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Table of Contents
2006
FZ1-N(V)
FZ1-S(V)
SERVICE MANUAL
2D1-28197-E0

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Table of Contents

   Summary of Contents for Yamaha FZ1-N

  • Page 1 2006 FZ1-N(V) FZ1-S(V) SERVICE MANUAL 2D1-28197-E0...
  • Page 2 EAS20040 FZ1-N (V)/FZ1-S (V) SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd. First edition, December 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6.
  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION..................1-1 VEHICLE IDENTIFICATION NUMBER........... 1-1 MODEL LABEL..................1-1 FEATURES ....................1-2 FI SYSTEM ....................1-3 INSTRUMENT FUNCTIONS.................1-4 IMPORTANT INFORMATION ............... 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-8 REPLACEMENT PARTS ................ 1-8 GASKETS, OIL SEALS AND O-RINGS..........1-8 LOCK WASHERS/PLATES AND COTTER PINS ........1-8 BEARINGS AND OIL SEALS ..............1-9 CIRCLIPS ....................1-9 CHECKING THE CONNECTIONS .............1-10...
  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
  • Page 11: Features

    FEATURES EAS20170 FEATURES 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: Fi System

    FI SYSTEM ET2D1001 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 kg/cm , 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 13: Instrument Functions

    INSTRUMENT FUNCTIONS ET2D1002 kilometers and miles, press the “SELECT” INSTRUMENT FUNCTIONS button for at least one second. Multi-function meter unit Tachometer 1. Coolant temperature display/air intake tem- 1. Tachometer perature display 2. Tachometer red zone 2. Speedometer The electric tachometer allows the rider to 3.
  • Page 14 “ODO” and off for approximately 3 seconds. If this occurs, the tripmeter modes “TRIP A” and “TRIP B” in have a Yamaha dealer check the electrical cir- the following order: cuit. TRIP A → TRIP B → ODO → TRIP A...
  • Page 15 • When the key is turned to “ON”, the coolant to a Yamaha dealer and have the standard temperature is automatically displayed, even keys re-registered. if the air intake temperature was displayed If the display indicates any error codes, note prior to turning the key to “OFF”.
  • Page 16 INSTRUMENT FUNCTIONS 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” button. 3. Turn the key to “ON”, and then release the “SELECT” button after five seconds. 4. Push the “RESET” button to select the desired brightness level. 5.
  • Page 17: 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...
  • Page 18: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s 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 19: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog Pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
  • Page 20 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 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-13 90890-01426 YU-38411 Rod holder 4-50, 4-55 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-54 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 4-54 90890-01436 Universal damping rod bleeding tool set...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-11 90890-03081 Engine compression tester YU-33223 Valve spring compressor 5-23, 5-29 90890-04019 YM-04019 Valve spring compressor attachment 5-23, 5-29 90890-04108 Valve spring compressor adapter (22 mm) YM-04108 Valve spring compressor attachment 5-23, 5-29 90890-04114 Valve spring compressor adapter...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø4) 5-25 90890-04111 Valve guide remover (4.0 mm) YM-04111 Valve guide remover (ø4.5) 5-25 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø4) 5-25 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide installer (ø4.5) 5-25...
  • Page 24: Special Tools

    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No.1215 5-67, 6-12 (Three Bond No.1215®) 90890-85505 Digital circuit tester 7-9, 7-10 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum/pressure pump gauge set 90890-06756 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Fuel pressure adapter 90890-03176 YM-03176 Pressure gauge 3-14, 7-8 90890-03153 YU-03153 Camshaft wrench 5-11, 5-16 90890-04143 YM-04143 1-16...
  • Page 26 SPECIAL TOOLS 1-17...
  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS..............2-1 ENGINE SPECIFICATIONS................2-1 CHASSIS SPECIFICATIONS ............... 2-8 ELECTRICAL SPECIFICATIONS...............2-10 TIGHTENING TORQUES................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-12 ENGINE TIGHTENING TORQUES ............2-13 CHASSIS TIGHTENING TORQUES ............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE ....................2-20 CHASSIS ....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-23 ENGINE OIL LUBRICATION CHART ...........2-23 LUBRICATION DIAGRAMS ..............
  • Page 28: General Specifications

    3C39 (AUS) Dimensions Overall length 2140 mm (84.3 in) Overall width 770 mm (30.3 in) Overall height 1060 mm (41.7 in) (FZ1-N) 1205 mm (47.4 in) (FZ1-S) Seat height 815 mm (32.1 in) Wheelbase 1460 mm (57.5 in) Ground clearance 135 mm (5.31 in)
  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS Inner-rotor-to-outer-rotor-tip clearance 0.010–0.100 mm (0.0004–0.0039 in) Limit 0.18 mm (0.0071 in) Outer-rotor-to-oil-pump-housing clearance 0.090–0.150 mm (0.0035–0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.06–0.13 mm (0.0024–0.0051 in) Limit 0.20 mm (0.0079 in) Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) Relief valve operating pressure 600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80...
  • Page 30 ENGINE SPECIFICATIONS Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links RH2020/122 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.21–0.25 mm (0.0083–0.0098 in) Valve dimensions Valve head diameter A (intake) 23.40–23.60 mm (0.9213–0.9291 in) Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in)
  • Page 31 ENGINE SPECIFICATIONS Limit 4.425 mm (0.1742 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in) Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.550 mm (0.1791 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust)
  • Page 32 ENGINE SPECIFICATIONS Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in) Piston ring Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Ring side clearance...
  • Page 33 ENGINE SPECIFICATIONS Journal oil clearance (using plastigauge®) 0.014–0.037 mm (0.0006–0.0015 in) Bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit...
  • Page 34 ENGINE SPECIFICATIONS Idling condition Engine idling speed 1100–1300 r/min Intake vacuum 30.0 kPa (8.9 inHg) (225 mmHg) 95.0–105.0 °C (203.00–221.00 °F) Water temperature 80.0–90.0 °C (176.00–194.00 °F) Oil temperature Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
  • Page 35: Chassis Specifications

    Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) Loading condition 90–196 kg (198–432 lb) (FZ1-N) 90–190 kg (198–419 lb) (FZ1-S) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
  • Page 36 CHASSIS SPECIFICATIONS Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.20 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal free play 4.3–9.3 mm (0.17–0.37 in) Rear disc brake...
  • Page 37: Electrical Specifications

    1.12 A Headlight Bulb type Halogen bulb Bulb voltage, wattage × quantity 12 V, 60 W/55.0 W × 1 (FZ1-N) Headlight 12 V, 60 W/55.0 W × 2 (FZ1-S) 12 V, 5.0 W × 2 Auxiliary light 12 V, 5.0 W/21.0 W × 1 Tail/brake light 12 V, 10.0 W ×...
  • Page 38 Model/manufacturer 5VY/SOMIC ISHIKAWA Servo motor Model/manufacturer 2D1/YAMAHA Fuses Main fuse 50.0 A Headlight fuse 15.0 A (FZ1-N) 25.0 A (FZ1-S) Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A 10.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A...
  • Page 39: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
  • Page 40: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head nut See NOTE Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft caps bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Cylinder head stud bolt (exhaust...
  • Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head and exhaust pipe 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) EXUP pulley and shaft arm nut 7 Nm (0.7 m·kg, 5.1 ft·lb) EXUP valve pulley cover bolt 14 Nm (1.4 m·kg, 10 ft·lb) EXUP cable nut...
  • Page 42 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch spring bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Use a lock washer Drive sprocket nut 85 Nm (8.5 m·kg, 61 ft·lb) Bearing plate bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Shift fork stopper plate bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Stopper screw...
  • Page 43 TIGHTENING TORQUES 2-16...
  • Page 44: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut 113 Nm (11.3 m·kg, 82 ft·lb) Upper handlebar holder bolt 24 Nm (2.4 m·kg, 17 ft·lb) Lower handlebar holder nut 32 Nm (3.2 m·kg, 23 ft·lb) Lower bracket pinch bolt...
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake hose holder screw 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt (front) 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt (rear) 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bracket screw 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank cap bolt...
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch cable adjust nut 7 Nm (0.7 m·kg, 5.1 ft·lb) NOTE: 1 First, tighten the ring nut to approximately 52 Nm (5.2 m•kg, 38 ft•lb) with a torque wrench, then loosen the lower ring nut completely. 2 Retighten the lower ring nut 18 Nm (1.8 m•kg, 13 ft•lb).
  • Page 47: Lubrication Points And Lubricant Types

    Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No. 1215 Crankcase mating surface Yamaha bond No. 1215 Clutch cover (crankcase mating surface) Yamaha bond No.
  • Page 48 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Pickup rotor cover Yamaha bond No. 1215 2-21...
  • Page 49: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Engine mount bolts (front left and right) Relay arm, connecting rod and rear shock absorber collar Pivot shaft...
  • Page 50: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23...
  • Page 51 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.Piston cooler 14.Chain tensioner...
  • Page 52: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-26...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 55 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 2-28...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 57 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 2-30...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-32...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-34...
  • Page 62: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 63 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-36...
  • Page 64 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 65 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-38...
  • Page 66: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-39...
  • Page 67 CABLE ROUTING 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Horn stay assembly 7. Throttle cable (pull side) 8. Throttle cable (return side) 9. Wire harness 10.Brake hose 11.Throttle cables 12.Right handlebar switch lead A.
  • Page 68 CABLE ROUTING 2-41...
  • Page 69 CABLE ROUTING M. Pass the radiator fan motor lead (right) 1. Wire harness above the coolant reservoir hose and route 2. Right handlebar switch lead it to the inside of the frame. 3. Throttle cable N. Pass the coolant reservoir hose to the vehi- 4.
  • Page 70 CABLE ROUTING 2-43...
  • Page 71 CABLE ROUTING H. Route the hose assembly 1 by the vehicle 1. Clutch cable front side where the water pump inlet pipe 2. Water pump breather hose is routed. For the hose tip position, route 3. Oil level switch lead the hose so that 10 mm (0.39 in) or more 4.
  • Page 72 CABLE ROUTING 2-45...
  • Page 73 CABLE ROUTING AF.The coolant reservoir tank drain hose shall cross with the speed sensor lead under the rear arm bracket. The coolant reservoir tank drain hose shall be positioned above the vehicle. 2-46...
  • Page 74 CABLE ROUTING 2-47...
  • Page 75 CABLE ROUTING 53.Direct ignition coil lead 1. Throttle cables 54.Speed sensor lead 2. Right handlebar switch lead 55.Lean angle sensor lead 3. Wire harness 56.Battery box 4. Throttle cable (pull side) 57.Turn signal light relay lead 5. Throttle cable (return side) 58.Rear frame 6.
  • Page 76 CABLE ROUTING 2-49...
  • Page 77 CABLE ROUTING AJ.Clamp each lead at the positioning taping Q. Pass the turn signal light lead (right) and section (white) and then insert it to the license plate light lead under the rear cover. (In random order) fender bracket and route between the ribs of the battery box.
  • Page 78 CABLE ROUTING 2-51...
  • Page 79 CABLE ROUTING FZ1-S 1. Clutch cable 2. Left handlebar switch lead 3. Immobilizer lead 4. Main switch lead 5. Protector 6. Throttle cables 7. Right handlebar switch lead 8. Throttle cable (pull side) 9. Throttle cable (return side) 10.Bracket 11.Wire harness 12.Turn signal light lead 13.Seat lock cable 14.Tail/brake light lead...
  • Page 80 CABLE ROUTING 2-53...
  • Page 81 CABLE ROUTING 1. Fuel tank 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Clip 5. Air filter bracket 6. 3 way connector 7. Hose 8. Fuel hose 9. Damper 10.Collar 11.Fuel tank bracket 12.O-ring 13.Fuel pump A. Hook the cover pawl to the fuel tank bracket.
  • Page 82 CABLE ROUTING 2-55...
  • Page 83: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-6 ADJUSTING THE EXHAUST GAS VOLUME.........3-8 ADJUSTING THE ENGINE IDLING SPEED ..........3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-9 CHECKING THE SPARK PLUGS............
  • Page 84 LUBRICATING THE CENTERSTAND (FZ1-S) ........3-34 LUBRICATING THE REAR SUSPENSION ..........3-34 ELECTRICAL SYSTEM................3-35 CHECKING AND CHARGING THE BATTERY........3-35 CHECKING THE FUSES..............3-35 REPLACING THE HEADLIGHT BULBS..........3-35 ADJUSTING THE HEADLIGHT BEAM ..........3-36...
  • Page 86: Periodic Maintenance

    • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READ-...
  • Page 87 PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 • Check chain slack, alignment and condition. Every 1000 km and after wash- Drive chain • Adjust and lubricate chain with a ing the motorcycle or riding in special O-ring chain lubricant thor- the rain...
  • Page 88 PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 • Check the air cut-off valve, reed Air induction valve, and hose for damage. ✓ ✓ ✓ ✓ ✓ system • Replace the entire air induction sys- tem if necessary.
  • Page 89: Engine

    ENGINE EAS20470 • Valve clearance ENGINE Out of specification → Adjust. Valve clearance (cold) EAS20490 ADJUSTING THE VALVE CLEARANCE Intake valve The following procedure applies to all of the 0.11–0.20 mm (0.0043–0.0079 valves. Exhaust valve NOTE: • Valve clearance adjustment should be made 0.21–0.25 mm (0.0083–0.0098 on a cold engine, at room temperature.
  • Page 90 ENGINE 6. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. Valve lapper 90890-04101 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
  • Page 91: Synchronizing The Throttle Bodies

    ENGINE If the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062in) g. Install the exhaust and intake camshafts, d. Calculate the sum of the values obtained in timing chain and camshaft caps. steps (b) and (c) to determine the required valve pad thickness and the valve pad Camshaft cap bolt number.
  • Page 92 ENGINE Refer to "GENERAL CHASSIS" on page 4- • Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel tank a. With throttle body #3 as standard, adjust Refer to "FUEL TANK" on page 7-1. throttle bodies #1, #2, and #4 using the air 3.
  • Page 93: Adjusting The Exhaust Gas Volume

    ENGINE Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: • Throttle cable free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" on page 3-9. Throttle cable free play (at the flange of the throttle grip) 4.
  • Page 94: Adjusting The Engine Idling Speed

    ENGINE 8. Simultaneously press the “SELECT” and Throttle cable free play “RESET” buttons to return to the cylinder (at the flange of the throttle selection (step 5). grip) 9. Turn the main switch to “OFF” to cancel the 3.0–5.0 mm (0.12–0.20 in) mode.
  • Page 95: Checking The Spark Plugs

    ENGINE 6. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.6–0.7 mm (0.0236–0.0276 in) c. Tighten the locknut. EW2D1001 WARNING After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.
  • Page 96: Checking The Engine Oil Level

    ENGINE ECA13340 NOTE: CAUTION: The difference in compression pressure Before removing the spark plugs, use com- between cylinders should not exceed 100 kPa pressed air to blow away any dirt accumu- (1 kg/cm², 1 bar, 14.22 psi). lated in the spark plug wells to prevent it c.
  • Page 97: Changing The Engine Oil

    ENGINE Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmo- spheric temperatures. API standard SE or higher grade ACEA standard G4 or G5 ECA13360 4. Start the engine, warm it up for several CAUTION: minutes, and then turn it off.
  • Page 98: Measuring The Engine Oil Pressure

    ENGINE 5. If the oil filter cartridge is also to be 8. Fill: replaced, perform the following procedure. • Crankcase (with the specified amount of the recom- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil mended engine oil) filter wrench “2”.
  • Page 99: Adjusting The Clutch Cable Free Play

    ENGINE to measure the engine oil pressure after NOTE: warming up the engine. Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and 3. Remove: • Oil gallery bolt “1” viscosity, the oil pressure may fluctuate when measuring.
  • Page 100: Replacing The Air Filter Element

    ENGINE 2. Adjust • Clutch cable free play ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS20960 Handlebar side REPLACING THE AIR FILTER ELEMENT a. Turn the adjusting dial “1” in direction “b” or 1. Remove: “c” until the specified clutch cable free play • Rider and passenger seat is obtained.
  • Page 101: Checking The Throttle Body Joints

    ENGINE 4. Install: 1. Remove: • Air filter case cover • Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4- ECA14400 CAUTION: • Fuel tank Never operate the engine without the air fil- ter element installed. Unfiltered air will Refer to "FUEL TANK"...
  • Page 102: Checking The Exhaust System

    ENGINE Refer to "FUEL TANK" on page 7-1. Exhaust pipe nut 2. Check: 20 Nm (2.0 m·kg, 14 ft·lb) • Crankcase breather hose “1” Exhaust pipe and exhaust pipe Cracks/damage → Replace. bracket bolt Loose connection → Connect properly. 20 Nm (2.0 m·kg, 14 ft·lb) ECA13450 Exhaust pipe and muffler bolt CAUTION:...
  • Page 103: Checking The Exup Servo Motor

    ENGINE 2. Check: • EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”. Refer to "FUEL INJECTION SYSTEM" on page 8-31. b. Set the engine stop switch to “ ”. c. Check that the EXUP valve operates prop- erly.
  • Page 104: Checking The Cooling System

    ENGINE • Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level. ECA13470 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant.
  • Page 105 ENGINE 7. Drain: 4. Drain: • Coolant • Coolant (from the water pump inlet pipe and outlet (from the coolant reservoir) pipe) 5. Remove: 8. Check: • Radiator cap “1” • Copper washers “1” EWA13030 WARNING 9. Install: • Coolant drain bolts “2” A hot radiator is under pressure.
  • Page 106 ENGINE Coolant is potentially harmful and should NOTE: be handled with special care. Before checking the coolant level, wait a few EWA13040 minutes until the coolant has settled. WARNING 18. Install: • If coolant splashes in your eyes, thor- • Rider and passenger seat oughly wash them with water and consult Refer to "GENERAL CHASSIS"...
  • Page 107: Chassis

    CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position EAS21160 ADJUSTING THE FRONT DISC BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Adjust: a. Loosen the locknut “1”. • Brake lever position b. Turn the adjusting bolt “2” in direction “a” or (distance “a”...
  • Page 108: Checking The Brake Fluid Level

