504 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end-bear- ing clearance 0.034–0.058 (0.0013– 0.0023 in) 3. Measure: Limit • Piston pin bore inside diameter “b” 0.09 mm (0.0035 in) Out of specification →...
Page 339 CONNECTING RODS AND PISTONS To install the big end bearing, care should be taken not to install it at an angle and the posi- tion should not be out of alignment. d. Assemble the connecting rod halves. ECA39P1501 Tighten the connecting rod bolts using the plastic-region tightening angle method.
Page 340 CONNECTING RODS AND PISTONS h. Put a mark “1” on the corner of the con- k. Remove the connecting rod and big end necting rod bolt “2” and the connecting rod bearings. cap “3”. Measure the compressed Plastigauge® width on the crankshaft pin. If the crank- shaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings.
Page 341 CONNECTING RODS AND PISTONS 2. Tighten: • Connecting rod bolts ECA14B1042 Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. Install by carrying out the following procedures in order to assemble in the most suitable con- EAS26190 dition.
Page 342 CONNECTING RODS AND PISTONS • Install the piston pin clips, so that the clip ends are 3 mm (0.12 in) “c” or more from the cutout in the piston. • Reinstall each piston into its original cylinder. a. Side machined face b.
Page 343 CONNECTING RODS AND PISTONS 7. Lubricate: • Crankshaft pins • Connecting rod big end bearing inner sur- face (with the recommended lubricant) Recommended lubricant Engine oil 8. Check: 11. Tighten: • Cylinder stud bolts • Connecting rod bolts “1” Cylinder stud bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 9.
Page 344 CONNECTING RODS AND PISTONS EWA13400 WARNING If the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. ECA13950 Do not use a torque wrench to tighten the connecting rod bolt to the specified angle.
Page 345 CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-70. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Timing chain drive sprocket Straight key...
Page 346 CRANKSHAFT EAS25980 2. Check: REMOVING THE CRANKSHAFT ASSEMBLY • Crankshaft journal surfaces 1. Remove: • Crankshaft pin surfaces • Crankshaft assembly • Bearing surfaces • Crankshaft journal bearings Scratches/wear → Replace the crank- shaft. Identify the position of each crankshaft journal 3.
Page 347 CRANKSHAFT Do not put the Plastigauge® over the oil hole in the crankshaft journal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Select: • Crankshaft journal bearings (J –J e. Install the crankshaft journal lower bear- ings “1” into the lower crankcase and assemble the crankcase halves. •...
Page 348 CRANKSHAFT EAS26200 INSTALLING THE CRANKSHAFT 1. Install: • Crankshaft journal upper bearings (into the upper crankcase) • Crankshaft journal lower bearings (into the lower crankcase) • Crankshaft • Align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the crankcase.
Page 349 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase lower Refer to “CRANKCASE” on page 5-65. Drive axle assembly Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L”...
Page 350 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Oil pipe Oil baffle plate Bearing For installation, reverse the removal proce- dure. 5-85...
Page 351 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks When installing secondary pinion gear “1”, 2nd pinion gear install the gear with groove “a” facing to the toothed lock washer. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer...
Page 352 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer Collar...
Page 353 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle For assembly, reverse the disassembly pro- cedure. 5-88...
Page 354 TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
Page 355 TRANSMISSION 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2. Measure: • Drive axle runout (with a centering device and dial gauge “1”) Out of specification →...
Page 356 TRANSMISSION 4. Check: “c” on the retainer with an axle spline “b”, and • Transmission gear engagement then install the toothed lock washer “2”. (each pinion gear to its respective wheel • Be sure to align the projection on the toothed gear) lock washer that is between the alignment Incorrect →...
Page 357 TRANSMISSION • The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. • Carefully position the shift forks so that they are installed correctly into the transmission gears.
Page 358 TRANSMISSION 5-93...
Page 359 COOLING SYSTEM RADIATOR ....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-5 CHECKING THE OIL COOLER..............6-6 INSTALLING THE OIL COOLER ............6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT............6-9 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-9 INSTALLING THE THERMOSTAT ASSEMBLY ........6-10 WATER PUMP ....................6-11 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............6-12 ASSEMBLING THE WATER PUMP............6-12...
Page 360 Refer to “ENGINE REMOVAL” on page 5-3. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27. Radiator side cover Coolant reservoir hose Disconnect. Radiator inlet hose Disconnect. Water pump breather hose 1 Disconnect. Oil cooler outlet hose Radiator outlet hose Radiator upper cover FZ8NA...
Page 361 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator upper panel FZ8SA Radiator fan motor coupler Disconnect. Radiator Radiator fan motor Water pump breather hose 2 Disconnect. Water pump inlet pipe For installation, reverse the removal proce- dure.
Page 362 RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. 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 363 RADIATOR b. Apply 122.7 kPa (1.23 kgf/cm², 17.8 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
Page 364 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-24. Water jacket joint inlet hose Oil cooler inlet hose Oil cooler union bolt Washer...
Page 365: Oil Cooler
OIL COOLER EAS26420 • Crankcase CHECKING THE OIL COOLER (with the specified amount of the recom- 1. Check: mended engine oil) • Oil cooler Refer to “CHANGING THE ENGINE OIL” Cracks/damage → Replace. on page 3-24. 2. Check: 4. Check: •...
Page 366 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. FZ8SA Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air filter case Refer to “GENERAL CHASSIS”...
Page 367 THERMOSTAT Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks Thermostat housing cover Thermostat Thermostat housing For assembly, reverse the disassembly pro- cedure.
Page 368 THERMOSTAT EAS26450 CHECKING THE THERMOSTAT If the accuracy of the thermostat is in doubt, 1. Check: replace it. A faulty thermostat could cause seri- • Thermostat ous overheating or overcooling. Does not open at 71–85 °C (159.8–185.0 °F) → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 369 THERMOSTAT EAS26480 INSTALLING THE THERMOSTAT ASSEM- 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-27. 2. Check: • Cooling system Leaks → Repair or replace any faulty part.