    CHASSIS EAS21240 the brake fluid and could cause vapor CHECKING THE BRAKE FLUID LEVEL lock. 1. Stand the vehicle on a level surface. ECA13540 NOTE: CAUTION: • Place the vehicle on a suitable stand. Brake fluid may damage painted surfaces •...
  • Page 109: Checking The Front Brake Hoses

    CHASSIS EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • Brake hose “1” Cracks/damage/wear → Replace. 2. Check: • Brake hose clamp “2” Loose Connection → Tighten the clamp bolt.
  • Page 110: Bleeding The Hydraulic Brake System

    CHASSIS nut “2” in direction “a” or “b” until the rear c. Connect a clear plastic hose “1” tightly to brake light comes on at the proper time. the bleed screw “2”. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later.
  • Page 111: Adjusting The Shift Pedal

    CHASSIS EWA13110 NOTE: WARNING Place the vehicle on a suitable stand so that After bleeding the hydraulic brake system, the rear wheel is elevated. check the brake operation. 2. Spin the rear wheel several times and find ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the tightest position of drive chain. 3.
  • Page 112: Lubricating The Drive Chain

    CHASSIS d. Tighten both locknuts to specification. Refer to "STEERING HEAD" on page 4-57. 4. Adjust: Locknut • Steering head 16 Nm (1.6 m·kg, 12 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring e. Tighten the wheel axle nut to specification. nut “2”, and the rubber washer “3”.
  • Page 113: Checking The Front Fork

    CHASSIS d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to "STEERING HEAD" on page 4-57. e.
  • Page 114: Adjusting The Front Fork Legs

    CHASSIS EWA13120 EWA13150 WARNING WARNING Securely support the vehicle so that there • Always adjust both front fork legs evenly. is no danger of it falling over. Uneven adjustment can result in poor handling and loss of stability. 2. Check: •...
  • Page 115 CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (Right side front fork) Compression damping (Left side front fork) EC2D1006 CAUTION: ECA13590 CAUTION: • Never go beyond the maximum or mini- • Never go beyond the maximum or mini- mum adjustment positions. mum adjustment positions. •...
  • Page 116: Adjusting The Rear Shock Absorber Assembly

    CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping EAS21620 ADJUSTING THE REAR SHOCK ECA13590 ABSORBER ASSEMBLY CAUTION: EWA13120 Never go beyond the maximum or minimum WARNING adjustment positions. Securely support the vehicle so that there 1. Adjust: is no danger of it falling over. •...
  • Page 117: Checking The Tires

    EAS21650 CHECKING THE TIRES Basic weight (with oil and a full The following procedure applies to both of the fuel tank) tires. FZ1-N 1. Check: 214kg (472lb) • Tire pressure FZ1-S Out of specification → Regulate. 220kg (485lb) Loading condition* 0–90 kg (0–198 lb)
  • Page 118 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. 1. Tire tread depth Front tire 2.
  • Page 119: Checking The Wheels

    CHASSIS EAS21670 EAS21710 CHECKING THE WHEELS LUBRICATING THE PEDAL The following procedure applies to both of the Lubricate the pivoting point and metal-to-metal wheels. moving parts of the pedal. 1. Check: Recommended lubricant • Wheel Damage/out-of-round → Replace. Lithium - soap - based grease EWA13260 WARNING EAS21720...
  • Page 120 A. FZ1-N EAS21780 REPLACING THE HEADLIGHT BULBS B. FZ1-S 1. Remove: 4. Remove: • Headlight side cover bolts “1” (FZ1-N) • Headlight bulb cover “1” (FZ1-S) 2. Disconnect: 5. Remove: • Headlight sub-wire harness coupler “2” • Headlight bulb holder “1”...
  • Page 121 Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. A. FZ1-N B. FZ1-S EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
  • Page 122 ELECTRICAL SYSTEM A. FZ1-N B. FZ1-S ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-37...
  • Page 123 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE COVER............... 4-7 INSTALLING THE COVER ..............4-7 FRONT WHEEL .................... 4-8 REMOVING THE FRONT WHEEL ............4-10 CHECKING THE FRONT WHEEL............4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-11 INSTALLING THE FRONT WHEEL (DISC) ..........4-12 REAR WHEEL ....................4-14 REMOVING THE REAR WHEEL (DISC) ..........
  • Page 124 REMOVING THE HANDLEBAR ............4-45 CHECKING THE HANDLEBAR............4-45 INSTALLING THE HANDLEBAR ............4-45 FRONT FORK.....................4-48 REMOVING THE FRONT FORK LEGS ..........4-50 DISASSEMBLING THE FRONT FORK LEGS ........4-50 CHECKING THE FRONT FORK LEGS..........4-51 ASSEMBLING THE FRONT FORK LEGS ...........4-52 INSTALLING THE FRONT FORK LEGS ..........
  • Page 126 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Passenger seat Rider seat Battery band Battery cover Battery negative lead Battery positive lead Battery Battery seat For installation, reverse the removal procedure.
  • Page 127 GENERAL CHASSIS Removing the headlight and meter assembly (FZ1-N) Order Job/Parts to remove Q’ty Remarks Headlight side cover bolt (left and right) Headlight coupler Disconnect. Headlight sub-wire harness coupler Disconnect. Headlight assembly Headlight bracket Headlight side cover (left and right)
  • Page 128 GENERAL CHASSIS Removing the front cowling (FZ1-S) Order Job/Parts to remove Q’ty Remarks Inner panel Headlight assembly coupler Disconnect. Meter coupler Disconnect. Front cowling assembly Rear view mirror Cowling stay Meter assembly Headlight unit For installation, reverse the removal procedure.
  • Page 129 GENERAL CHASSIS Removing the rear fender (FZ1-N) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Mud guard assembly Rear fender Tail/brake light lead coupler Disconnect.
  • Page 130 GENERAL CHASSIS Removing the rear fender (FZ1-S) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Mud guard assembly Rear fender Tail/brake light lead coupler Disconnect.
  • Page 131 GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Intake air temperature sensor lead cou- Disconnect. pler Intake air temperature sensor Air filter case cover...
  • Page 132: General Chassis

    GENERAL CHASSIS EAS21840 REMOVING THE COVER 1. Remove: • Tail cover • Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1. Install: • Rear fender •...
  • Page 133 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Brake hose holder (left and right) Front brake caliper (left and right) Front wheel axle pinch bolt Front wheel axle Collar (left and right) Dust cover Front wheel Front brake disc (left and right)
  • Page 134 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassem- bly procedure.
  • Page 135: Front Wheel

    FRONT WHEEL EAS21900 Refer to "CHECKING THE TIRES" on page REMOVING THE FRONT WHEEL 3-32 and "CHECKING THE WHEELS" on 1. Stand the vehicle on a level surface. page 3-34. EWA13120 3. Measure: WARNING • Radial wheel runout “1” Securely support the vehicle so that there •...
  • Page 136: Adjusting The Front Wheel Static Balance

    FRONT WHEEL • Adjust the front wheel static balance with the brake disc installed. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Remove the wheel bearings “3” with a gen- a.
  • Page 137: Installing The Front Wheel (disc)

    FRONT WHEEL a. Install a balancing weight “1” onto the rim EAS22000 INSTALLING THE FRONT WHEEL (DISC) exactly opposite the heavy spot “X”. The following procedure applies to both of the NOTE: brake discs. Start with the lightest weight. 1. Lubricate: •...
  • Page 138 FRONT WHEEL EWA13490 WARNING Make sure the brake cable is routed prop- erly. NOTE: Make sure that there is enough space between the brake pads before installing the brake cali- pers onto the brake discs. 4-13...
  • Page 139 REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left) Adjusting block (right) Rear wheel Brake caliper bracket For installation, reverse the removal...
  • Page 140 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Coller (left and right) Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal procedure.
  • Page 141 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Coller Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassem- bly procedure. 4-16...
  • Page 142: Rear Wheel

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 143: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22120 CHECKING AND REPLACING THE REAR EAS22150 WHEEL SPROCKET ADJUSTING THE REAR WHEEL STATIC 1. Check: BALANCE • Rear wheel sprocket NOTE: More than 1/4 tooth “a” wear → Replace • After replacing the tire, wheel or both, the the rear wheel sprocket.
  • Page 144 REAR WHEEL EWA13500 WARNING Make sure the brake hose is routed prop- erly. 4-19...
  • Page 145: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw For installation, reverse the removal procedure.
  • Page 146 Q’ty Remarks Brake fluid Drain. Refer to "BLEEDING THE HYDRAU- LIC BRAKE SYSTEM" on page 3- Right rearview mirror (FZ1-N) Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder diaphragm Brake lever Front brake light switch lead coupler Disconnect.
  • Page 147 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 disassem- bly procedure. 4-22...
  • Page 148 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to "BLEEDING THE HYDRAU- LIC BRAKE SYSTEM" on page 3- Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal procedure.
  • Page 149 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassem- bly procedure. 4-24...
  • Page 150: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 151: Replacing The Front Brake Pads

    FRONT BRAKE NOTE: Brake pad lining thickness Tighten the brake disc bolts in stages and in a (inner) crisscross pattern. 4.5 mm (0.18 in) Limit Brake disc bolt 0.5 mm (0.02 in) 18 Nm (1.8 m·kg, 13 ft·lb) Brake pad lining thickness LOCTITE®...
  • Page 152: Removing The Front Brake Calipers