Page 370 WATER PUMP EAS26500 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-57. Oil pump rotor Refer to “OIL PUMP” on page 5-57. Water pump cover Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing...
Page 371 WATER PUMP EAS26520 EAS26541 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover “1” • Impeller “2” Cracks/damage/wear → Replace. Remove the water pump seal from the inside •...
Page 372 WATER PUMP 2. Install: • Water pump seal “1” ECA14080 Never lubricate the water pump seal sur- face with oil or grease. Install the water pump seal with the special tools. 4. Measure: Mechanical seal installer • Impeller shaft tilt 90890-04078 Out of specification →...
Page 373 FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK COVER ..........7-2 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-3 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK...............7-3 INSTALLING THE FUEL TANK COVER ..........7-3 CHECKING THE FUEL PRESSURE............7-4 THROTTLE BODIES..................7-5...
Page 374 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. FZ8SA Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank cover Fuel hose connector cover Fuel hose connector Disconnect.
Page 375: Fuel Tank
FUEL TANK EAS39P1713 EWA39P1702 REMOVING THE FUEL TANK COVER WARNING 1. Remove: Cover fuel hose connection with a cloth • Fuel tank cover “1” when disconnecting them. Residual pres- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ sure in the fuel lines could cause fuel to a. Remove the bolts. spurt out when removing the hose.
Page 376 FUEL TANK EAS26690 is in the correct position, otherwise the fuel CHECKING THE FUEL PUMP OPERATION hose will not be properly installed. 1. Check: • Fuel pump operation Refer to “CHECKING THE FUEL PRES- • Install the fuel hose securely onto the fuel SURE”...
Page 377 FUEL TANK EAS39P1709 CHECKING THE FUEL PRESSURE 1. Check: • Fuel pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rider seat and fuel tank cover. Refer to “GENERAL CHASSIS” on page 4- 1 and “FUEL TANK” on page 7-1. b. Remove the fuel tank bolt and holdup the fuel tank.
Page 378 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. FZ8SA Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
Page 379 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Coolant temperature sensor coupler Disconnect. Throttle bodies Throttle body joint For installation, reverse the removal proce- dure.
Page 380 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Fuel injection system sub-wire harness Hose joint Negative pressure hose (Thin) Negative pressure hose (Thick) Intake air pressure sensor Throttle position sensor Sub-throttle position sensor Idle adjust screw wire Air screw set Collar Fuel rail...
Page 381 THROTTLE BODIES EAS39P1710 battery terminal before checking the REMOVING THE FUEL HOSE (THROTTLE injectors. BODY SIDE) ECA39P1701 1. Remove: • Fuel tank • When checking the injectors, do not allow Refer to “REMOVING THE FUEL TANK” any foreign material to enter or adhere to on page 7-2.
Page 382 THROTTLE BODIES 1. Check: EAS39P1706 CHECKING AND CLEANING THE THROT- • Injector pressure TLE BODIES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the injector pressure adapter “1” Before cleaning the throttle bodies, check the to the fuel rail joint “2”, and then connect an following items: air compressor “3”...
Page 383 THROTTLE BODIES 2. Clean: c. Push the lever in the direction shown in the • Throttle bodies illustration to hold the throttle valves in the ECA39P1703 open position. EWA14B1022 WARNING Observe the following precautions; other- wise, the throttle bodies may not operate When cleaning the throttle bodies, be care- properly.
Page 384 THROTTLE BODIES f. After removing the carbon deposits, clean EAS39P1711 INSTALLING THE FUEL HOSE (THROTTLE the inside of the throttle bodies with a BODY SIDE) petroleum-based solvent, and then dry the 1. Connect: throttle bodies using compressed air. • Fuel hose (throttle body side) g.
Page 385 THROTTLE BODIES c. Connect the throttle position sensor, sub- EAS39P1708 ADJUSTING THE SUB-THROTTLE POSI- throttle position sensor and sub-throttle TION SENSOR servo motor to the wire harness. EWA39P1701 d. Set the main switch to “OFF” and set the WARNING engine stop switch to “ ”.
Page 386 THROTTLE BODIES • Positive tester probe Green/yellow (wire harness color) • Negative tester probe Black/blue (wire harness color) d. Set the main switch to “ON” and fully close the sub-throttle valves. e. Measure the sub-throttle position sensor voltage. f. Adjust the sub-throttle position sensor angle so that the voltage is within the spec- ified range.
Page 387 THROTTLE BODIES 7-14...
Page 388: Air Induction System
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-15...
Page 389 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-16...
Page 390 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. FZ8SA Inner panel/side panel/front cowling side panel Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
Page 391 AIR INDUCTION SYSTEM EAS27060 1. Check: CHECKING THE AIR INDUCTION SYSTEM • Hoses Loose connections → Connect properly. Air injection Cracks/damage → Replace. The air induction system burns unburned 2. Check: exhaust gases by injecting fresh air (second- • Reed valve ary air) into the exhaust port, reducing the •...
Page 392 AIR INDUCTION SYSTEM • Reed valve assembly Install the reed valve assembly so that the open side turns to the exhaust side of the engine. A. Exhaust side 2. Install: • Reed valve cover Reed valve cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®...
Page 393: General Information
ELECTRICAL SYSTEM IGNITION SYSTEM..................8-1 CIRCUIT DIAGRAM................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....8-5 TROUBLESHOOTING ................8-7 ELECTRIC STARTING SYSTEM..............8-11 CIRCUIT DIAGRAM................8-11 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION.......8-15 TROUBLESHOOTING ................8-17 CHARGING SYSTEM .................8-19 CIRCUIT DIAGRAM................8-19 TROUBLESHOOTING ................8-23 LIGHTING SYSTEM ...................8-25 CIRCUIT DIAGRAM................8-25 TROUBLESHOOTING ................8-29 SIGNALING SYSTEM.................8-31 CIRCUIT DIAGRAM................8-31 TROUBLESHOOTING ................8-35...
Page 394 ABS (ANTI-LOCK BRAKE SYSTEM) ............8-127 CIRCUIT DIAGRAM................8-127 ABS COMPONENTS CHART.............8-131 ABS COUPLER LOCATION CHART ..........8-133 MAINTENANCE OF THE ABS ECU...........8-135 ABS TROUBLESHOOTING OUTLINE ..........8-135 BASIC INSTRUCTIONS FOR TROUBLESHOOTING......8-136 BASIC PROCESS FOR TROUBLESHOOTING .........8-137 [A] CHECKING THE ABS WARNING LIGHT ........8-138 [B-1] THE ABS WARNING LIGHT FAILS TO COME ON ....8-138 [B-2] THE ABS WARNING LIGHT FLASHES........8-138 [B-3] THE ABS WARNING LIGHT REMAINS ON ......8-138...
Page 396 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 397 IGNITION SYSTEM FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 21.Lean angle sensor 23.Cylinder identification sensor 24.Crankshaft position sensor 25.ECU (engine control unit)
Page 398 IGNITION SYSTEM...
Page 399 IGNITION SYSTEM FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 21.Lean angle sensor 23.Cylinder identification sensor 24.Crankshaft position sensor 25.ECU (engine control unit) 26.Ignition coil #1 27.Ignition coil #2...
Page 400 IGNITION SYSTEM EAS39P1804 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 401 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Neutral switch 12.Battery negative lead...
Page 402 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (FZ8SA) 4. Right inner panel (FZ8SA) 5. Left side panel (FZ8SA) 6.
Page 403 IGNITION SYSTEM 7. Check the cylinder identification NG→ sensor. Replace the cylinder identification Refer to “CHECKING THE CYLIN- sensor. DER IDENTIFICATION SENSOR” on page 8-201. OK↓ 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit.
Page 404 IGNITION SYSTEM 16.Check the entire ignition system’s NG→ wiring. Properly connect or repair the ignition Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-1. OK↓ Replace the ECU.
Page 405 IGNITION SYSTEM 8-10...
Page 406 ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM 8-11...
Page 407 ELECTRIC STARTING SYSTEM FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 56.Right handlebar switch 58.Engine stop switch 59.Start switch...
Page 408 ELECTRIC STARTING SYSTEM 8-13...
Page 409 ELECTRIC STARTING SYSTEM FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 56.Right handlebar switch 58.Engine stop switch 59.Start switch 61.Left handlebar switch 62.Clutch switch...
Page 410 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 411 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
Page 412 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (FZ8SA) 4. Right inner panel (FZ8SA) 5. Left side panel (FZ8SA) 6. Right side panel (FZ8SA) 7.
Page 413 ELECTRIC STARTING SYSTEM 7. Check the starter relay. NG→ Refer to “CHECKING THE Replace the starter relay. RELAYS” on page 8-189. OK↓ 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 8-179. OK↓...
Page 414 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-19...
Page 415 CHARGING SYSTEM FZ8NA 2. Rectifier/regulator 3. AC magneto 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 8-20...
Page 416 CHARGING SYSTEM 8-21...
Page 417 CHARGING SYSTEM FZ8SA 2. Rectifier/regulator 3. AC magneto 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 8-22...
Page 418 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-185. OK↓...
Page 419 CHARGING SYSTEM 8-24...
Page 420 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-25...
Page 421 LIGHTING SYSTEM FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.ECU (engine control unit) 43.Meter assembly 51.High beam indicator light 54.Meter light 61.Left handlebar switch 63.Pass switch 64.Dimmer switch 74.Headlight...
Page 422 LIGHTING SYSTEM 8-27...
Page 423 LIGHTING SYSTEM FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.ECU (engine control unit) 43.Meter assembly 51.High beam indicator light 54.Meter light 61.Left handlebar switch 63.Pass switch 64.Dimmer switch 74.Auxiliary light 75.Headlight (high beam) 76.Headlight (low beam)
Page 424 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (FZ8SA) 4.
Page 425 LIGHTING SYSTEM 7. Check the headlight relay (on/off). NG→ Refer to “CHECKING THE Replace the headlight relay. RELAYS” on page 8-189. OK↓ 8. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring.
Page 426 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-31...
Page 427 SIGNALING SYSTEM FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 17.Neutral switch 20.Fuel sender 25.ECU (engine control unit) 40.Coolant temperature sensor 43.Meter assembly 45.Oil level warning light 46.Neutral indicator light...
Page 428 SIGNALING SYSTEM 8-33...
Page 429 SIGNALING SYSTEM FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 17.Neutral switch 20.Fuel sender 25.ECU (engine control unit) 40.Coolant temperature sensor 43.Meter assembly 45.Oil level warning light 46.Neutral indicator light 47.Tachometer 48.Multi-function meter...
Page 430 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. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3.
Page 431 SIGNALING SYSTEM Check the signaling system The horn fails to sound. 1. Check the horn switch. NG→ Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 8-179. OK↓ 2. Check the horn. NG→ Refer to “CHECKING THE HORN” Replace the horn.
Page 432 SIGNALING SYSTEM The turn signal light, turn signal indicator light or both fail to blink. 1. Check the turn signal light bulb and NG→ socket. Replace the turn signal light bulb(s), Refer to “CHECKING THE BULBS socket(s) or both. AND BULB SOCKETS” on page 8- 184.
Page 433 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-31. OK↓ Replace the meter assembly. The oil level warning light fails to come on. 1.
Page 434 SIGNALING SYSTEM 2. Check the entire speed sensor wir- NG→ Properly connect or repair the speed ing. sensor wiring. Refer to TIP. OK↓ Replace the hydraulic unit assembly, ECU, meter assembly. Repair or replace if there is an open or short circuit. •...
Page 435 SIGNALING SYSTEM 8-40...
Page 436 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-41...
Page 437 COOLING SYSTEM FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.ECU (engine control unit) 40.Coolant temperature sensor 79.Radiator fan motor relay 80.Right radiator fan motor fuse 81.Right radiator fan motor 82.Left radiator fan motor fuse...
Page 438 COOLING SYSTEM 8-43...
Page 439 COOLING SYSTEM FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.ECU (engine control unit) 40.Coolant temperature sensor 80.Radiator fan motor relay 81.Right radiator fan motor fuse 82.Right radiator fan motor 83.Left radiator fan motor fuse 84.Left radiator fan motor 86.Ignition fuse...
Page 440 COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (FZ8SA) 4. Right inner panel (FZ8SA) 5. Left side panel (FZ8SA) 6. Right side panel (FZ8SA) 7. Front cowling (FZ8SA) 8.
Page 441 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 8-41. OK↓ Replace the ECU. 8-46...
Page 442 FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-47...
Page 443 FUEL INJECTION SYSTEM FZ8NA 1. Main switch 4. Backup fuse 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 17.Neutral switch 18.Sidestand switch 19.Fuel pump 21.Lean angle sensor...
Page 444 FUEL INJECTION SYSTEM 8-49...
Page 445 FUEL INJECTION SYSTEM FZ8SA 1. Main switch 4. Backup fuse 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 17.Neutral switch 18.Sidestand switch 19.Fuel pump 21.Lean angle sensor 22.Atmospheric pressure sensor 23.Cylinder identification sensor...
Page 446 FUEL INJECTION SYSTEM EAS27351 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 447 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor 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 448 FUEL INJECTION SYSTEM EAS30580 The engine operation is not normal, but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sen- engine trouble warning light comes on. sors and actuators in the diagnostic mode.
Page 449 FUEL INJECTION SYSTEM EAS27411 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ON”. 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 450 FUEL INJECTION SYSTEM EAS27462 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method.
Page 451 FUEL INJECTION SYSTEM Fault code No. Cylinder identification sensor: no normal signals are received from Item the cylinder identification sensor. Unable to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
Page 452 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
Page 453 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: open or short circuit detected. (no nor- Item mal signals are received from the intake air pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure.
Page 454 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: open or short circuit detected. (no nor- Item mal signals are received from the intake air pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure.
Page 455 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or Item detached hose). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure. Set the engine stop switch to “ ”, and then operate the throttle Procedure while pushing the start switch “...
Page 456 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: open or short circuit detected. (no normal Item signals are received from the throttle position sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
Page 457 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: open or short circuit detected. (no normal Item signals are received from the throttle position sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
Page 458 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor detected. Item (signal from throttle position sensor will not change.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
Page 459 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow lead Item of the ECU is detected. (no normal signals are received from the sid- estand switch.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
Page 460 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow lead Item of the ECU is detected. (no normal signals are received from the sid- estand switch.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
Page 461 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when Item the main switch is set to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 462 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when Item the main switch is set to “ON”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 463 FUEL INJECTION SYSTEM Fault code No. Coolant temperature sensor: open or short circuit detected. (no nor- Item mal signals are received from the coolant temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:06 Meter display Displays the coolant temperature.
Page 464 FUEL INJECTION SYSTEM Fault code No. Intake air temperature sensor: open or short circuit detected. (no Item normal signals are received from the intake air temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:05 Meter display Displays the intake air temperature.
Page 465 FUEL INJECTION SYSTEM Fault code No. Intake air temperature sensor: open or short circuit detected. (no Item normal signals are received from the intake air temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:05 Meter display Displays the intake air temperature.
Page 466 FUEL INJECTION SYSTEM Fault code No. Atmospheric pressure sensor: open or short circuit detected. (no Item normal signals are received from the atmospheric pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:02 Meter display Displays the atmospheric pressure.
Page 467 FUEL INJECTION SYSTEM Fault code No. Atmospheric pressure sensor: open or short circuit detected. (no Item normal signals are received from the atmospheric pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:02 Meter display Displays the atmospheric pressure.
Page 468 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
Page 469 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
Page 470 FUEL INJECTION SYSTEM Fault code No. Latch up detected. Item No normal signals are received from the lean angle sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
Page 471 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 472 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 473 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 474 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 475 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 476 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 477 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 478 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 479 FUEL INJECTION SYSTEM Fault code No. Injector: open circuit detected. (no normal signals are received from Item the injector.) Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 480 FUEL INJECTION SYSTEM Fault code No. Injector: open circuit detected. (no normal signals are received from Item the injector.) Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 481 FUEL INJECTION SYSTEM Fault code No. Injector: open circuit detected. (no normal signals are received from Item the injector.) Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 482 FUEL INJECTION SYSTEM Fault code No. Lean angle sensor: open or short circuit detected. (no normal sig- Item nals are received from the lean angle sensor.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
Page 483 FUEL INJECTION SYSTEM Fault code No. Lean angle sensor: open or short circuit detected. (no normal sig- Item nals are received from the lean angle sensor.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
Page 484 FUEL INJECTION SYSTEM Fault code No. A. no normal signals are received from the rear wheel sensor. B. open or short circuit is detected in the neutral circuit of the Item neutral switch. C. open or short circuit is detected in the clutch circuit of the clutch switch.
Page 485 FUEL INJECTION SYSTEM A. Rear wheel sensor system malfunction Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect it Connection of rear wheel Check in the diagnostic code sensor (meter) coupler securely, or repair/replace the (Code No.
Page 486 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure ECU malfunction Replace the ECU. Check in the diagnostic code (Code No. d07). With the rear wheel rotated, check the pulse input. Then, check the fault code indication.
Page 487 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Open or short circuit → Continuity of leads between Start the engine. neutral switch and relay unit Replace the wire harness. Ride the vehicle at a low coupler Sky blue–Sky blue speed (approx.
Page 488 FUEL INJECTION SYSTEM Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Poor connection → Connect it Connection of wire harness Start the engine. ECU coupler securely, or repair/replace the Ride the vehicle at a low Check the connection of the wire harness.
Page 489 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector, Item fuel pump and main relay. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:09, d:50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 d:09...
Page 490 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector, Item fuel pump and main relay. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:09, d:50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 d:09...
Page 491 FUEL INJECTION SYSTEM Fault code No. EEPROM cylinder fault code number: an error is detected while Item reading or writing on EEPROM (CO adjustment value). Under certain conditions Fail-safe system Under certain conditions Diagnostic code No. d:60 EEPROM fault code display •...
Page 492 FUEL INJECTION SYSTEM Fault code No. EEPROM cylinder fault code number: an error is detected while Item reading or writing on EEPROM (CO adjustment value). Under certain conditions Fail-safe system Under certain conditions Diagnostic code No. d:60 EEPROM fault code display •...
Page 493 FUEL INJECTION SYSTEM Fault code No. Item Incorrect voltage is supplied to the ECU. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Charging system malfunction Check the charging system.
Page 494 FUEL INJECTION SYSTEM Fault code No. Sub-throttle position sensor: open or short circuit detected. (no nor- Item mal signals are received from the sub-throttle position sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —...
Page 495 FUEL INJECTION SYSTEM Fault code No. Sub-throttle servo motor: stuck sub-throttle servo motor detected. Item signal from sub-throttle position sensor will not change. (sub-throt- tle servo motor will not start.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 496 FUEL INJECTION SYSTEM Fault code No. Sub-throttle servo motor: stuck sub-throttle servo motor detected. Item signal from sub-throttle position sensor will not change. (sub-throt- tle servo motor will not start.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 497 FUEL INJECTION SYSTEM Fault code No. Engine idling stop: engine has been left idling. (The ECU automati- Item cally stops the engine after 20 minutes if it is left idling.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 498 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU internal malfunction (output signal error): no signals are Item received from the ECU. Able to start engine (Unable if ECU Failure) Fail-safe system Able to drive vehicle (Unable if ECU Failure) Diagnostic code No. —...
Page 499 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —...
Page 500 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU internal malfunction (output signal error): data from the ECU Item cannot be received correctly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
Page 501 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU internal malfunction (input signal error): non-registered data Item has been received from the meter. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
Page 502 FUEL INJECTION SYSTEM EAS30660 DIAGNOSTIC CODE TABLE The following tables contain information about diagnostic code numbers that do not have a corre- sponding fault code number. (These items are not listed in “TROUBLESHOOTING DETAILS”.) Diag- nostic Item Meter display/Actuation Procedure code d:48 Air induction system sole-...
Page 503 FUEL INJECTION SYSTEM Diag- nostic Item Meter display/Actuation Procedure code d:63 Malfunction code reinstate- ment (for fault code No. d24 only) • No malfunction code — • Malfunction code exists Fault code No. d24 To reinstate, set the engine • (If more than one code stop switch from “...
Page 504 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-109...
Page 505 FUEL PUMP SYSTEM FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 19.Fuel pump 25.ECU (engine control unit) 56.Right handlebar switch 58.Engine stop switch...
Page 506 FUEL PUMP SYSTEM 8-111...
Page 507 FUEL PUMP SYSTEM FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 19.Fuel pump 25.ECU (engine control unit) 56.Right handlebar switch 58.Engine stop switch 86.Ignition fuse 8-112...
Page 508 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (FZ8SA) 4. Right inner panel (FZ8SA) 5. Left side panel (FZ8SA) 6.
Page 509 FUEL PUMP SYSTEM 7. Check the entire fuel pump sys- NG→ tem’s wiring. Properly connect or repair the fuel Refer to “CIRCUIT DIAGRAM” on pump system’s wiring. page 8-109. OK↓ Replace the ECU. 8-114...
Page 510 IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-115...
Page 511 IMMOBILIZER SYSTEM FZ8NA 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.ECU (engine control unit) 43.Meter assembly 44.Immobilizer system indicator light 48.Multi-function meter 85.Ignition fuse...
Page 512 IMMOBILIZER SYSTEM 8-117...
Page 513 IMMOBILIZER SYSTEM FZ8SA 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.ECU (engine control unit) 43.Meter assembly 44.Immobilizer system indicator light 48.Multi-function meter 86.Ignition fuse 8-118...
Page 514 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 515 IMMOBILIZER SYSTEM EAS27691 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
Page 516 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 517 IMMOBILIZER SYSTEM Standard key registration i. Registration mode a. Main switch “ON” b. Main switch “OFF” A. Registration of the second standard key is c. LED on complete. d. LED off B. Immobilizer system indicator light stops e. Less than 5.0 s flashing when the registration of the second f.
Page 518 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 8-185.
Page 519 IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code.
Page 520 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was Register another UNIT tion malfunction. attempted to be regis- standard key. tered two consecutive times. Undefinition code is Noise interference or dis- 1. Check the wire received.
Page 521 IMMOBILIZER SYSTEM 8-126...
Page 522 ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-127...
Page 523 ABS (ANTI-LOCK BRAKE SYSTEM) FZ8NA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 25.ECU (engine control unit) 43.Meter assembly 48.Multi-function meter 53.ABS warning light 56.Right handlebar switch...
Page 524 ABS (ANTI-LOCK BRAKE SYSTEM) 8-129...
Page 525 ABS (ANTI-LOCK BRAKE SYSTEM) FZ8SA 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 25.ECU (engine control unit) 43.Meter assembly 48.Multi-function meter 53.ABS warning light 56.Right handlebar switch 57.Front brake light switch 58.Engine stop switch...
Page 526 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 8-131...
Page 527 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly (ABS ECU) 2. ABS warning light 3. Rear wheel sensor rotor 4. Rear wheel sensor 5. Front wheel sensor 6. Front wheel sensor rotor 7. ABS test coupler 8. Fuse box 1 8-132...
Page 528 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART 8-133...
Page 529 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS test coupler 4. Front wheel sensor coupler 5. ABS ECU coupler 8-134...
Page 530 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake pipes that are con- nected to the assembly as a set. •...
Page 531 ABS (ANTI-LOCK BRAKE SYSTEM) Self-diagnosis and servicing The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the ABS ECU also stores the malfunction history. The multi-function display indicates all the fault codes recorded in the ABS ECU. Note all of the indicated fault codes if more than two fault codes are stored in the memory.
Page 532 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-137...
Page 533 ABS (ANTI-LOCK BRAKE SYSTEM) EWA4B56008 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[D-3] FINAL CHECK” on page 8-174.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
Page 534 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56016 [B-4] THE ABS WARNING LIGHT COMES ON FOR 2 SECONDS, THEN GOES OFF Remove the protective cap from the ABS test coupler “1”, and then connect the test coupler adapter “2” to the coupler. The T/C terminal (sky blue) is now grounded. 1.
Page 535 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56017 [B-5] MALFUNCTION ARE CURRENTLY DETECTED Connect the test coupler adapter to the ABS test coupler. When the test coupler adapter is connected to the ABS test coupler, the fault codes will be displayed in the multi-function display. Record all of the displayed fault codes. 1.
Page 536 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56020 [C-3] THE ABS WARNING LIGHT REMAINS ON 1. The battery voltage is low. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-186. • If the battery voltage is low, clean the battery terminals and recharge it, or replace the battery. 2.
Page 537 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56022 [C-5] DIAGNOSIS USING THE FAULT CODES Connect the test coupler adapter to the ABS test coupler, and then turn the main switch to “ON”. Information for the fault codes from the ABS ECU is contained in the following table. Refer to this table for troubleshooting.
Page 538 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Brake light signal is not received prop- • Brake light bulbs erly while vehicle is traveling (brake ABS_24 • Wire harness (brake light circuit) light circuit, or front or rear brake light •...
Page 539 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Hydraulic unit sensor power monitor cir- ABS_56 • Hydraulic unit assembly cuit is abnormal. • Front wheel sensor lead ABS_63 Front wheel sensor power is abnormal. • Wire harness • Hydraulic unit assembly •...
Page 540 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_11 Front wheel sensor signal is not received prop- Fault code No. Symptom ABS_25 erly. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 541 ABS (ANTI-LOCK BRAKE SYSTEM) Rear wheel sensor signal is not received prop- Fault code No. ABS_12 Symptom erly. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 542 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_13 Incorrect signal from the front wheel sensor is Fault code No. Symptom ABS_26 detected. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 543 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_14 Incorrect signal from the rear wheel sensor is Fault code No. Symptom ABS_27 detected. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 544 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Wire harness continuity. • Check for continuity between the blue terminal “1” and the blue terminal “3”...
Page 545 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault...
Page 546 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_16 Symptom No continuity in the rear wheel sensor circuit. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Wire harness continuity. • Check for continuity between the white terminal “1” and the white terminal “3”...
Page 547 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_16 Symptom No continuity in the rear wheel sensor circuit. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and rear wheel sensor coupler, and then delete the fault...
Page 548 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_18 Missing pulses detected in the rear wheel sen- Fault code No. Symptom ABS_46 sor signal. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel bearings, Check the components for loose- •...
Page 549 ABS (ANTI-LOCK BRAKE SYSTEM) Start switch signal is not received properly Fault code No. ABS_22 Symptom (start switch circuit or start switch monitor cir- cuit). Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Engine startability. Check the electric starting sys- •...
Page 550 ABS (ANTI-LOCK BRAKE SYSTEM) Brake light signal is not received properly while Fault code No. ABS_24 Symptom vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method...
Page 551 ABS (ANTI-LOCK BRAKE SYSTEM) Solenoid relay is defective. Fault code No. ABS_31 Symptom Power is not supplied to the solenoid relay. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Battery voltage Recharge or replace the battery. Turn the main Refer to “CHECKING AND switch to “ON”...
Page 552 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_32 Symptom Hydraulic unit solenoid relay is short-circuited. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Short circuit in solenoid relay. Replace the hydraulic unit assem- • Turn the main bly.
Page 553 ABS (ANTI-LOCK BRAKE SYSTEM) ABS motor is defective. Fault code No. ABS_33 Symptom Power is not supplied to the ABS motor. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Battery voltage Recharge or replace the battery. •...
Page 554 ABS (ANTI-LOCK BRAKE SYSTEM) Hydraulic unit ABS motor relay is short-cir- Fault code No. ABS_34 Symptom cuited. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Short circuit in ABS motor relay. Replace the hydraulic unit assem- •...
Page 555 ABS (ANTI-LOCK BRAKE SYSTEM) Front wheel will not recover from the locking tendency even though the signal is continu- Fault code No. ABS_41 Symptom ously transmitted from the ABS ECU to release the hydraulic pressure (when the battery volt- age is normal) Reinstatement Item/components and probable Order...
Page 556 Brake lines • Check the brake lines for kinks and deterioration. EWA4B56009 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake...
Page 557 ABS (ANTI-LOCK BRAKE SYSTEM) • If the brake pipe inlet and outlet connections are incorrect on the hydraulic unit, the front brake lever will be pulled to its full-stroke position without responding, and then it will be pushed back slowly without pulsating when the final check on page “[D-3] FINAL CHECK” on page 8-174 is per- formed.
Page 558 (particularly between the hydraulic unit and the rear brake caliper). EWA4B56009 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
Page 559 ABS (ANTI-LOCK BRAKE SYSTEM) Rear wheel will not recover from the locking ten- ABS_42 dency even though the signal is continuously Fault code No. Symptom ABS_47 transmitted from the ABS ECU to release the hydraulic pressure. Reinstatement Item/components and probable Order Check or maintenance job confirmation...
Page 560 ABS (ANTI-LOCK BRAKE SYSTEM) Incorrect signal from the front wheel sensor is Fault code No. ABS_43 Symptom detected. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 561 ABS (ANTI-LOCK BRAKE SYSTEM) Incorrect signal from the rear wheel sensor is Fault code No. ABS_44 Symptom detected. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Installed condition of wheel sensor. Check for looseness. Repair or •...
Page 562 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_53 Symptom Power voltage is too low. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Battery voltage Recharge or replace the battery. • Turn the main Refer to “CHECKING AND switch to “ON”...
Page 563 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_54 Symptom Power voltage is too low. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Battery voltage Recharge or replace the battery. • Turn the main Refer to “CHECKING AND switch to “ON”...
Page 564 ABS (ANTI-LOCK BRAKE SYSTEM) Hydraulic unit sensor power monitor circuit is Fault code No. ABS_56 Symptom abnormal. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Defective internal monitor circuit (sen- Replace the hydraulic unit assem- • Turn the main sor power).
Page 565 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_63 Symptom Front wheel sensor power is abnormal. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Short circuit in wire harness. • Check that there is no short cir- Turn the main cuit between the blue terminal switch to “ON”...
Page 566 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_64 Symptom Rear wheel sensor power is abnormal. Reinstatement Item/components and probable Order Check or maintenance job confirmation cause method Short circuit in wire harness. • Check that there is no short cir- Turn the main cuit between the white/red ter- switch to “ON”...
Page 567 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56023 [D-1] DELETING THE FAULT CODES ECA4B56026 Since the fault codes remain in the memory of the ABS ECU until they are deleted, always delete the fault codes after the ser- vice has been completed. 1. Connect the test coupler adapter “1” to the ABS test coupler “2”.
Page 568 ABS (ANTI-LOCK BRAKE SYSTEM) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester (DC 20 V) to the ABS ECU coupler. Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 • Positive tester probe → b. Check for continuity between the ABS ECU Brown/white “1”...
Page 569 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4B56024 [D-3] FINAL CHECK Checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-14. 2. Check the wheel sensor housings and wheel sensors for proper installation. Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)”...
Page 570 ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 8-175...
Page 571 ELECTRICAL COMPONENTS 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Ignition coil 6. Fuse box 2 7. Main fuse 8. Battery 9. Fuse box 1 10.Fuel injection system fuse 11.Starter relay 12.Rear brake light switch 13.O sensor 14.Sidestand switch...
Page 572 ELECTRICAL COMPONENTS 8-177...
Page 573 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. ECU (engine control unit) 3. Intake air pressure sensor 4. Fuel pump 5. Atmospheric pressure sensor 6. Relay unit 7. Lean angle sensor 8. Turn signal/hazard relay 9. Headlight relay 10.Radiator fan motor relay 11.Rear wheel sensor 12.Coolant temperature sensor 13.Crankshaft position sensor...
Page 574 ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES 8-179...
Page 575 ELECTRICAL COMPONENTS FZ8NA 1. Clutch switch 2. Pass switch 3. Dimmer switch 4. Hazard switch 5. Turn signal switch 6. Horn switch 7. Main switch 8. Oil level switch 9. Sidestand switch 10.Front brake light switch 11.Engine stop switch 12.Start switch 13.Neutral switch...
Page 576 ELECTRICAL COMPONENTS 8-181...
Page 577 ELECTRICAL COMPONENTS FZ8SA 1. Clutch switch 2. Pass switch 3. Dimmer switch 4. Hazard switch 5. Turn signal switch 6. Horn switch 7. Main switch 8. Oil level switch 9. Sidestand switch 10.Front brake light switch 11.Engine stop switch 12.Start switch 13.Neutral switch 14.Rear brake light switch 8-182...
Page 578 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 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 579 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 580 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace The following procedure applies to all of the the fuse.
Page 581 ELECTRICAL COMPONENTS ignition systems to malfunction and could appropriate charging method. If the bat- possibly cause a fire. tery is overcharged, the electrolyte level will drop considerably. Therefore, take ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ special care when charging the battery. 4. Install: • Rider seat Since VRLA (Valve Regulated Lead Acid) bat- Refer to “GENERAL CHASSIS”...
Page 582 ELECTRICAL COMPONENTS voltage when the positive battery terminal is EWA13300 WARNING disconnected). • No charging is necessary when the open-cir- Do not quick charge a battery. cuit voltage equals or exceeds 12.8 V. ECA13671 b. Check the charge of the battery, as shown •...
Page 583 ELECTRICAL COMPONENTS f. If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the volt- age to obtain the standard charging cur- rent.
Page 584 ELECTRICAL COMPONENTS 7. Connect: Starter relay • Battery leads (to the battery terminals) ECA13630 First, connect the positive battery lead “1”, and then the negative battery lead “2”. 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4.
Page 585 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Radiator fan motor relay 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 1. Positive battery terminal 4. Negative tester probe 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3”...
Page 586 ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. The pocket tester or the analog pocket tester c.
Page 587 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Continuity a. Disconnect the relay unit coupler from the Positive tester probe wire harness. Sky blue “1” b. Connect the pocket tester (Ω × 1) to the Negative tester probe relay unit terminal as shown. Yellow/black “2” c.
Page 588 ELECTRICAL COMPONENTS 2. Check: • Secondary coil resistance Out of specification → Replace. Secondary coil resistance 8.50–11.50 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1 k) to the ignition coil as shown. Pocket tester 2. Ignition coil 90890-03112 Analog pocket tester b.
Page 589 ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor resistance. c. Set the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. When turn the lean angle sensor to 65°. EAS28131 e. Measure the lean angle sensor output volt- CHECKING THE LEAN ANGLE SENSOR age.
Page 590 ELECTRICAL COMPONENTS EAS28150 EAS28170 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1. Disconnect: 1. Check: • Stator coil coupler • Rectifier/regulator input voltage Out of specification → Correct the stator (from the wire harness) 2. Check: coil condition. • Stator coil resistance Refer to “CHECKING THE STATOR Out of specification →...
Page 591 ELECTRICAL COMPONENTS 2. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rectifier/regulator output voltage a. Disconnect the horn leads from the horn Out of specification → Replace the recti- terminals. fier/regulator. b. Connect the digital circuit tester to the horn terminals. Rectifier/regulator output volt- Digital circuit tester 14.2–14.8 V 90890-03174 Model 88 Multimeter with...
Page 592 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Sender unit resistance (full) a. Connect the pocket tester (Ω × 100) to the 19.0–21.0 Ω oil level switch terminal as shown. Sender unit resistance (empty) 139.0–141.0 Ω Pocket tester 90890-03112 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Analog pocket tester a. Connect the pocket tester (Ω × 10) to the YU-03112-C fuel sender terminals as shown.
Page 593 ELECTRICAL COMPONENTS 2. Check: • Coolant temperature sensor resistance Out of specification → Replace. Coolant temperature sensor resistance 2.45 kΩ at 20 °C (68 °F) 290–354 Ω at 80 °C (176 °F) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 1 k/ × 100) EAS28250 CHECKING THE RADIATOR FAN MOTORS to the coolant temperature sensor as...
Page 594 ELECTRICAL COMPONENTS 3. Install: d. While slowly turning the throttle position • Coolant temperature sensor sensor shaft, check that the throttle posi- tion sensor resistance is within the speci- Coolant temperature sensor fied range. 18 Nm (1.8 m·kgf, 13 ft·lbf) The resistance does not change or it changes abruptly →...
Page 595 ELECTRICAL COMPONENTS c. Connect the pocket tester (Ω × 1 k) to the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ sub-throttle position sensor as shown. a. Remove the air induction system solenoid coupler from the air induction system sole- • Tester positive lead → noid. Green/yellow “3” b.
Page 596: Specifications
ELECTRICAL COMPONENTS b. Connect the digital circuit tester (DCV) to b. Connect the pocket tester (DC 20 V) to the the test harness S-pressure sensor 5S7 test harness-speed sensor (3P). (3P). Pocket tester Digital circuit tester 90890-03112 90890-03174 Analog pocket tester Model 88 Multimeter with YU-03112-C tachometer...
Page 597 ELECTRICAL COMPONENTS ECA16730 2. Check: • Intake air temperature sensor resistance Out of specification → Replace. Pay attention to the installing direction of the test harness S-pressure sensor 5S7 Intake air temperature sensor (3P) coupler. resistance b. Connect the digital circuit tester (DCV) to 5.40–6.60 kΩ...
Page 598 ELECTRICAL COMPONENTS 8-203...
Page 599: Engine
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 ..................9-3 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...
Page 600 TROUBLESHOOTING EAS28451 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • 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 601: Fuel System
TROUBLESHOOTING • Improper throttle cable free play Shift drum and shift forks • Flooded throttle body • Foreign object in a shift drum groove • Faulty air induction system • Seized shift fork • Bent shift fork guide bar Electrical system 1.
Page 602: Chassis
TROUBLESHOOTING 2. Engine oil EAS28610 OVERCOOLING • Incorrect oil level • Incorrect oil viscosity (high) Cooling system • Deteriorated oil 1. Thermostat • Thermostat stays open EAS30480 OVERHEATING EAS28620 POOR BRAKING PERFORMANCE Engine • Worn brake pad 1. Clogged coolant passages •...
Page 603: Troubleshooting
TROUBLESHOOTING 3. Front fork leg(s) Tail/brake light does not come on • Uneven oil levels (both front fork legs) • Wrong tail/brake light bulb • Unevenly tensioned fork spring (both • Too many electrical accessories front fork legs) • Incorrect connection •...
Page 604: Wiring Diagram
EAS28740 56. Right handlebar switch Black/Blue WIRING DIAGRAM 57. Front brake light switch Black/Red 58. Engine stop switch FZ8NA 2011 Black/White 59. Start switch 1. Main switch Black/Yellow 60. Rear brake light switch 2. Rectifier/regulator Br/G Brown/Green 61. Left handlebar switch 3.
Page 605 FZ8SA 2011 58. Engine stop switch Black/Red 59. Start switch 1. Main switch Black/White 60. Rear brake light switch 2. Rectifier/regulator Black/Yellow 61. Left handlebar switch 3. AC magneto Br/G Brown/Green 62. Clutch switch 4. Backup fuse Br/L Brown/Blue 63. Pass switch 5.
Page 606 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 607 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES FZ8NA FZ8NA FZ8NA FZ8NA DE FZ8NA...
Page 608 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES FZ8NA FZ8NA FZ8NA FZ8NA DE FZ8NA...
Page 609 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES FZ8SA FZ8SA FZ8SA FZ8SA DE FZ8SA...
Page 610 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES FZ8SA FZ8SA FZ8SA FZ8SA DE FZ8SA...

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