    FRONT BRAKE NOTE: NOTE: The arrow mark “a” on the brake pad spring Before removing the brake caliper, drain the must point in the direction of disc rotation. brake fluid from the entire brake system. 1. Remove: • Union bolt “1” •...
  • Page 153: Checking The Front Brake Calipers

    FRONT BRAKE c. Remove the brake caliper piston seals. EAS22410 d. Repeat the previous steps to force out the ASSEMBLING THE FRONT BRAKE CALI- right side pistons from the brake caliper. PERS EWA13620 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WARNING • Before installation, all internal brake com- EAS22390 CHECKING THE FRONT BRAKE CALIPERS ponents should be cleaned and lubricated...
  • Page 154: Removing The Front Brake Master Cylinder

    FRONT BRAKE “a” touches the projection “b” on the brake ECA13540 CAUTION: caliper. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM"...
  • Page 155: Checking The Front Brake Master Cylinder

    FRONT BRAKE EAS22520 ASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. 2. Remove: Recommended fluid •...
  • Page 156 FRONT BRAKE • When refilling, be careful that water does Brake hose union bolt not enter the brake master cylinder reser- 30 Nm (3.0 m·kg, 22 ft·lb) voir. Water will significantly lower the boiling point of the brake fluid and could EWA13530 cause vapor lock.
  • Page 157: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring For installation, reverse the removal procedure. 4-32...
  • Page 158 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to "BLEEDING THE HYDRAU- LIC BRAKE SYSTEM" on page 3- Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint...
  • Page 159 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Hose joint Bushing Brake master cylinder body For assembly, reverse the disassem- bly procedure. 4-34...
  • Page 160 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose Barke caliper For installation, reverse the removal procedure. 4-35...
  • Page 161 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassem- bly procedure.
  • Page 162: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 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 BRAKE preventive measures: DISCS" on page 4-25. •...
  • Page 163: Removing The Rear Brake Caliper

    REAR BRAKE a. Connect a clear plastic hose “1” tightly to Refer to "CHECKING THE BRAKE FLUID the bleed screw “2”. Put the other end of LEVEL" on page 3-23. the hose into an open container. 5. Check: • Brake pedal operation b.
  • Page 164: Checking The Rear Brake Caliper

    REAR BRAKE Scratches/wear → Replace the brake cali- per assembly. • Brake caliper body “3” Cracks/damage → Replace the brake cali- per assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a.
  • Page 165: Installing The Rear Brake Caliper

    REAR BRAKE EAS22670 • Brake caliper INSTALLING THE REAR BRAKE CALIPER Refer to "REPLACING THE REAR BRAKE 1. Install: PADS" on page 4-37. • Brake caliper “1” (temporarily) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) • Copper washers “2” Brake caliper bolt (rear) •...
  • Page 166: Removing The Rear Brake Master Cylinder

    REAR BRAKE 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 7. Check: EWA13520 • Brake pedal operation WARNING Soft or spongy feeling →...
  • Page 167 REAR BRAKE 5. Check: 2. Fill: • Brake pedal operation • Brake fluid reservoir Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- system. mended brake fluid) Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Recommended fluid 6.
  • Page 168: Handlebar

    Job/Parts to remove Q’ty Remarks Front cowling (FZ1-S) Refer to "GENERAL CHASSIS" on page 4-1. Rear view mirror (FZ1-N) Front brake light switch connector Disconnect. Front master cylinder bracket Front brake master cylinder assembly Right handlebar switch Throttle cable housing...
  • Page 169 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Handlebar Lower handlebar holder For installation, reverse the removal procedure. 4-44...
  • Page 170: Removing The Handlebar

    HANDLEBAR EAS22860 EAS22930 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. 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 171 HANDLEBAR Grip end 26 Nm (2.6 m·kg, 19 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Side the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
  • Page 172 HANDLEBAR NOTE: • Align the projections "a" on the handlebar switch with the holes "b" in the handlebar. • Threre should be 1–3 mm (0.04–0.12 in) of clearance “c” between the handlebar grip and the grip end. 10. Install: • Front brake master cylinder assembly •...
  • Page 173: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "CHECKING THE TIRES" Front brake calipers on page 3-32 and "CHECKING THE WHEELS" on page 3-34. Front fender Cap bolt Loosen.
  • Page 174 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Damper adjusting rod Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube For assembly, reverse the disassem-...
  • Page 175: Removing The Front Fork Legs

    FRONT FORK EAS22970 • Nut “3” REMOVING THE FRONT FORK LEGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to both of the a. Press down on the spacer with the fork front fork legs. spring compressor “4”. NOTE: b. Install the rod holder “5” between the nut Each front fork leg is eqipped with a spring “3”...
  • Page 176: Checking The Front Fork Legs

    FRONT FORK A. Compression side B. Rebound side NOTE: While holding the damper rod with the damper rod holder “1”, loosen the damper rod assem- bly bolt. Damper rod holder 90890-01423 Damping rod holder YM-01423 3. Remove: • Oil seal clip “1” (with a flat-head screwdriver) ECA14180 CAUTION:...
  • Page 177: Assembling The Front Fork Legs

    FRONT FORK • Damper rod assembly bolt • Copper washer EC2D1080 CAUTION: For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left. NOTE: 3.
  • Page 178 FRONT FORK 6. Install: 4. Install: • Oil seal clip “1” • Dust seal “1” • Oil seal clip “2” NOTE: • Oil seal “3” Adjust the oil seal clip so that it fits into the • Washer “4” outer tube’s groove. ECA14220 CAUTION: Make sure the numbered side of the oil seal...
  • Page 179 FRONT FORK Rod puller 90890-01437 Rod puller attachment (M10) 90890-01436 11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. NOTE: Be sure to bleed the front fork leg of any resid- 9.
  • Page 180 FRONT FORK ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rod puller and adapter. f. Remove the rod puller and the rod puller b. Install the nut. attachment. c. Install the fork spring and spacer. g. Install the nut “1” and position it as speci- fied “b”.
  • Page 181: Installing The Front Fork Legs

    FRONT FORK EW2D1003 WARNING • The fork spring is compressed. • Always use a new cap bolt O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 3. Adjust: Each front fork leg is eqipped with a spring •...
  • Page 182: Steering Head

    Front brake calipers Refer to "FRONT BRAKE" on page 4-20. Front cowling (FZ1-S) Refer to "GENERAL CHASSIS" on page 4-1. Headlight and meter assembly (FZ1-N) Refer to "GENERAL CHASSIS" on page 4-1. Handlebar Refer to "HANDLEBAR" on page 4- Front fork legs Refer to "FRONT FORK"...
  • Page 183 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front brake hose joint bracket Horn Horn bracket Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Lower bearing Lower bearing dust seal Lower bearing inner race Bearing cover Upper bearing inner race Upper bearing...
  • Page 184: Removing The Lower Bracket

    STEERING HEAD Damage/pitting → Replace. EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut “1” 3.
  • Page 185: Installing The Steering Head

    STEERING HEAD 4. Check: Steering stem nut • Upper bracket 113 Nm (11.3 m·kg, 82 ft·lb) • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing •...
  • Page 186: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Side cover (left and right) Refer to "GENERAL CHASSIS" on page 4-1.
  • Page 187 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure. 4-62...
  • Page 188: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: 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 •...
  • Page 189: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY Gas leaks/oil leaks → Replace the rear 3. Tighten: shock absorber assembly. • Rear shock absorber assembly upper nut • Spring Rear shock absorber assembly Damage/wear → Replace the rear shock upper nut absorber assembly. 44 Nm (4.4 m·kg, 32 ft·lb) •...
  • Page 190: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to "REAR WHEEL" on page 4- Rear brake caliper Refer to "REAR BRAKE" on page 4- Rear shock absorber Refer to "REAR SHOCK ABSORBER ASSEMBLY" on page 4-61.
  • Page 191 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Drive chain Dust cover Drive chain guide Spacer Bearing For installation, reverse the removal procedure. 4-66...
  • Page 192: Removing The Swingarm

    SWINGARM EAS23350 If swingarm vertical movement is not REMOVING THE SWINGARM smooth or if there is binding, check the 1. Stand the vehicle on a level surface. spacers, bearings, washers, and dust cov- EWA13120 ers. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 193: Installing The Swingarm

    SWINGARM 5. Check: • Connecting arms “1” • Relay arm “2” Damage/wear → Replace. 3. Install: 6. Check: • Bearings “3” • Rear shock absorber assembly • Oil seals “4” • Rear wheel Damage/pitting → Replace. Refer to "INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY"...
  • Page 194: Chain Drive

    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 5-2. Drive chain guard Drive chain For installation, reverse the removal procedure. 4-69...
  • Page 195: Removing The Drive Chain

    CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2. Check: Place the vehicle on a suitable stand so that •...
  • Page 196: Checking The Drive Sprocket

    CHAIN DRIVE • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to "CHECKING AND REPLACING THE...
  • Page 197: Engine

    ENGINE ENGINE REMOVAL ..................5-2 INSTALLING THE ENGINE ..............5-8 CAMSHAFTS....................5-10 REMOVING THE CAMSHAFTS ............5-12 CHECKING THE CAMSHAFTS ............5-13 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-14 CHECKING THE TIMING CHAIN GUIDES ..........5-14 CHECKING THE TIMING CHAIN TENSIONER........5-14 INSTALLING THE CAMSHAFTS............
  • Page 198 CHECKING THE FRICTION PLATES ..........5-49 CHECKING THE CLUTCH PLATES.............5-49 CHECKING THE CLUTCH SPRINGS..........5-50 CHECKING THE CLUTCH HOUSING ..........5-50 CHECKING THE CLUTCH BOSS ............5-50 CHECKING THE PRESSURE PLATE ..........5-50 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-50 INSTALLING THE CLUTCH ..............5-51 SHIFT SHAFT .....................5-54 REMOVING THE SHIFT SHAFT ............
  • Page 199 CHECKING THE TRANSMISSION ............5-91 INSTALLING THE TRANSMISSION.............5-92...
  • Page 200: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Plate For installation, reverse the removal procedure.
  • Page 201 ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. EXUP pulley cover EXUP servo motor cover EXUP cables EXUP servo motor sensor Exhaust pipe assembly Exhaust pipe gasket Muffler Muffler gasket Muffler cover...
  • Page 202 ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks Pulley Spring Spring seat For assembly, reverse the disassem- bly procedure.
  • Page 203 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. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body assembly Refer to "THROTTLE BODIES" on page 7-4.
  • Page 204 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Crankshaft position sensor lead coupler Disconnect. Oil level switch connector Disconnect. Neutral switch connector Disconnect. Cylinder identification sensor coupler Disconnect. Speed sensor coupler Disconnect. For assembly, reverse the removal procedure.
  • Page 205 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 self-locking nut Upper engine mounting bolt Lower self-locking nut Lower engine mounting bolt Engine mounting adjust bolt Engine For assembly, reverse the removal procedure.
  • Page 206: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Right front engine mounting bolt 2 “1” Refer to "CYLINDER HEAD" on page 5-19. 2. Tighten: • Right front engine mounting bolt 2 Right front engine mounting bolt 2 7. Tighten: 50 Nm (5.0 m·kg, 36 ft·lb) •...
  • Page 207 ENGINE REMOVAL Left front engine mounting bolt 45 Nm (4.5 m·kg, 33 ft·lb) Right front engine mounting bolt 1 45 Nm (4.5 m·kg, 33 ft·lb) 8. Tighten: • Lower self-locking nut “1” • Upper self-locking nut “2” Upper self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb)
  • Page 208: Camshafts

    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 body assembly Refer to "THROTTLE BODIES" on page 7-4. Radiator assembly Refer to "RADIATOR" on page 6-1. Air cut-off valve Refer to "AIR INDUCTION SYS- TEM"...
  • Page 209 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Pickup rotor cover Refer to "CRANKSHAFT POSITION SENSOR" on page 5-38. Camshaft sprocket bolt Loosen. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Dowel pin Refer to "REMOVING THE CAM- SHAFTS"...
  • Page 210: Removing The Camshafts

    CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "CRANKSHAFT POSITION SEN- SOR" on page 5-38. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.
  • Page 211: Checking The Camshafts

    CAMSHAFTS 3. Measure: EAS23850 • Camshaft runout CHECKING THE CAMSHAFTS Out of specification → Replace. 1. Check: • Camshaft lobes Camshaft runout limit Blue discoloration/pitting/scratches → 0.03 mm (0.0012 in) Replace the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...
  • Page 212: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprockets and the timing chain as a set. a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Correct 5. Measure: 1. Timing chain roller • Camshaft journal diameter “a” 2.
  • Page 213 CAMSHAFTS b. Squeeze the timing chain tensioner clip “2” NOTE: and push the timing chain tensioner rod “3”. Squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring NOTE: and timing chain tensioner rod. When the timing chain tensioner rod “3” is pushed while holding the grip of the timing chain tensioner clip “2”, make sure not to release the timing chain tensioner rod “3”...
  • Page 214: Installing The Camshafts

    CAMSHAFTS 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 position #1 is at TDC, align the “T” mark “a” with the crankcase mating surface “b”.
  • Page 215 CAMSHAFTS • The camshaft cap bolts must be tightened • Timing chain tensioner “1” evenly or damage to the cylinder head, • Timing chain tensioner bolts “2” camshaft caps, and camshafts will result. Timing chain tensioner bolt • Do not turn the crankshaft when installing 10 Nm (1.0 m·kg, 7.2 ft·lb) the camshaft to avoid damage or improper valve timing.
  • Page 216 CAMSHAFTS 11. Measure: • Valve clearance Out of specification → Adjust. Refer to "ADJUSTING THE VALVE CLEARANCE" on page 3-4. 12. Install: • Pickup coil rotor cover "CRANKSHAFT POSITION SENSOR" on page 5-38. 5-18...
  • Page 217: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to "ENGINE REMOVAL" on page 5-2. Intake camshaft Refer to "CAMSHAFTS" on page 5-10. Exhaust camshaft Refer to "CAMSHAFTS" on page 5-10. Cylinder head Cylinder head gasket Dowel pin Coolant pipe...
  • Page 218: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to "REMOVING THE CAMSHAFTS" on page 5-12. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: a. Place a straightedge “1” and a thickness • Cylinder head nuts gauge “2” across the cylinder head. •...
  • Page 219 CYLINDER HEAD 5. Install: • Gasket “1” • Exhaust camshaft • Dowel pins • Intake camshaft Refer to "INSTALLING THE CAMSHAFTS" on page 5-16. 3. Install: • Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 4. Tighten: •...
  • Page 220 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 5-19. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve stem seal Intake valve lower spring seat...
  • Page 221: Valves And Valve Springs

    VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure. 5-23...
  • Page 222: Removing The Valves

    VALVES AND VALVE SPRINGS EAS24280 NOTE: REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “2” and the valve spring compressor attach- NOTE: ment “3”.
  • Page 223: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS EAS24290 NOTE: CHECKING THE VALVES AND VALVE To ease valve guide removal and installation, GUIDES and to maintain the correct fit, heat the cylinder The following procedure applies to all of the head to 100°C (212°F) in an oven. valves and valve guides.
  • Page 224: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Intake Valve guide remover (ø4) 90890-04111 YM-04111 Exhaust Valve guide remover (ø4.5) 90890-04116 YM-04116 Intake Valve guide installer (ø4) 90890-04112 6. Measure: YM-04112 • Valve stem runout Out of specification → Replace the valve. Exhaust Valve guide installer (ø4.5) NOTE: 90890-04117 •...
  • Page 225 VALVES AND VALVE SPRINGS NOTE: Valve seat width After replacing the cylinder head or replacing Intake the valve and valve guide, the valve seat and 0.90–1.10 mm valve face should be lapped. (0.0354–0.0433 in) Exhaust ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 0.90–1.10 mm a. Apply a coarse lapping compound “a” to (0.0354–0.0433 in) the valve face.
  • Page 226: Checking The Valve Springs

    VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: i. Press the valve through the valve guide • Compressed valve spring force “a” Out of specification → Replace the valve and onto the valve seat to make a clear impression.
  • Page 227: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 3. Install: EAS24320 • Valve “1” CHECKING THE VALVE LIFTERS • Lower spring seat “2” The following procedure applies to all of the • Valve stem seal “3” valve lifters. • Valve spring “4” 1. Check: •...
  • Page 228 VALVES AND VALVE SPRINGS • Each valve lifter and valve pad must be rein- Valve spring compressor stalled in its original position. 90890-04019 YM-04019 Intake Valve spring compressor attachment 90890-04114 YM-04114 Exhaust Valve spring compressor attachment 90890-04108 YM-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.
  • Page 229: Generator

    GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Engine oil Drain. Refer to "CHANGING THE ENGINE OIL"...
  • Page 230 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Bearing Stator coil assembly lead holder Idler gear Idler gear shaft Washer Bearing For assembly, reverse the removal procedure. 5-32...
  • Page 231: Removing The Generator

    GENERATOR EAS24490 REMOVING THE GENERATOR 1. Remove: • Plug • Generator rotor cover “1” NOTE: • While pushing generator rotor, remove the generator rotor cover. • Loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern. •...
  • Page 232 GENERATOR Generator rotor cover bolt (M6) 12 Nm (1.2 m·kg, 8.7 ft·lb) Generator rotor cover bolt (M8) 22 Nm (2.2 m·kg, 16 ft·lb) NOTE: • First tighten the M8 bolts and then tighten the M6 bolts. • Tighten the generator rotor cover bolts in stages and in a crisscross pattern.
  • Page 233: Starter Clutch

    STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O-ring For assembly, reverse the removal procedure. 5-35...
  • Page 234: Removing The Starter Clutch

    STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer “1” • O-ring “2” • Washer “3” EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” Damage/wear → Replace. 2. Remove: • Starter clutch drive gear “1” •...
  • Page 235: Installing The Starter Clutch

    STARTER CLUTCH otherwise the starter clutch is faulty and 3. Install: must be replaced. • Washer “1” c. When turning the starter clutch drive gear • O-ring “2” clockwise “B”, it should turn freely, other- • Spacer “3” wise the starter clutch is faulty and must be NOTE: replaced.
  • Page 236: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Engine oil Drain.
  • Page 237: Removing The Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR EAS24530 REMOVING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor • O-ring • Pickup coil rotor cover “1” NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
  • Page 238: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Throttle body assembly Refer to "THROTTLE BODIES" on page 7-4.
  • Page 239 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly O-ring Starter motor lead Brush holder Rear cover For assembly, reverse the disassem- bly procedure. 5-41...
  • Page 240: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the starter Commutator resistance “1”...
  • Page 241: Assembling The Starter Motor

    ELECTRIC STARTER NOTE: Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers. 7. Check: • Gear teeth Damage/wear → Replace the gear. EAS24800 ASSEMBLING THE STARTER MOTOR EAS24810 1.
  • Page 242: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-12. Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal procedure.
  • Page 243 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 procedure. 5-45...
  • Page 244 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire circlip Clutch plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat Clutch boss nut Washer Clutch boss assembly...
  • Page 245 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks For assembly, reverse the removal procedure. 5-47...
  • Page 246: Removing The Clutch

    CLUTCH EAS25080 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Clutch cover “1” • Gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 247: Checking The Friction Plates

    CLUTCH • Thrust plate 1. Check: 8. Remove: • Friction plate Damage/wear → Replace the friction • Wire circlip “1” plates as a set. NOTE: 2. Measure: There is a built-in damper between the clutch • Friction plate thickness boss and the clutch plate. It is not necessary to Out of specification →...
  • Page 248: Checking The Clutch Springs

    CLUTCH 2. Check: • Bearing Damage/wear → Replace the bearing and EAS25140 CHECKING THE CLUTCH SPRINGS clutch housing. The following procedure applies to all of the clutch springs. EAS25160 CHECKING THE CLUTCH BOSS 1. Check: 1. Check: • Clutch spring Damage →...
  • Page 249: Installing The Clutch

    CLUTCH • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 3. Install: • Wire circlip “1” 2. Check: • Pull rod bearing Damage/wear →...
  • Page 250 CLUTCH • Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle. • While holding the clutch boss assembly “1” with the clutch holding tool “3”, tighten the clutch boss nut.
  • Page 251 CLUTCH 12. Tighten 10. Install: • Clutch cover bolts “1” • Pull lever Clutch cover bolt NOTE: 12 Nm (1.2 m·kg, 8.7 ft·lb) Install the pull lever with the “O“ mark facing toward lower side. • Clutch cover bolt “2” Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE®...
  • Page 252: Shift Shaft

    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 5-44. Shift arm and shift rod Refer to "ENGINE REMOVAL" on page 5-2. Circlip Washer Shift shaft Collar Shift shaft spring...
  • Page 253 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure. 5-55...
  • Page 254: Removing The Shift Shaft

    SHIFT SHAFT ET2D1011 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refetr to "CLUTCH" on page 5-44 2. Remove: • Shift arm • Shift rod Refetr to "ENGINE REMOVAL" on page 5- 3. Remove: • Circlip “1” • Washer “2” EAS25420 CHECKING THE SHIFT SHAFT (left side of the engine)
  • Page 255 SHIFT SHAFT • Stopper lever spring “3” • Shift rod • Shift arm Refer to "ENGINE REMOVAL" on page 5- 5. Install: • Clutch assembly Refer to "CLUTCH" on page 5-44. 2. Install: • Washer • Collar • Shift shaft spring “1” •...
  • Page 256: Oil Pump

    OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-12. EXUP cables Refer to "ENGINE REMOVAL" on page 5-2. sensor Refer to "ENGINE REMOVAL"...
  • Page 257 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar...
  • Page 258 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly For assembly, reverse the removal procedure. 5-60...
  • Page 259 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 outer roter Oil pump inner roter For assembly, reverse the disassem- bly procedure. 5-61...
  • Page 260: Removing The Oil Pan

    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 rotor housing “2” • Oil pan gasket •...
  • Page 261: Checking The Relief Valve

    OIL PUMP EAS24970 CHECKING THE RELIEF VALVE ET2D1013 CHECKING THE OIL NOZZLES 1. Check: The following procedure applies to all of the oil • Relief valve body “1” nozzles. • Relief valve “2” 1. Check: • Spring “3” • Oil nozzle “1” •...
  • Page 262: Installing The Oil/water Pump Assembly

    OIL PUMP NOTE: When installing the inner rotor, align the pin “1” in the oil pump shaft with the groove in the inner rotor “2”. 2. Install: • Washer • Oil/water pump assembly drive chain “1” • Oil/water pump assembly drive sprocket “2” •...
  • Page 263: Installing The Oil Pan

    OIL PUMP EAS25050 4. Install: INSTALLING THE OIL PAN 1. Install: • Oil delivery pipe “1” • Dowel pins Oil delivery pipe bolt • Gasket 10 Nm (1.0 m·kg, 7.2 ft·lb) • Oil pan “1” LOCTITE® Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) •...
  • Page 264: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body assembly Refer to "THROTTLE BODIES" on page 7-4. Engine Refer to "ENGINE REMOVAL" on page 5-2. Cylinder head Refer to "CYLINDER HEAD"...
  • Page 265 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Oil pump Refer to "OIL PUMP" on page 5-58. Starter motor Refer to "ELECTRIC STARTER" on page 5-40. Timing chain Timing chain guide (intake side) Timing chain guide (exhaust side) Left side cover O-ring Lower crankcase...
  • Page 266: Disassembling The Crankcase

    Engine oil 2. Apply: 3. Remove: • Sealant • Lower crankcase ECA13900 Yamaha bond No. 1215 CAUTION: (Three Bond No.1215®) Tap on one side of the crankcase with a 90890-85505 soft-face hammer. Tap only on reinforced portions of the crankcase, not on the NOTE: crankcase mating surfaces.
  • Page 267 CRANKCASE Crankcase bolt Bolt “1”–“10” 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd*: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4 m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2 m·kg, 8.7 ft·lb) *Following the tightening order, loosen the 3.
  • Page 268: Crankshaft

    CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to "CRANKCASE" on page 5- Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring...
  • Page 269 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Crankcase Separate. Refer to "CRANKCASE" on page 5- Connecting rod and connecting rod Refer to "REMOVING THE CON- caps NECTING RODS AND PISTONS" on page 5-72. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear...
  • Page 270: Removing The Connecting Rods And Pistons

    CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND Piston pin puller set PISTONS 90890-01304 The following procedure applies to all of the Piston pin puller connecting rods and pistons. YU-01304 1. Remove: • Connecting rod cap “1” • Big end bearings NOTE: •...
  • Page 271: Checking The Cylinder And Piston

    CRANKSHAFT 4 mm (0.16 in) “a” from the bottom edge of NOTE: the piston Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its Piston size “P” original place. 76.975 - 76.990 mm (3.0305 - 3.0311 in) ET2D1032 CHECKING THE CYLINDER AND PISTON...
  • Page 272: Checking The Piston Pins

    CRANKSHAFT Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 mm 0.15–0.25 mm (0.0012–0.0026 in) (0.0059–0.0098 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring 0.020–0.055 mm 0.30–0.45 mm (0.0008–0.0022 in) (0.0118–0.0177 in) Limit Limit...
  • Page 273: Checking The Big End Bearings

    CRANKSHAFT end bearings must be installed in their orig- Piston pin bore inside diameter inal positions. 17.002–17.013 mm a. Clean the big end bearings, crankshaft (0.6694–0.6698 in) pins, and the inside of the connecting rods Limit halves. 17.043 mm (0.6710 in) b.
  • Page 274 CRANKSHAFT Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. k. Tighten the connecting rod bolts. e. Tighten the connecting rod bolts. Connecting rod bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE:...
  • Page 275 CRANKSHAFT p. After the installation, check that the section ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ shown “a” is flush with each other by touch- 2. Select: ing the surface. • Big end bearings (P1 – P4) • Side machined face “a” NOTE: EWA13120 • The numbers “A” stamped into the crank- WARNING shaft wed and the numbers “1”...
  • Page 276: Installing The Connecting Rod And Piston

    CRANKSHAFT EAS26190 (with the recommended lubricant) INSTALLING THE CONNECTING ROD AND PISTON Recommended lubricant The following procedure applies to all of the Engine oil connecting rods and pistons. 4. Offset: 1. Install: • Piston ring end gaps • Top ring “1” •...
  • Page 277 CRANKSHAFT NOTE: • Install by carrying out the following proce- dures in order to assemble in the most suit- able condition. • First tighten the bolts to 15 Nm (1.5 m·kg, 11 ft·lb) • Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 278 CRANKSHAFT ECA14980 CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. a. Clean the connecting rod bolts. b. Tighten the connecting rod bolts. c. Put a mark “1” on the connecting rod bolt “2” and the connecting rod cap “3”. 11.
  • Page 279: Checking The Crankshaft

    CRANKSHAFT • If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “9”. In this case, make sure to replace the con- necting rod bolt. ECA14680 CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
  • Page 280 CRANKSHAFT Crankcase bolt Bolt “1”–“10” 1st: 20 Nm (2.0 m·kg, 14 ft·lb) 2nd: 20 Nm (2.0 m·kg, 14 ft·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2m·kg, 8.7 ft·lb) M9 x 105 mm (4.1 in) bolts: “1”–“10” d.
  • Page 281: Installing The Crankshaft

    CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • Crankshaft journal bearings (J1–J5) NOTE: • The numbers “A” stamped into the crank- shaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J1–J5” refer to the bearings shown in the crankshaft illustration.
  • Page 282 CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place. 3. Install: • Crankshaft 4. Install: •...
  • Page 283: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Crankcase lower Separate. Refer to "CRANKCASE" on page 5- Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L”...
  • Page 284 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Main axle assembly Oil pipe O-ring Oil baffle plate For installation, reverse the removal procedure. 5-86...
  • Page 285 TRANSMISSION Disassembling the main axle assenbly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For assembly, reverse the disassem- bly procedure.
  • Page 286 TRANSMISSION Disassembling the drive axle assenbly 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 287 TRANSMISSION Disassembling the drive axle assenbly Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Drive axle For assembly, reverse the disassem- bly procedure. 5-89...
  • Page 288: Removing The Transmission

    TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle asseembly “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 289: Checking The Shift Drum Assembly

    TRANSMISSION Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 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.
  • Page 290 TRANSMISSION ET2D1022 INSTALLING THE TRANSMISSION 1. Install: • Bearing “1” NOTE: Make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. • Oil pipe “2” 3. Install: •...
  • Page 291 TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-93...
  • Page 292 COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER.............. 6-5 INSTALLING THE OIL COOLER ............6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT............6-8 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP ....................6-10 DISASSEMBLING THE WATER PUMP ..........
  • Page 293 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Rider and passenger seat 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.
  • Page 294 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Water pump inlet pipe O-ring For installation, reverse the removal procedure.
  • Page 295 RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
  • Page 296 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-12. Oil cooler inlet hose Oil cooler bolt Washer Oil cooler O-ring Water pump outlet pipe O-ring Water jacket joint inlet hose O-ring...
  • Page 297: Oil Cooler

    OIL COOLER EAS26420 3. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to "CHANGING THE COOLANT" on page 3-19. • Crankcase (with the specified amount of the recom- mended engine oil) Refer to "CHANGING THE ENGINE OIL"...
  • Page 298 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Q’ty Remarks Rider and passenger seat 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.
  • Page 299 THERMOSTAT Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks Thermostat housing cover Thermostat Thermostat housing O-ring For assembly, reverse the disassem- bly procedure.
  • Page 300 THERMOSTAT EAS26450 • Thermostat housing “2” CHECKING THE THERMOSTAT Cracks/damage → Replace. 1. Check: • Thermostat Does not open at 71 – 85°C (160 – 185°F) → Replace. EAS26460 ASSEMBLING THE THERMOSTAT ASSEM- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container 1.
  • Page 301 THERMOSTAT Below the specified pressure → Replace the radiator cap. Refer to "CHECKING THE RADIATOR" on page 6-3.
  • Page 302: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the impeller shaft Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to "OIL PUMP" on page 5-58. Oil pump roter Refer to "OIL PUMP" on page 5-58. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing...
  • Page 303 WATER PUMP EAS26520 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” • Water pump housing “2” NOTE: Tap out the water pump seal from the inside of the water pump housing. EAS26540 CHECKING THE WATER PUMP 1. Check: •...
  • Page 304 (4). tools. ECA14090 • Before installing the water pump seal, apply CAUTION: Yamaha bond No.1215 (Three Bond Make sure the rubber damper and rubber No.1215® ) “2” to the water pump housing damper holder are flush with the impeller. “3”.
  • Page 305 WATER PUMP 6-13...
  • Page 306 FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 INSTALLING THE FUEL PUMP ............. 7-2 INSTALLING THE FUEL TANK...............7-3 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS ...............7-8 CHECKING THE THROTTLE BODIES ..........
  • Page 307 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel hose Disconnect. Fuel sender coupler Disconnect. Fuel pump coupler Disconnect. Fuel tank drain hose Disconnect.
  • Page 308: Fuel Tank

    FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK CAUTION: 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •...
  • Page 309 FUEL TANK ET2D1023 INSTALLING THE FUEL TANK 1. Install: • Fuel hose • Fuel hose connector cover ECA14740 CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi- tion, otherwise the fuel hose will not be properly installed.
  • Page 310: Throttle Bodies

    THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Rider and passenger seat 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.
  • Page 311 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure.
  • Page 312 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Throttle position sensor coupler Disconnect. Sub-throttle position sensor coupler Disconnect. Sub-throttle motor assembly coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Cylinder #3-injector coupler Disconnect.
  • Page 313 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Washer Link Sub-throttle servo motor assembly Throttle position sensor Throttle body assembly For installation, reverse the removal procedure.
  • Page 314 THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. c. Connect the pressure gauge “2” and adapter “3” to the fuel hose (fuel tank to pri- mary injector fuel rail). EAS26990 CHECKING THE THROTTLE BODIES Vacuum/pressure pump gauge 1.
  • Page 315 THROTTLE BODIES 1. Check: ET2D1024 ADJUSTING THE SUB-THROTTLE POSI- • Throttle position sensor TION SENSOR Refer to "CHECKING THE THROTTLE 1. Check: POSITION SENSOR" on page 8-109. • Sub-throttle position sensor 2. Adjust: Refer to "CHECKING THE SUB-THROT- • Throttle position sensor angle TLE POSITION SENSOR"...
  • Page 316 THROTTLE BODIES 4. Adjust: • Sub-throttle position sensor voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the sub-throttle position sensor coupler to the wire harness. b. Connect the digital circuit tester to the sub- throttle position sensor. • Positive tester probe Green/Yellow terminal “1” •...
  • Page 317 THROTTLE BODIES Out of specification → Replace. a. Before adjusting the distance, push the rod ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ “b” in order to be fitted in several times by hand. a. Check whether or not the sub-throttle valve is seized. b. Measure the outside air temperature, and 1 Turn the nut of worm shaft of the sub-throt- adjust the distance “a”...
  • Page 318 THROTTLE BODIES it shorter when the coolant temperature is high.) • In case of turning the adjusting bolt two-third turn, the temperature varies about 10°C (50°F). 7-12...
  • Page 319: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty Remarks Air cut-off valve coupler Disconnect. Air cut-off valve hose 1 Disconnect. Air cut-off valve hose 2 Disconnect. Air cut-off valve hose 3 Disconnect.
  • Page 320 AIR INDUCTION SYSTEM EAS27060 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
  • Page 321 AIR INDUCTION SYSTEM Out of specification → Replace the reed • Plate valve. • Reed valve assembly • Reed valve cap Reed valve bending limit 2. Install: 0.4 mm (0.016 in) • Air cut-off valve • Air cut-off valve hose 1 •...
  • Page 322: General Information

    CIRCUIT DIAGRAM................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING................8-9 CHARGING SYSTEM ................. 8-11 CIRCUIT DIAGRAM................8-11 TROUBLESHOOTING................8-13 LIGHTING SYSTEM ...................8-15 CIRCUIT DIAGRAM (FZ1-N) ..............8-15 CIRCUIT DIAGRAM (FZ1-S) ..............8-17 TROUBLESHOOTING................8-19 SIGNALING SYSTEM................. 8-21 CIRCUIT DIAGRAM................8-21 TROUBLESHOOTING................8-23 COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM................8-27 TROUBLESHOOTING................8-29...
  • Page 323 ELECTRICAL COMPONENTS..............8-89 CHECKING THE SWITCHES...............8-93 CHECKING THE BULBS AND BULB SOCKETS.........8-96 CHECKING THE FUSES..............8-97 CHECKING AND CHARGING THE BATTERY........8-97 CHECKING THE RELAYS..............8-100 CHECKING THE TURN SIGNAL/HAZARD RELAY ......8-102 CHECKING THE RELAY UNIT (DIODE) ..........8-102 CHECKING THE IGNITION COILS............8-103 CHECKING THE CRANKSHAFT POSITION SENSOR.....8-104 CHECKING THE LEAN ANGLE SENSOR.........8-105 CHECKING THE STARTOR MOTOR OPERATION ......8-105...
  • Page 325: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 326 IGNITION SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 17.Crankshaft position sensor 21.Lean angle sensor 23.ECU 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Ignition coil #4 28.Spark plug 56.Engine stop switch 60.Clutch switch 78.Fuse (ignition)
  • Page 327 IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 1 Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to "CHECKING THE FUSES"...
  • Page 328 IGNITION SYSTEM 8 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-93. OK↓ 9 Check the neutral switch. NG→ Refer to "CHECKING THE Replace the neutral switch. SWITCHES" on page 8-93. OK↓...
  • Page 329: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 330 ELECTRIC STARTING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 9. Starter relay 10.Starter motor 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 56.Engine stop switch 57.Start switch 60.Clutch switch 78.Fuse (ignition)
  • Page 331 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 332 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 333 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case NG→ 1 Check the fuses. (Main and ignition) Replace the fuse(s). Refer to "CHECKING THE FUSES"...
  • Page 334 ELECTRIC STARTING SYSTEM 8 Check the main switch. NG→ Refer to "CHECKING THE Replace the immobilizer kit. SWITCHES" on page 8-93. OK↓ 9 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-93. OK↓...
  • Page 335: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 336 CHARGING SYSTEM 2. Rectifier/regulator 3. A.C.magneto 6. Fuse (main) 7. Battery 8-12...
  • Page 337 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 1 Check the fuse. NG→ (Main) Replace the fuse. Refer to "CHECKING THE FUSES" on page 8-97. OK↓...
  • Page 338 CHARGING SYSTEM 8-14...
  • Page 339: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (FZ1-N) 8-15...
  • Page 340 LIGHTING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 23.ECU 49.High beam indicator light 52.Meter light 61.Pass switch 62.Dimmer switch 72.Auxiliary light 73.Headlight 74.License plate light 75.Tail/brake light 76.Headlight relay (on/off) 77.Fuse (tail light)) 81.Fuse (headlight) 8-16...
  • Page 341 LIGHTING SYSTEM ET2D1026 CIRCUIT DIAGRAM (FZ1-S) 8-17...
  • Page 342 LIGHTING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 23.ECU 49.High beam indicator light 52.Meter light 61.Pass switch 62.Dimmer switch 72.Auxiliary light 73.Headlight 74.License plate light 75.Tail/brake light 76.Headlight relay (on/off) 77.Headlight relay (dimmer) 78.Fuse (tail light) 82.Fuse (headlight) 8-18...
  • Page 343 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the each bulbs and bulb NG→...
  • Page 344 Replace the headlight relay. Refer to "CHECKING THE RELAYS" on page 8-100. OK↓ 10 Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to "CIRCUIT DIAGRAM system’s wiring. (FZ1-N)" on page 8-15. OK↓ This circuit is OK. 8-20...
  • Page 345: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 346 SIGNALING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 11.Relay unit 14.Neutral switch 16.Fuel pump 19.Speed sensor 23.ECU 42.Fuel level warning light 43.Oil level warning light 44.Neutral indicator light 45.Tacho meter 46.Multi function meter 48.Coolant temperature indicator light 50.Turn signal indicator light (left) 51.Turn signal indicator light (right) 53.Oil level switch 55.Front brake light switch...
  • Page 347 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses.
  • Page 348 SIGNALING SYSTEM 3 Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to "CIRCUIT DIAGRAM" on ing system wiring. page 8-21. OK↓ This circuit is OK. The tail/brake light fails to come on. 1 Check the tail/brake light bulb and NG→...
  • Page 349 SIGNALING SYSTEM 3 Check the hazard switch. NG→ Refer to "CHECKING THE Replace the left handlebar switch. SWITCHES" on page 8-93. OK↓ 4 Check the turn signal/hazard relay. NG→ Refer to "CHECKING THE Replace the turn signal/hazard relay. RELAYS" on page 8-100. OK↓...
  • Page 350 SIGNALING SYSTEM 1 Check the fuel sender. NG→ Refer to "CHECKING THE FUEL Replace the fuel pump assembly. SENDER" on page 8-107. OK↓ 2 Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to "CIRCUIT DIAGRAM" on ing system’s wiring.
  • Page 351: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
  • Page 352 COOLING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 23.ECU 38.Coolant temperature sensor 78.Fuse (ignition) 82.Radiator fan motor relay 83.Fuse (radiator fan motor left) 84.Fuse (radiator fan motor right) 85.Radiator fan motor (left) 86.Radiator fan motor (right) 8-28...
  • Page 353 COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. NG→ (Main, ignition and radiator fan motor) Replace the fuse(s). Refer to "CHECKING THE FUSES" on page 8-97.
  • Page 354 COOLING SYSTEM 8-30...
  • Page 355: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
  • Page 356 FUEL INJECTION SYSTEM 1. Main switch 4. Fuse (backup) 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Sidestand switch 16.Fuel pump 17.Crankshaft position sensor 18.Cylinder identification sensor 19.Speed sensor 20.Atmospheric pressure sensor 21.Lean angle sensor 22.O...
  • Page 357 FUEL INJECTION SYSTEM EAS27370 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case NG→ 1 Check the fuses. (Main, backup, fuel injection and ignition) Replace the fuse(s).
  • Page 358 FUEL INJECTION SYSTEM 8 Check the main switch. NG→ Refer to "CHECKING THE Replace the immobilizer kit. SWITCHES" on page 8-93. OK↓ 9 Check the engine stop switch. NG→ Refer to "CHECKING THE Replace the right handlebar switch. SWITCHES" on page 8-93. OK↓...
  • Page 359 FUEL INJECTION SYSTEM 17 Checking the aomospheric pres- NG→ sure sensor. Replace the atomospheric pressure Refer to "CHECKING THE ATMO- sensor. SPHERIC PRESSURE SENSOR" on page 8-111. OK↓ 18 Check the injector. NG→ Refer to "CHECKING THE INJEC- Replace the injector. TORS"...
  • Page 360 FUEL INJECTION SYSTEM 24 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. 8-36...
  • Page 361 FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 362: Self-diagnostic Function Table

    FUEL INJECTION SYSTEM a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 sec- onds ET2D1027 SELF-DIAGNOSTIC FUNCTION TABLE 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 363 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Coolant temperature Coolant temperature sensor: sensor open or short circuit detected. Able Able (open or short circuit) Intake air temperature Intake air temperature sensor: sensor open or short circuit detected.
  • Page 364 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Injector Injector: Able Able (open circuit) open circuit detected. (depend- (depend- ing on ing on the num- the num- ber of ber of faulty faulty cylin- cylin-...
  • Page 365 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive ECU internal malfunc- No signals are received from the ECU Er-2 tion within the specified duration. Unable Unable (output signal error) ECU internal malfunc- Data from the ECU cannot be received Er-3 tion...
  • Page 366 FUEL INJECTION SYSTEM If a malfunction is detected in the sensors If no malfunction is detected in the sensors or actuators, repair or replace all faulty and actuators, check and repair inner parts parts. of the engine. EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1.
  • Page 367 FUEL INJECTION SYSTEM The data representing the operating conditions of the sensor appears on the odometer/tripme- ter/fuel reserve tripmeter LCD. • Actuator operation Set the engine stop switch to “ ” to operate the actuator. NOTE: If the engine stop switch is set to “ ”, set it to “...
  • Page 368 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. When the main switch is • Atmospheric pressure sensor hose is turned to “ON”, the atmo- clogged. spheric pressure sensor • Intake air pressure sensor hose is clogged, voltage and intake air pres- kinked, or pinched.
  • Page 369 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Open circuit detected in the • Open or short circuit in wire harness. primary lead of the cylinder- • Malfunction in ignition coil. #4 ignition coil. • Malfunction in a component of ignition cut- off circuit system.
  • Page 370 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. No signals are received • Improper connection in wire harness. Er-2 from the ECU within the • Malfunction in meter. — specified duration. • Malfunction in ECU. Data from the ECU cannot •...
  • Page 371 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “ ” and then compare with the actually measured battery voltage. (If the bat- tery voltage is lower, recharge the battery.) Sidestand switch Set ON/OFF the sidestand...
  • Page 372 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction code reinstate • No mulfunction code — • Malfunction code exists Fault code 24 To reinstate, set the engine • (If more than one code stop switch to “ “...
  • Page 373 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Injector #3 Actuates the injector #3 five Check the operating sound times at one-second inter- of the injector #3 five times. vals. Illuminates the engine trou- ble warning light. Injector #4 Actuates the injector #4 five Check the operating sound times at one-second inter-...
  • Page 374 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Sub-throttle servo motor Actuate the servo motor turns Check the operating sound to close side and to open of the Sub-throttle servo side. motor. Illuminates the engine trou- ble warning light only while the motor is runnning.
  • Page 375 FUEL INJECTION SYSTEM No normal signals are received from the crankshaft posi- Fault code No. Symptom tion sensor. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor:open or short circuit detected. Diagnostic code No. Intake air pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Turn the main •...
  • Page 377 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor:open or short circuit detected. Diagnostic code No. Throttle position sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
  • Page 378 FUEL INJECTION SYSTEM Fault code No. 16 Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of throttle position • Check the installed area for Reinstated by sensor.
  • Page 379 FUEL INJECTION SYSTEM Fault code No. 18 Symptom EXUP servo motor is stuck. Diagnostic code No. EXUP servo motor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
  • Page 380 FUEL INJECTION SYSTEM When the main switch is turned to “ON”, the atmospheric Fault code No. Symptom pressure sensor voltage and intake air pressure sensor voltage differ greatly. Atmospheric pressure sensor Diagnostic code No. Intake air pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause...
  • Page 381 FUEL INJECTION SYSTEM Intake air temperature sensor:open or short circuit Fault code No. 22 Symptom detected. Diagnostic code No. Intake air temperature sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
  • Page 382 FUEL INJECTION SYSTEM Atmospheric pressure sensor:open or short circuit Fault code No. 23 Symptom detected. Diagnostic code No. Atmospheric pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
  • Page 383 FUEL INJECTION SYSTEM No normal signal is received from the O sensor. Fault code No. 24 Symptom Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of O sensor. Check for looseness or pinching. Start and warm up the engine Connections •...
  • Page 384 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 33 Symptom #1 ignition coil. Diagnostic code No. Cylinder-#1 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •...
  • Page 385 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 34 Symptom #2 ignition coil Diagnostic code No. Cylinder-#2 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •...
  • Page 386 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 35 Symptom #3 ignition coil Diagnostic code No. Cylinder-#3 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •...