Page 1 2008 SERVICE MANUAL FZ1-N(X) FZ1-S(X) FZ1-SA FZ1-NA 5D0-28197-E1...
Page 2 EAS20040 FZ1-N(X)/FZ1-S(X)/FZ1-SA/FZ1-NA SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. First edition, December 2007 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 15.Molybdenum-disulfide grease SYMBOLS 16.Silicon grease The following symbols are used in this manual 17.Apply locking agent (LOCTITE®) for easier understanding. 18.Replace the part NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3.
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ..............1-26 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-26 REPLACEMENT PARTS...............1-26 GASKETS, OIL SEALS AND O-RINGS..........1-26 LOCK WASHERS/PLATES AND COTTER PINS .........1-26 BEARINGS AND OIL SEALS ...............1-27 CIRCLIPS .....................1-27 CHECKING THE CONNECTIONS .............1-28...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS5D01032 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
FEATURES EAS5D01013 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
FEATURES EAS5D01014 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- perature display 1. Tachometer 2. Speedometer 2. Tachometer red zone 3. Tachometer The electric tachometer allows the rider to 4.
Page 14 “TRIP A” and “TRIP B” in off for approximately 3 seconds. If this occurs, the following order: have a Yamaha dealer check the electrical cir- TRIP A → TRIP B → ODO → TRIP A cuit. When the fuel amount in the fuel tank decreases to 3.4 L (0.90 US gal) (0.75...
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 6. Rear wheel sensor 7. Rear wheel sensor rotor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
Page 17 FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. •...
Page 18 FEATURES e. Less slippery road surface a. Friction force between the tire and road surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d. Slip ratio (%) Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors.
Page 19 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem condition and allows normal braking even if the ABS is not operating properly.
Page 20 FEATURES ABS block diagram 8. Rear brake caliper 1. Rear brake master cylinder 9. Front brake caliper 2. Hydraulic unit 10.ABS ECU 3. Hydraulic pump 11.Rear wheel sensor 4. ABS motor 12.Front wheel sensor 5. Buffer chamber 13.ABS warning light 6.
Page 21 FEATURES 7. Wheel sensor rotor 4. At low speed 8. Voltage 5. At high speed 9. Time 6. Wheel sensor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is oper- ating properly.
Page 22 FEATURES 6. To the front brake master cylinder 1. To the rear brake master cylinder 7. To the rear brake caliper 2. Hydraulic pump 8. To the ABS ECU 3. ABS motor 9. To the front brake caliper 4. Buffer chamber 5.
Page 23 FEATURES 3. Spool 1. Orifice 4. Flow control valve 2. Solenoid valve • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 3. Raised piston 1. Buffer chamber (pressurized) 2. Buffer chamber (depressurized) ABS ECU (electronic control unit) The ABS ECU “1”...
Page 24 FEATURES B. FZ1-NA A. FZ1-SA As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 1. Battery 16.ABS test coupler 2. Engine stop switch 17.ABS ECU 3.
Page 25 FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis These operations are performed once every 8/1000th of a second. When a failure is detected in the ABS, a malfunction code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.
Page 26 FEATURES Composition and operation The ABS motor relay is activated by signals transmitted from the ABS ECU and operates simulta- neously when the ABS starts to reduce the hydraulic pressure of the brake fluid. If the solenoid relay is turned off, the ABS motor relay is also deactivated and the motor stops operating if there is a mal- function.
Page 27 FEATURES 15.ABS ECU 1. Brake master cylinder 16.ABS warning light 2. Brake light switch 17.Brake fluid pressure 3. ABS motor 18.Time 4. Hydraulic pump 19.Repressurizing 5. Buffer chamber 6. Flow control valve 7. Port A 8. Spool 9. Port B 10.Orifice 11.Port D 12.Solenoid valve...
Page 28 FEATURES Emergency braking (ABS activated) 1. Depressurized state When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the spool of the flow control valve compresses the return spring and closes port B “9”.
Page 29 FEATURES 9. Port B 10.Orifice 11.Port D 12.Solenoid valve 13.Port C 14.Brake caliper 15.ABS ECU 16.ABS warning light 17.Brake fluid pressure 18.Time 19.Repressurizing 2. Pressurized state Port D “11” is closed by the “pressurization” signal transmitted from the ABS ECU. Before this occurs, the spool of the flow control valve has compressed the return spring and closed port B “9”.
Page 30 FEATURES 12.Solenoid valve 1. Brake master cylinder 13.Port C 2. Brake light switch 14.Brake caliper 3. ABS motor 15.ABS ECU 4. Hydraulic pump 16.ABS warning light 5. Buffer chamber 17.Brake fluid pressure 6. Flow control valve 18.Time 7. Port A 19.Repressurizing 8.
Page 31 FEATURES Instances when the ABS warning light comes on 1. The ABS warning light comes on when the main switch is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
Page 32 FEATURES c. Goes off a. ABS warning light d. Preparation b. Comes on 4. The ABS warning light “1” flashes and a malfunction code “2” is indicated on the multi-function display when the test coupler adapter “3” is connected to the ABS test coupler “4” for trouble- shooting the ABS.
Page 33 FEATURES B. FZ1-NA A. FZ1-SA • Diagnosis indication The place where the ABS diagnosis code is displayed is also used for the indication of the FI diag- nosis code, odometer, trip meter and fuel trip. As the priority level of indication, the diagnosis code for FI is the first and the diagnosis code for ABS is the second.
Page 34 FEATURES ABS function • A brake system in which the hydraulic control has been performed by the ABS alerts a rider that the wheels had a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.
Page 35: Important Information
EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 36: Bearings And Oil Seals
IMPORTANT INFORMATION 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 37: 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 38 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 39 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-13 90890-01426 YU-38411 Rod holder 4-64, 4-69 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-67 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 4-67 90890-01436 Universal damping rod bleeding tool set...
Page 40 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages 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 YM-04114 Middle driven shaft bearing driver 6-11...
Page 41 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Ignition checker 8-148 90890-06754 Opama pet-4000 spark checker YU-34487 Yamaha bond No.1215 5-64, 6-11 (Three Bond No.1215®) 90890-85505 Digital circuit tester 7-8, 7-9 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Pivot shaft wrench...
Page 42: Special Tools
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 90890-01476 Pocket tester 1-28, 5-41, 8- 90890-03112 137, 8-138, 8- Analog pocket tester 139, 8-142, 8- YU-03112-C 144, 8-145, 8- 146, 8-147, 8- 148, 8-149, 8- 150, 8-151, 8- 152, 8-153, 8- 154, 8-155, 8- 156, 8-157...
Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Camshaft wrench 5-11, 5-16 90890-04143 YM-04143 Test coupler adapter 1-23, 4-54, 4-55 90890-03149 1-34...
Page 44 SPECIAL TOOLS 1-35...
Page 45: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-8 ELECTRICAL SPECIFICATIONS...............2-11 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-19 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 CHASSIS ....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ...............2-37...
Page 46: General Specifications
Dimensions Overall length 2140 mm (84.3 in) Overall width 770 mm (30.3 in) Overall height 1060 mm (41.7 in) (FZ1-N(X), FZ1-NA) 1205 mm (47.4 in) (FZ1-S(X), FZ1-SA) Seat height 815 mm (32.1 in) Wheelbase 1460 mm (57.5 in) Ground clearance 135 mm (5.31 in)
Page 47: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm (60.90 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 11.50 : 1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8 kgf/cm /350 r/min)
Page 48 ENGINE SPECIFICATIONS Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump 65/43 × 25/32 (1.181) Reduction ratio Max impeller shaft tilt limit 0.15 mm (0.0059 in) Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 12.20–13.00 cm...
Page 49 ENGINE SPECIFICATIONS 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) Valve face width B (intake) 1.760–2.900 mm (0.0693–0.1142 in) Valve face width B (exhaust) 1.760–2.900 mm (0.0693–0.1142 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Page 50 ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) 40.47 mm (1.59 in) Free length (exhaust) 40.53 mm (1.60 in) Installed length (intake) 32.66 mm (1.29 in) Installed length (exhaust) 33.88 mm (1.33 in) Spring rate K1 (intake) 17.53 N/mm (100.10 lb/in) (1.79 kgf/mm) Spring rate K2 (intake) 22.86 N/mm (130.53 lb/in) (2.33 kgf/mm) Spring rate K1 (exhaust)
Page 51 ENGINE SPECIFICATIONS End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Oil ring...
Page 52 ENGINE SPECIFICATIONS Secondary reduction system Chain drive Secondary reduction ratio 45/17 (2.647) Operation Left foot operation Gear ratio 38/15 (2.533) 33/16 (2.063) 37/21 (1.762) 35/23 (1.522) 27/20 (1.350) 29/24 (1.208) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type...
Page 53: Chassis Specifications
) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm ) (2.90 bar) Loading condition 90–196 kg (198–432 lb) (FZ1-N(X)) 90–190 kg (198–419 lb) (FZ1-S(X)) 90–189 kg (198-417 lb) (FZ1-NA) 90–184 kg (198-406 lb) (FZ1-SA) Front 250 kPa (36 psi) (2.50 kgf/cm ) (2.50 bar)
Page 54 Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length 194.8 mm (7.67 in) (FZ1-N(X)), (FZ1-S(X)) 169.8 mm (6.69 in) (FZ1-SA), (FZ1-NA) Installed length 181.8 mm (7.16 in) (FZ-N(X)), (FZ1-S(X)) 156.8 mm (6.17 in) (FZ1-SA), (FZ1-NA) Spring rate K1 102.90 N/mm (587.56 lb/in) (10.49 kgf/mm)
Page 55 CHASSIS SPECIFICATIONS Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available Enclosed gas/air pressure (STD) 1000 kPa (142.2 psi) (10.0 kgf/cm Drive chain Type/manufacturer 50VA8/DAIDO Link quantity Drive chain slack 25.0–35.0 mm (0.98–1.38 in) 15-link length limit 239.3 mm (9.42 in) 2-10...
Page 56: Electrical Specifications
1.12 A Headlight Bulb type Halogen bulb Bulb voltage, wattage × quantity 12 V, 60 W/55.0 W × 1 (FZ1-N(X)), (FZ1-NA) Headlight 12 V, 60 W/55.0 W × 2 (FZ1-S(X)), (FZ1-SA) 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 57 10 W × 2.0 +3.4 W Wattage Oil level gauge Model/manufacturer 5VY/SOMIC ISHIKAWA Servo motor Model/manufacturer 2D1/YAMAHA Fuses Main fuse 50.0 A Headlight fuse 15.0 A (FZ1-N(X)), (FZ1-NA) 25.0 A (FZ1-S(X)), (FZ1-SA) Taillight fuse 10.0 A Signaling system fuse 10.0 A 2-12...
Page 58 ELECTRICAL SPECIFICATIONS Ignition fuse 15.0 A 10.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A ABS motor fuse 30.0 A (FZ1-SA), (FZ1-NA) ABS control unit fuse 10.0 A (FZ1-SA), (FZ1-NA) Backup fuse 10.0 A Reserve fuse 30.0 A (FZ1-SA), (FZ1-NA) Reserve fuse 25.0 A (FZ1-S(X)), (FZ1-SA)
Page 59: 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 60: 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 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size 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 6 Nm (0.6 m·kg, 4.3 ft·lb) Exhaust pipe and exhaust pipe 20 Nm (2.0 m·kg, 14 ft·lb) bracket bolt...
Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Left Shift rod locknut (rear) 7 Nm (0.7 m·kg, 5.1 ft·lb) thread Shift rod joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Neutral switch 20 Nm (2.0 m·kg, 14 ft·lb) Sub-throttle servo motor cover...
Page 63 TIGHTENING TORQUES 2-18...
Page 64: 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 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive chain guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear fender screw 7 Nm (0.7 m·kg, 5.1 ft·lb) 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)
Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle cable adjust nut 4 Nm (0.4 m·kg, 2.9 ft·lb) Clutch cable adjust nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Centerstand bracket nut (FZ1- 55 Nm (5.5 m·kg, 40 ft·lb) S(X), (FZ1-SA)) Centerstand bracket adapter bolt 73 Nm (7.3 m·kg, 53 ft·lb) (FZ1-S(X), (FZ1-SA))
Page 67: Lubrication Points And Lubricant Types
Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond No. Cylinder head cover mating surface 1215 Yamaha bond No. Crankcase mating surface 1215 Yamaha bond No.
Page 68: 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 69 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...
Page 70: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil 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.Piston cooler 13.Piston cooler 14.Chain tensioner...
Page 72: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-28...
Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 75 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 2-30...
Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 77 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 2-32...
Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-34...
Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-36...
Page 82: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-37...
Page 83 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-38...
Page 84 COOLING SYSTEM DIAGRAMS 2-39...
Page 85 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-40...
Page 86: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING 2-41...
Page 87 CABLE ROUTING FZ1-N(X)/FZ1-S(X)/FZ1-SA/FZ1-NA R. The clamp attaching position should be in 1. Clutch cable a range from 20 mm to 40 mm (0.79 in to 1.57 in) from the end of the brake hose 2. Left handlebar switch lead grommet. The front wheel sensor lead 3.
Page 88 CABLE ROUTING FZ1-N(X) / FZ1-S(X) FZ1-S(X) 2-43...
Page 89 CABLE ROUTING FZ1-N(X)/FZ1-S(X) M. To the wire harness 1. Wire harness N. To the coolant reservoir tank 2. Right handlebar switch lead O. Route the radiator fan motor lead (right) so 3. Throttle cable that there is no slack as much as possible in this section.
Page 90 CABLE ROUTING 2-45...
Page 91 CABLE ROUTING FZ1-SA O. Pass the coolant reservoir hose to the vehi- 1. Throttle cables cle inner side of the radiator inlet hose and route it to the lower outside of the vehicle of 2. Radiator inlet hose the thermostat assembly. 3.
Page 92 CABLE ROUTING 2-47...
Page 93 CABLE ROUTING FZ1-NA K. Bind the two EXUP cables with the clamp. 1. Throttle cables A part of the clamp should be located within 10 mm (0.39 in) from the edge of 2. Radiator inlet hose wire bending attachment. Clamp opening 3.
Page 94 CABLE ROUTING FZ1-N(X) / FZ1-S(X) Q(FZ1-N(X)) PP(FZ1-N(X)) 2-49...
Page 95 CABLE ROUTING FZ1-N(X)/FZ1-S(X) H. Route the hose assembly 1 by the vehicle 1. Clutch cable front side where the water pump inlet pipe is routed. For the hose tip position, route 2. Water pump breather hose the hose so that 10 mm (0.39 in) or more 3.
Page 96 CABLE ROUTING 2-51...
Page 97 CABLE ROUTING FZ1-SA H. Route the water pump breather hose by 1. Clutch cable the vehicle front side where the water pump inlet pipe is routed. For the hose tip 2. Clutch cable swaging metal position, route the hose so that 10 mm 3.
Page 98 CABLE ROUTING 2-53...
Page 99 CABLE ROUTING AC.Route the water pump breather hose finally in the guide after passing other hoses so that it can be positioned on the outside of the vehicle. AD.Route the coolant reservoir tank drain hose so that it is positioned at the inner- most part in hoses and leads.
Page 100 CABLE ROUTING 2-55...
Page 101 CABLE ROUTING FZ1-NA H. Route the water pump breather hose in 1. Clutch cable front of the water pump inlet pipe. Route the hose so that 10 mm (0.39 in) or more 2. Clutch cable swaging metal can be assured as shown in the illustration. 3.
Page 102 CABLE ROUTING FZ1-N(X) / FZ1-S(X) 2-57...
Page 103 CABLE ROUTING FZ1-N(X)/FZ1-S(X) 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...
Page 104 CABLE ROUTING FZ1-N(X) / FZ1-S(X) 2-59...
Page 105 CABLE ROUTING AL.Clamp each lead at the positioning taping R. Pass the license plate light lead and turn section (white) and then insert it to the signal light lead under the turn signal relay. cover. (In random order) S. Pass the turn signal light lead (right) and AM.Clamp each lead at the positioning taping license plate light lead under the rear section (blue) and then insert it to the...
Page 106 CABLE ROUTING 2-61...
Page 107 CABLE ROUTING FZ1-SA 53.Radiator fan motor lead (left) 1. Throttle cables 54.Oil level switch lead 2. Right handlebar switch lead 55.O sensor lead 3. Throttle cable (pull side) 56.Sidestand switch lead 4. Throttle cable (return side) 57.Speed sensor lead 5. Coolant reservoir tank hose 58.Radiator fan motor lead (Right) 6.
Page 108 CABLE ROUTING 2-63...
Page 109 CABLE ROUTING AJ.Installation procedure 1. Secure the main M. Route the fuse box lead under the radiator switch lead and immobilizer lead with Vel- fan motor relay. cro strap. 2. Secure the left handlebar N. Route the battery positive lead under the switch lead with Velcro strap.
Page 110 CABLE ROUTING FZ1-NA 2-65...
Page 111 CABLE ROUTING FZ1-NA 53.Frame 1. Throttle cables 54.Cover 2. Throttle cable (pull side) 55.Direct ignition coil lead 3. Throttle cable (return side) 56.Fuel hose 4. Wire harness 57.Radiator fan motor lead (right) 5. Right handlebar switch lead 58.Radiator fan motor lead (left) 6.
Page 112 CABLE ROUTING FZ1-NA 2-67...
Page 113 CABLE ROUTING AK.Installation procedure 1. Secure the main O. Route the fuse box lead under the radiator switch lead and immobilizer lead with Vel- fan motor relay. cro strap. 2. Secure the left handlebar P. Route the battery positive lead under the switch lead with Velcro strap.
Page 114 CABLE ROUTING FZ1-S(X) 2-69...
Page 115 CABLE ROUTING FZ1-S(X) 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 116 CABLE ROUTING 2-71...
Page 117 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 118 CABLE ROUTING 2-73...
Page 119: 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............3-10 MEASURING THE COMPRESSION PRESSURE .......3-10 CHECKING THE ENGINE OIL LEVEL ..........3-11 CHANGING THE ENGINE OIL.............3-12...
Page 120 LUBRICATING THE CENTERSTAND (FZ1-S(X)/FZ1-SA)....3-35 LUBRICATING THE REAR SUSPENSION ..........3-35 ELECTRICAL SYSTEM................3-36 CHECKING AND CHARGING THE BATTERY........3-36 CHECKING THE FUSES..............3-36 REPLACING THE HEADLIGHT BULBS..........3-36 ADJUSTING THE HEADLIGHT BEAM ..........3-37...
Page 122: 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 123 √ √ √ √ pedal pivot grease. shafts (FZ1-SA) Sidestand • Check operation. √ √ √ √ √ (FZ1-N(X))/ • Lubricate. (FZ1-NA) Sidestand, cen- • Check operation. √ √ √ √ √ ter stand (FZ1- • Lubricate. S(X)/FZ1-SA) Sidestand √...
Page 124 PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 Moving parts √ √ √ √ √ • Lubricate. and cables • Check operation and free play. Throttle grip • Adjust the throttle cable free play if √...
Page 125: 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 126 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 Valve lapping tool YM-A8998 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.
Page 127: Synchronizing The Throttle Bodies
ENGINE Example: • The valve lifter must turn smoothly when If the valve pad is marked “158”, the pad rotated by hand. thickness is 1.58 mm (0.062 in) d. Calculate the sum of the values obtained in g. Install the exhaust and intake camshafts, steps (b) and (c) to determine the required timing chain and camshaft caps.
Page 128 ENGINE 2. Remove: 8. Adjust: • Rider and passenger seat • Throttle body synchronization Refer to “GENERAL CHASSIS” on page ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4-1. a. With throttle body #3 as standard, adjust • Fuel tank throttle bodies #1, #2, and #4 using the air Refer to “FUEL TANK”...
Page 129: Adjusting The Exhaust Gas Volume
ENGINE 9. Measure: • Engine idling speed Out of specification → Adjust. 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”...
Page 130: Adjusting The Engine Idling Speed
ENGINE 8. Simultaneously press the “SELECT” and Throttle cable free play (at the “RESET” buttons to return to the cylinder flange of the throttle grip) selection (step 5). 3.0–5.0 mm (0.12–0.20 in) 9. Turn the main switch to “OFF” to cancel the mode.
Page 131: Checking The Spark Plugs
ENGINE (with a spark plug cleaner or wire brush) 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. EWA5D01003 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...
Page 132: 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 133: Changing The Engine Oil
ENGINE Type SAE10W-30 or SAE10W-40 or SAE15W-40 or SAE20W-40 or SAE20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13360 CAUTION: • Engine oil also lubricates the clutch and 4. Start the engine, warm it up for several the wrong oil types or additives could minutes, and then turn it off.
Page 134: 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 135: Adjusting The Clutch Cable Free Play
ENGINE EWA12980 only as a reference when measuring the WARNING engine oil pressure. The engine, muffler and engine oil are extremely hot. Engine oil pressure Possible causes • Faulty oil pump • Clogged oil filter Below specification • Leaking oil passage •...
Page 136: Replacing The Air Filter Element
ENGINE 2. Adjust • Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting dial “1” in direction “b” or “c” until the specified clutch cable free play is obtained. Direction “b” Clutch cable free play is increased. Direction “c” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 137: Checking The Throttle Body Joints
ENGINE 4. Install: 1. Remove: • Air filter case cover • Rider and passenger seat ECA14400 Refer to “GENERAL CHASSIS” on page CAUTION: 4-1. • Fuel tank Never operate the engine without the air fil- Refer to “FUEL TANK” on page 7-1. ter element installed.
Page 138: Checking The Exhaust System
ENGINE 2. Check: Exhaust pipe nut • Crankcase breather hose “1” 20 Nm (2.0 m·kg, 14 ft·lb) Cracks/damage → Replace. Exhaust pipe and exhaust pipe Loose connection → Connect properly. bracket bolt ECA13450 20 Nm (2.0 m·kg, 14 ft·lb) CAUTION: Exhaust pipe and muffler bolt Make sure the crankcase breather hose is 20 Nm (2.0 m·kg, 14 ft·lb)
Page 139: 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 140: Checking The Cooling System
ENGINE 2. Check: • 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 141 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 142 ENGINE Handling notes for coolant NOTE: Coolant is potentially harmful and should Before checking the coolant level, wait a few be handled with special care. minutes until the coolant has settled. EWA13040 WARNING 18. Install: • Rider and passenger seat •...
Page 143: 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 144: Checking The Brake Fluid Level
CHASSIS EAS21240 will significantly lower the boiling point of CHECKING THE BRAKE FLUID LEVEL the brake fluid and could cause vapor 1. Stand the vehicle on a level surface. lock. NOTE: ECA13540 • Place the vehicle on a suitable stand. CAUTION: •...
Page 145: Checking The Front Brake Hoses
CHASSIS EAS21280 2. Check: CHECKING THE FRONT BRAKE HOSES • Brake hose clamp “2” The following procedure applies to all of the Loose Connection → Tighten the clamp brake hoses and brake hose clamps. bolt. 1. Check: • Brake hose “1” Cracks/damage/wear →...
Page 146: Bleeding The Hydraulic Brake System
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • The system is disassembled. • A brake hose is loosened, disconnected or replaced. • The brake fluid level is very low. A. Front brake caliper •...
Page 147 CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Bleeding the ABS brake EWA14010 WARNING Bleed the ABS whenever: • the system is disassembled. A. Front • a brake hose is loosened, disconnected B. Rear or replaced.
Page 148: Adjusting The Shift Pedal
CHASSIS EWA14020 NOTE: WARNING Place the vehicle on a suitable stand so that After bleeding the ABS, check the brake the rear wheel is elevated. operation. 2. Spin the rear wheel several times and find ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the tightest position of drive chain. 3.
Page 149: Lubricating The Drive Chain
CHASSIS Refer to “STEERING HEAD” on page 4- Locknut 16 Nm (1.6 m·kg, 12 ft·lb) 4. Adjust: • Steering head e. Tighten the wheel axle nut to specification. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring Wheel axle nut nut “2”, and the rubber washer “3”.
Page 150: Checking The Front Fork
CHASSIS c. Hook a spring gauge “2” onto the plastic locking tie. 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, d. Hold the spring gauge at a 90° angle from remove the lower bracket and check the the handlebar, pull the spring gauge, and upper and lower bearings.
Page 151: 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 152 CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (Right side front fork) Compression damping (Left side front fork) ECA5D01014 CAUTION: ECA5D01019 CAUTION: • Never go beyond the maximum or mini- • Never go beyond the maximum or mini- mum adjustment positions. mum adjustment positions. •...
Page 153: 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 154: Checking The Tires
Rear 290 kPa (2.9 kg/cm , 2.9 bar, 42 psi) Maximum load* 196 kg (432 lb) (FZ1-N(X)) 190 kg (419 lb) (FZ1-S(X)) 184 kg (406 lb) (FZ1-SA) 189 kg (417 lb) (FZ1-NA) * Total weight of rider, passenger, cargo and accessories.
Page 155 Minimum tire tread depth concerning handling characteristics can be 1.6 mm (0.06 in) given if a tire combination other than one approved by Yamaha is used on this vehi- EWA14080 WARNING cle. • Do not use a tubeless tire on a wheel...
Page 156: Checking The Wheels
CHASSIS • Install the tire with the mark pointing in the NOTE: direction of wheel rotation. Hold the cable end upright and pour a few • Align the mark “2” with the valve installation drops of lubricant into the cable sheath or use point.
Page 157: Electrical System
A. FZ1-N(X)/FZ1-NA EAS21780 REPLACING THE HEADLIGHT BULBS B. FZ1-S(X)/FZ1-SA 1. Remove: 4. Remove: • Headlight side cover bolts “1” (FZ1-N(X)), • Headlight bulb cover “1” (FZ1-S(X)/FZ1- (FZ1-NA) 2. Disconnect: 5. Remove: • Headlight sub-wire harness coupler “2” • Headlight bulb holder “1”...
Page 158 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(X)/FZ1-NA B. FZ1-S(X)/FZ1-SA 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 159 ELECTRICAL SYSTEM A. FZ1-N(X)/FZ1-NA B. FZ1-S(X)/FZ1-SA ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-38...
Page 160 ELECTRICAL SYSTEM 3-39...
Page 161 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE COVER...............4-8 INSTALLING THE COVER ..............4-8 FRONT WHEEL ....................4-9 REMOVING THE FRONT WHEEL ............4-12 CHECKING THE FRONT WHEEL............4-12 [D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ............4-13 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-14 INSTALLING THE FRONT WHEEL ............4-15 REAR WHEEL ....................4-17 REMOVING THE REAR WHEEL ............4-21...
Page 162 INSTALLING THE REAR BRAKE MASTER CYLINDER......4-48 ABS (ANTI-LOCK BRAKE SYSTEM) ............4-50 [D-5] MAINTENANCE OF THE HYDRAULIC UNIT......4-52 HYDRAULIC UNIT OPERATION TEST ..........4-53 [D-6-5] TRIAL RUN ................4-57 HANDLEBAR....................4-58 REMOVING THE HANDLEBAR ............4-59 CHECKING THE HANDLEBAR............4-59 INSTALLING THE HANDLEBAR ............4-59 FRONT FORK.....................4-62 REMOVING THE FRONT FORK LEGS ..........4-64 DISASSEMBLING THE FRONT FORK LEGS ........4-64 CHECKING THE FRONT FORK LEGS..........4-65...
Page 164: General Chassis
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 proce- dure.
Page 165 GENERAL CHASSIS Removing the headlight and meter assembly (FZ1-N(X)), (FZ1-NA) 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 166 GENERAL CHASSIS Removing the front cowling (FZ1-S(X)/FZ1-SA) 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 proce- dure.
Page 167 GENERAL CHASSIS Removing the under cowling (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Under cowling Rectifier/regulator Right under cowling bracket Left under cowling bracket For installation, reverse the removal proce- dure.
Page 168 GENERAL CHASSIS Removing the rear fender (FZ1-N(X)), (FZ1-NA) 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...
Page 169 GENERAL CHASSIS Removing the rear fender (FZ1-S(X)/FZ1-SA) 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 170 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 coupler Disconnect. Intake air temperature sensor Air filter case cover Air filter...
Page 171: Removing The Cover
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 172: Front Wheel
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs (FZ1-N(X)/FZ1-S(X)) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel axle pinch bolt Front wheel axle Collar Dust cover Front wheel Front brake disc For installation, reverse the removal proce- dure.
Page 173 FRONT WHEEL Removing the front wheel sensor and sensor rotor (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel sensor Front wheel axle pinch bolt Front wheel axle Collar Sensor housing Dust cover Front wheel Front brake disc For installation, reverse the removal proce-...
Page 174 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-11...
Page 175: Removing The Front Wheel
FRONT WHEEL EAS21900 Refer to “CHECKING THE TIRES” on REMOVING THE FRONT WHEEL page 3-33 and “CHECKING THE 1. Stand the vehicle on a level surface. WHEELS” on page 3-35. EWA13120 3. Measure: WARNING • Radial wheel runout “1” Securely support the vehicle so that there •...
Page 176: [D-3] Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL Keep them away from dirt and do not sub- ject them to shocks. • The ABS wheel sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. Removing the front wheel sensor 1.
Page 177: Adjusting The Front Wheel Static Balance
FRONT WHEEL • Brake hose holder “4” NOTE: The wheel sensor rotor of the vehicle is NOTE: inserted under pressure by a special process When installing the front wheel sensor, check and cannot be replaced as a single unit. To the wheel sensor lead for twists and the sensor replace the sensor rotor, replace the wheel electrode for foreign materials.
Page 178: Installing The Front Wheel
FRONT WHEEL b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. Turn the front wheel 90° so that the “X ” c. If the heavy spot does not stay in that posi- mark is positioned as shown. tion, install a heavier weight.
Page 179 FRONT WHEEL 4. Lower the front wheel so that it is on the ground. 5. Tighten: • Wheel axle Wheel axle nut 72 Nm (7.2 m·kg, 52 ft·lb) • Wheel axle pinch bolt Wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) ECA14140 CAUTION: Before tightening the front wheel axle, push...
Page 180: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel (FZ1-N(X)/FZ1-S(X)) Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut Loosen. Adjusting bolt Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left) Adjusting block (right) Rear wheel Brake caliper bracket For installation, reverse the removal proce- dure.
Page 181 REAR WHEEL Removing the rear wheel sensor and sensor rotor (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor protector Rear wheel sensor Rear wheel sensor lead stay Rear brake caliper Lock nut Loosen. Adjusting nut Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left)
Page 182 REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (left and right) Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
Page 183 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-20...
Page 184: Removing The Rear Wheel
REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 185: Checking And Replacing The Rear Wheel Sprocket
REAR WHEEL EAS22120 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING AND REPLACING THE REAR WHEEL SPROCKET EAS22200 1. Check: [D-4] MAINTENANCE OF THE REAR • Rear wheel sprocket WHEEL SENSOR AND SENSOR ROTOR More than 1/4 tooth “a” wear → Replace ECA5D01002 the rear wheel sprocket. CAUTION: Bent teeth →...
Page 186 REAR WHEEL 3. Remove: • Rear wheel sensor protector • Rear wheel sensor “4” 2. Install: • Rear wheel Refer to “INSTALLING THE REAR WHEEL” on page 4-24. 4. Remove: ECA14470 • Rear wheel CAUTION: Refer to “REMOVING THE REAR Make sure there are no foreign materials in WHEEL”...
Page 187: Adjusting The Rear Wheel Static Balance
REAR WHEEL • Rear wheel sensor coupler “5” 4. Check: • Check the clearance “a” between the rear ECA14500 CAUTION: wheel sensor and sensor rotor. Out of specification → Check the exist- To route the rear wheel sensor lead, refer to ence of foreign matters in the wheel sen- “CABLE ROUTING”...
Page 188 REAR WHEEL • Wheel axle nut • Brake caliper bolts Wheel axle nut 150 Nm (15 m·kg, 108 ft·lb) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) 22 Nm (2.2 m·kg, 16 ft·lb) EWA13500 WARNING Make sure the brake hose is routed prop- erly.
Page 189: 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 proce- dure.
Page 190 Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Right rear view mirror (FZ1-N(X)), (FZ1-NA) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder diaphragm Brake lever Front brake light switch lead coupler Disconnect.
Page 191 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-28...
Page 192 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure.
Page 193 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 dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 194: 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 195: Replacing The Front Brake Pads
FRONT BRAKE NOTE: Brake 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 lining thickness LOCTITE®...
Page 196: 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 197: Checking The Front Brake Calipers
FRONT BRAKE • Do not loosen the bolts “3”. EAS22410 ASSEMBLING THE FRONT BRAKE CALI- c. Remove the brake caliper piston seals. PERS d. Repeat the previous steps to force out the EWA13620 right side pistons from the brake caliper. WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 198: Removing The Front Brake Master Cylinder
FRONT BRAKE ECA14170 • When refilling, be careful that water does CAUTION: not enter the brake fluid reservoir. Water will significantly lower the boiling point of When installing the brake hose onto the brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.
Page 199: 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 brake fluid •...
Page 200 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 201: 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 proce- dure.
Page 202 REAR BRAKE Removing the rear brake master cylinder (FZ1-N(X)/FZ1-S(X)) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
Page 203 REAR BRAKE Removing the rear brake master cylinder (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint...
Page 204 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 disassembly pro- cedure. 4-41...
Page 205 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure. 4-42...
Page 206 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 dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 207: 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 preventive measures: BRAKE DISCS” on page 4-31. •...
Page 208: Removing The Rear Brake Caliper
REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “CHECKING THE BRAKE a. Connect a clear plastic hose “1” tightly to FLUID LEVEL” on page 3-23. the bleed screw “2”. Put the other end of the hose into an open container. 5. Check: • Brake pedal operation Soft or spongy feeling →...
Page 209: Checking The Rear Brake Caliper
REAR BRAKE Scratches/wear → Replace the brake cal- iper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a.
Page 210: Installing The Rear Brake Caliper
REAR BRAKE EAS22670 Refer to “REPLACING THE REAR INSTALLING THE REAR BRAKE CALIPER BRAKE PADS” on page 4-44. 1. Install: • Brake caliper “1” Brake caliper bolt (front) (temporarily) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) • Copper washers “2” 22 Nm (2.2 m·kg, 16 ft·lb) •...
Page 211: 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 212 Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. A. FZ1-N(X)/FZ1-S(X) B. FZ1-SA/FZ1-NA 2. Fill: • Brake fluid reservoir (with the specified amount of the recom- 5.
Page 213 ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
Page 214 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose (hydraulic unit to rear brake caliper) Union bolt Copper washer Brake hose (rear brake master cylinder to hydraulic unit) ABS motor coupler Hydraulic unit solenoid coupler Brake hose holder...
Page 215: [D-5] Maintenance Of The Hydraulic Unit
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22770 • Brake hose “3” (to the rear brake caliper) [D-5] MAINTENANCE OF THE HYDRAULIC • Brake hose “4” (from the rear brake mas- UNIT ter cylinder) ECA15060 CAUTION: Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve.
Page 216: Hydraulic Unit Operation Test
ABS (ANTI-LOCK BRAKE SYSTEM) Installing the hydraulic unit EWA13940 Proceed in the reverse order of disassembly. WARNING Pay attention to the following items. The brake hoses to the front and rear brake 1. Install: calipers can be distinguished by the rubber •...
Page 217 ABS (ANTI-LOCK BRAKE SYSTEM) action that is generated in the brake lever Test coupler adapter and brake pedal when the ABS is activated. 90890-03149 • Hydraulic unit operation test 2: this test checks the function of the ABS after the sys- tem was disassembled, adjusted, or ser- viced.
Page 218 ABS (ANTI-LOCK BRAKE SYSTEM) When the main switch is set to “ON”, the Hydraulic unit operation test 2 ABS warning light comes on for 2 seconds, EWA13120 WARNING goes off for 3 seconds, then starts flashing. When the ABS warning light starts flashing, Securely support the vehicle so that there the brake lever “1”...
Page 219 ABS (ANTI-LOCK BRAKE SYSTEM) 10. After the pulsating action has stopped in the brake lever, it is generated in the brake A. FZ1-SA pedal “2” 0.5 second after and continues B. FZ1-NA for approximately 1 second. 6. Set the engine stop switch to “ ”.
Page 220: [D-6-5] Trial Run
ABS (ANTI-LOCK BRAKE SYSTEM) • If the pulsating action is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hydraulic unit. 12. Set the main switch to “OFF”. 13. Remove the test coupler adaptor from the test coupler.
Page 221: Handlebar
Order Job/Parts to remove Q’ty Remarks Front cowling (FZ1-S(X)/FZ1-SA) Refer to “GENERAL CHASSIS” on page 4-1. Rear view mirror (FZ1-N(X)), (FZ1-NA) Front brake light switch connector Disconnect. Front master cylinder bracket Front brake master cylinder assembly Right handlebar switch Throttle cable housing...
Page 222: 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 223 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 224 HANDLEBAR NOTE: • Align the projections “a” on the handlebar switch with the holes “b” in the handlebar. • There 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 225: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Refer to “CHECKING THE TIRES” on page Front wheel 3-33 and “CHECKING THE WHEELS” on Front brake calipers page 3-35. Front fender Cap bolt Loosen.
Page 226 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 disassembly pro-...
Page 227: Removing The Front Fork Legs
FRONT FORK EAS22970 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE FRONT FORK LEGS a. Press down on the spacer with the fork The following procedure applies to both of the spring compressor “4”. front fork legs. b. Install the rod holder “5” between the nut NOTE: “3”...
Page 228: Checking The Front Fork Legs
FRONT FORK 3. Remove: • Oil seal clip “1” (with a flat-head screwdriver) ECA14180 CAUTION: Do not scratch the inner tube. EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: •...
Page 229: Assembling The Front Fork Legs
FRONT FORK 3. Check: NOTE: • Damper rod “1” The left side (for the compression) damper rod Damage/wear → Replace. assembly has the four holes of oil path, unlike Obstruction → Blow out all of the oil pas- the right side. sages with compressed air.
Page 230 FRONT FORK 4. Install: NOTE: • Dust seal “1” Adjust the oil seal clip so that it fits into the • Oil seal clip “2” outer tube’s groove. • Oil seal “3” • Washer “4” ECA14220 CAUTION: Make sure the numbered side of the oil seal faces up.
Page 231 FRONT FORK 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- ual air. 12. Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without 9.
Page 232: Installing The Front Fork Legs
FRONT FORK d. Press down in the spacer with the fork h. Set the cap bolt distance “c” to specifica- spring compressor “1” tion. e. Pull up the rod puller and install the rod holder “2” between the damper adjusting Distance “c”...
Page 233 FRONT FORK 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: • Lower bracket pinch bolt “1” Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) •...
Page 234: Steering Head
Front brake calipers Refer to “FRONT BRAKE” on page 4-26. Front cowling (FZ1-S(X)/FZ1-SA) Refer to “GENERAL CHASSIS” on page 4-1. Headlight and meter assembly (FZ1-N(X)), Refer to “GENERAL CHASSIS” on page 4-1. (FZ1-NA) Handlebar Refer to “HANDLEBAR” on page 4-58.
Page 235 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower bearing Lower bearing dust seal Lower bearing inner race Bearing cover Upper bearing inner race Upper bearing Bearing outer race For installation, reverse the removal proce- dure. 4-72...
Page 236: 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 237: 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 238: 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. Brake fluid reservoir tank bolt Refer to “REAR BRAKE”...
Page 239: 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 240: Checking The Connecting Arm And Relay Arm
REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber 3. Tighten: Gas leaks/oil leaks → Replace the rear • Rear shock absorber assembly upper nut shock absorber assembly. Rear shock absorber assembly • Spring upper nut Damage/wear → Replace the rear shock 44 Nm (4.4 m·kg, 32 ft·lb) absorber assembly.
Page 241: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-17. Rear brake caliper Refer to “REAR BRAKE” on page 4-38. Refer to “REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY” on page 4-75. Drive sprocket Refer to “ENGINE REMOVAL”...
Page 242: 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 243: Installing The Swingarm
SWINGARM 5. Check: • Connecting arms “1” • Relay arm “2” Damage/wear → Replace. 3. Install: 6. Check: • Rear shock absorber assembly • Bearings “3” • Oil seals “4” • Rear wheel Damage/pitting → Replace. Refer to “INSTALLING THE REAR 7.
Page 244: 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 5-1. Drive chain guard Drive chain For installation, reverse the removal proce- dure. 4-81...
Page 245: 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 246: Checking The Drive Sprocket
CHAIN DRIVE EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: • 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.
Page 247: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS ............5-11 CHECKING THE CAMSHAFTS ............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-13 CHECKING THE TIMING CHAIN GUIDES ..........5-13 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS ............5-15 CYLINDER HEAD..................5-18 REMOVING THE CYLINDER HEAD ............5-19 CHECKING THE CYLINDER HEAD ............5-19...
Page 248 CHECKING THE CLUTCH PLATES.............5-47 CHECKING THE CLUTCH SPRINGS ..........5-48 CHECKING THE CLUTCH HOUSING ..........5-48 CHECKING THE CLUTCH BOSS ............5-48 CHECKING THE PRESSURE PLATE ..........5-48 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-49 INSTALLING THE CLUTCH..............5-49 SHIFT SHAFT .....................5-52 REMOVING THE SHIFT SHAFT ............5-53 CHECKING THE SHIFT SHAFT ............5-53 CHECKING THE STOPPER LEVER............5-53 INSTALLING THE SHIFT SHAFT ............5-53...
Page 249 INSTALLING THE TRANSMISSION.............5-88...
Page 250: 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 proce- dure.
Page 251 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 252 ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks Pulley Spring Spring seat For assembly, reverse the disassembly pro- cedure.
Page 253 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. Drain.
Page 254 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks For assembly, reverse the removal proce- dure.
Page 255 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 proce- dure.
Page 256: 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- 2. Tighten: • Right front engine mounting bolt 2 Right front engine mounting 7. Tighten: bolt 2 •...
Page 257 ENGINE REMOVAL 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) NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut.
Page 258: 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. Refer to “AIR INDUCTION SYSTEM”...
Page 259 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT POSITION SEN- Pickup rotor cover SOR” on page 5-37. Camshaft sprocket bolt Loosen. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Refer to “REMOVING THE CAMSHAFTS” Dowel pin on page 5-11.
Page 260: Removing The Camshafts
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to “CRANKSHAFT POSITION SENSOR” on page 5-37. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. 5.
Page 261: 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 262: 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: • Camshaft journal diameter “a” 1. Timing chain roller Out of specification →...
Page 263 CAMSHAFTS • Timing chain tensioner spring “3” b. Squeeze the timing chain tensioner clip “2” and push the timing chain tensioner rod “3”. NOTE: Squeeze the timing chain tensioner clip, and NOTE: then remove the timing chain tensioner spring When the timing chain tensioner rod “3” is and timing chain tensioner rod.
Page 264: 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 265 CAMSHAFTS • The camshaft cap bolts must be tightened • Gasket evenly or damage to the cylinder head, • Timing chain tensioner “1” camshaft caps, and camshafts will result. • Timing chain tensioner bolts “2” • Do not turn the crankshaft when installing the camshaft to avoid damage or Timing chain tensioner bolt improper valve timing.
Page 266 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 5-37. 5-17...
Page 267 CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Refer to Engine “ENGINE REMOVAL” on page 5-1. Refer to Intake camshaft “CAMSHAFTS” on page 5-9. Refer to Exhaust camshaft “CAMSHAFTS” on page 5-9. Cylinder head Cylinder head gasket Dowel pin Coolant pipe...
Page 268: Cylinder Head
CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-11. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: a. Place a straightedge “1” and a thickness • Cylinder head nuts gauge “2” across the cylinder head. •...
Page 269 CYLINDER HEAD 2. Install: • Gasket “1” • Dowel pins 5. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAM- 3. Install: SHAFTS” on page 5-15. • Cylinder head NOTE: Pass the timing chain through the timing chain cavity.
Page 270 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 5-18. 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 271: Valves And Valve Springs
VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-22...
Page 272: 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 273: 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 274: 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 275 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 (0.0354–0.0433 valve face should be lapped. Exhaust ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 0.90–1.10 mm (0.0354–0.0433 a. Apply a coarse lapping compound “a” to the valve face.
Page 276: 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 277: 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 278 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 Valve spring compressor attachment 90890-04114 Valve spring compressor adapter YM-04114 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter (22 mm) YM-04108 5.
Page 279: 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. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-12.
Page 280 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Washer Bearing For assembly, reverse the removal proce- dure. 5-31...
Page 281: 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 282 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 283: 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 proce- dure. 5-34...
Page 284: 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 285: Installing The Starter Clutch
STARTER CLUTCH b. When turning the starter clutch drive gear counterclockwise “A”, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear clockwise “B”, it should turn freely, other- wise the starter clutch is faulty and must be replaced.
Page 286: 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. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 287: 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 288: 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. Starter motor lead Starter motor For assembly, reverse the removal proce-...
Page 289 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 disassembly pro- cedure. 5-40...
Page 290: 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 Commutator resistance “1” starter motor.
Page 291: 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 292: Clutch
CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-12. Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce- dure.
Page 293 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal proce- dure. 5-44...
Page 294 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 295: 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 296: 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 297: Checking The Clutch Springs
CLUTCH 2. Check: • Bearing Damage/wear → Replace the bearing EAS25140 CHECKING THE CLUTCH SPRINGS and 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 298: Checking The Pull Lever Shaft And Pull Rod
CLUTCH EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 3.
Page 299 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 300 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 301: 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 5-43. Shift arm and shift rod Refer to “ENGINE REMOVAL” on page 5-1. Circlip Washer Shift shaft Collar Shift shaft spring...
Page 302: Removing The Shift Shaft
SHIFT SHAFT EAS5D01019 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refer to “CLUTCH” on page 5-43 2. Remove: • Shift arm • Shift rod Refer to “ENGINE REMOVAL” on page 5- 3. Remove: • Circlip “1” • Washer “2” EAS25420 CHECKING THE SHIFT SHAFT (left side of the engine)
Page 303 SHIFT SHAFT • Stopper lever spring “3” 4. Install: • Shift rod • Shift arm Refer to “ENGINE REMOVAL” on page 5- 5. Install: • Clutch assembly Refer to “CLUTCH” on page 5-43. 2. Install: • Washer • Collar • Shift shaft spring “1” •...
Page 304: Oil Pump
OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-12. EXUP cables Refer to “ENGINE REMOVAL” on page 5-1. sensor Refer to “ENGINE REMOVAL”...
Page 305 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin Oil/water pump assembly For assembly, reverse the removal proce- dure.
Page 306 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 rotor Oil pump inner rotor For assembly, reverse the disassembly pro- cedure. 5-57...
Page 307: 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 308: Checking The Relief Valve
OIL PUMP EAS24970 CHECKING THE RELIEF VALVE EAS25600 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 309: 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 310: Installing The Oil Pan
OIL PUMP EAS25050 INSTALLING THE OIL PAN 1. Install: • Dowel pins • Gasket • Oil pan “1” Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) • Oil level switch “2” Oil level switch bolt 4. Install: 10 Nm (1.0 m·kg, 7.2 ft·lb) •...
Page 311: 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 5-1. Cylinder head Refer to “CYLINDER HEAD”...
Page 312 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Lower crankcase Dowel pin Damper For assembly, reverse the removal proce- dure. 5-63...
Page 313: 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 314 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 315: 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 5-62. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring...
Page 316 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-62. Refer to “REMOVING THE CONNECTING Connecting rod and connecting rod caps RODS AND PISTONS” on page 5-68. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear...
Page 317: 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 318: 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) EAS24390 CHECKING THE CYLINDER AND PISTON...
Page 319: Checking The Piston Pins
CRANKSHAFT Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 (0.0012– 0.15–0.25 mm (0.0059–0.0098 0.0026 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring 0.020–0.055 (0.0008– 0.30–0.45 mm (0.0118–0.0177 0.0022 in) Limit Limit 0.115 mm (0.0045 in)
Page 320: 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 (0.6694– a. Clean the big end bearings, crankshaft 0.6698 in) pins, and the inside of the connecting rods Limit halves. 17.043 mm (0.6710 in) b.
Page 321 CRANKSHAFT j. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. k. Tighten the connecting rod bolts. e. Tighten the connecting rod bolts. Connecting rod bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE:...
Page 322 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: EWA5D01010 • The numbers “A” stamped into the crank- WARNING shaft wed and the numbers “1”...
Page 323: 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 324 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 325 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 326: 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 327 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 (2.4 m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2 m·kg, 8.7 ft·lb) M9 x 105 mm (4.1 in) bolts: “1”–“10” d.
Page 328: 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 329 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 330: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase lower Refer to “CRANKCASE” on page 5-62. Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L”...
Page 331 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-82...
Page 332 TRANSMISSION Disassembling the main axle assembly 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 disassembly pro- cedure.
Page 333 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer Collar...
Page 334 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure. 5-85...
Page 335: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
Page 336: 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 337 TRANSMISSION EAS26350 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 338 TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-89...
Page 339: Cooling System
COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR ..............6-2 OIL COOLER ....................6-3 CHECKING THE OIL COOLER..............6-4 INSTALLING THE OIL COOLER ............6-4 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT............6-7 ASSEMBLING THE THERMOSTAT ASSEMBLY ........6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP..........6-10 CHECKING THE WATER PUMP ............6-10 ASSEMBLING THE WATER PUMP............6-10...
Page 340 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. Drain.
Page 341: Radiator
RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
Page 342: Oil Cooler
OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil 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 343: Checking The 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 344: Thermostat
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. Drain.
Page 345 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 disassembly pro- cedure.
Page 346: Checking The Thermostat
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 347 THERMOSTAT 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.
Page 348: 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 5-55. Oil pump rotor Refer to “OIL PUMP” on page 5-55. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing...
Page 349: Disassembling The Water Pump
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 350 (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 351: Fuel System
FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK...............7-3 THROTTLE BODIES..................7-4 CHECKING THE INJECTORS ...............7-7 CHECKING THE THROTTLE BODIES ..........7-7 CHECKING THE FUEL PRESSURE............7-7 ADJUSTING THE THROTTLE POSITION SENSOR ......7-7...
Page 352: Fuel Tank
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 353: Fuel Tank
FUEL TANK EAS26630 • Do not touch the base section of the fuel REMOVING THE FUEL TANK sender. 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. EAS26670 2. Remove: CHECKING THE FUEL PUMP BODY •...
Page 354 FUEL TANK EAS5D01024 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 355: 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. Sub-wire harness coupler Disconnect.
Page 356 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 357 THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Throttle position sensor Throttle body assembly For installation, reverse the removal proce- dure.
Page 358 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- EAS26990 mary injector fuel rail). CHECKING THE THROTTLE BODIES 1. Check: Vacuum/pressure pump gauge •...
Page 359 THROTTLE BODIES 1. Check: EAS5D01025 ADJUSTING THE SUB-THROTTLE POSI- • Throttle position sensor TION SENSOR Refer to “CHECKING THE THROTTLE 1. Check: POSITION SENSOR” on page 8-153. • Sub-throttle position sensor 2. Adjust: Refer to “CHECKING THE SUB-THROT- • Throttle position sensor angle TLE POSITION SENSOR”...
Page 360 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 361 THROTTLE BODIES EAS2D1011 EAS5D01026 CHECKING THE SUB-THROTTLE SERVO ADJUSTING THE THERMO WAX MOTOR 1. Adjust: 1. Check: • Thermo wax the end face distance “a” • Sub-throttle servo motor operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Out of specification → Replace. a. Before adjusting the distance, push the rod “b”...
Page 362 THROTTLE BODIES NOTE: • Setup tolerance of the longitudinal axis should be ± 0.2 mm (± 0.008 in). • After adjusting the thermo wax, check that the first idling is released at the coolant tem- perature around 60°C (140°F) by idling. •...
Page 363: 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 364 AIR INDUCTION SYSTEM EAS27060 A. From the air cleaner CHECKING THE AIR INDUCTION SYSTEM B. To the cylinder head Air injection 1. Check: The air induction system burns unburned • Hoses exhaust gases by injecting fresh air (second- Loose connections → Connect properly. ary air) into the exhaust port, reducing the Cracks/damage →...
Page 365 AIR INDUCTION SYSTEM c. Measure the air induction system solenoid resistance. Air induction system solenoid resistance 18–22Ω at 20°C (68°F) d. Out of specification → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS27070 INSTALLING THE AIR INDUCTION SYSTEM 1. Install: • Plate • Reed valve assembly •...
Page 366 AIR INDUCTION SYSTEM 7-15...
Page 367: Electrical System
ELECTRIC STARTING SYSTEM..............8-5 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(X)) ............8-15 CIRCUIT DIAGRAM (FZ1-S(X)) ............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 368 ABS (ANTI-LOCK BRAKE SYSTEM) ............8-89 CIRCUIT DIAGRAM (FZ1-SA)..............8-89 CIRCUIT DIAGRAM (FZ1-NA)..............8-91 ABS COMPONENTS CHART...............8-93 ABS CONNECTOR LOCATION CHART ..........8-97 ABS ECU AND ABS MOTOR RELAY..........8-101 [D-1] MAINTENANCE OF THE ABS ECU ..........8-103 [D-2] MAINTENANCE OF THE ABS MOTOR RELAY ......8-104 ABS TROUBLESHOOTING OUTLINE ..........8-105 BASIC INSTRUCTION FOR TROUBLESHOOTING ......8-106 BASIC PROCESS FOR TROUBLESHOOTING .........8-107...
Page 369 CHECKING THE INTAKE AIR PRESSURE SENSOR .......8-156 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-156...
Page 370: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 371 IGNITION SYSTEM 1. Main switch 6. Main fuse 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 (engine control unit) 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...
Page 372: Passenger Seat
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 373 IGNITION SYSTEM 8. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-135. OK↓ NG→ 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-135. OK↓...
Page 374: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 375 ELECTRIC STARTING SYSTEM 1. Main switch 6. Main fuse 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.Ignition fuse...
Page 376 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 377 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 378 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 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 379 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the immobilizer kit. SWITCHES” on page 8-135. OK↓ NG→ 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-135. OK↓...
Page 380: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
Page 381 CHARGING SYSTEM 2. Rectifier/regulator 3. AC magneto 6. Main fuse 7. Battery 8-12...
Page 382 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 8-139. OK↓...
Page 383 CHARGING SYSTEM 8-14...
Page 384: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (FZ1-N(X)) 8-15...
Page 385 LIGHTING SYSTEM 1. Main switch 6. Main fuse 7. Battery 23.ECU (engine control unit) 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.Taillight fuse 81.Headlight fuse 8-16...
Page 386 LIGHTING SYSTEM EAS5D01027 CIRCUIT DIAGRAM (FZ1-S(X)) 8-17...
Page 387 LIGHTING SYSTEM 1. Main switch 6. Main fuse 7. Battery 23.ECU (engine control unit) 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.Taillight fuse 82.Headlight fuse 8-18...
Page 388 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 NG→...
Page 389 Replace the headlight relay. Refer to “CHECKING THE RELAYS” on page 8-142. 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(X))” on page 8-15. OK↓ This circuit is OK. 8-20...
Page 390: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
Page 391 SIGNALING SYSTEM 1. Main switch 6. Main fuse 7. Battery 11.Relay unit 14.Neutral switch 16.Fuel pump 19.Speed sensor 23.ECU (engine control unit) 42.Fuel level warning light 43.Oil level warning light 44.Neutral indicator light 45.Tachometer 46.Multi-function meter 48.Coolant temperature indicator light 50.Left turn signal indicator light 51.Right turn signal indicator light 53.Oil level switch...
Page 392 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.
Page 393 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 394 SIGNALING SYSTEM 3. Check the hazard switch. NG→ Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 8-135. OK↓ NG→ 4. Check the turn signal/hazard relay. Refer to “CHECKING THE Replace the turn signal/hazard relay. RELAYS” on page 8-142. OK↓...
Page 395 SIGNALING SYSTEM 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 8-21. OK↓ This circuit is OK. The fuel level warning light fails to come on. 1.
Page 396 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
Page 397 COOLING SYSTEM 1. Main switch 6. Main fuse 7. Battery 23.ECU (engine control unit) 38.Coolant temperature sensor 78.Ignition fuse 82.Radiator fan motor relay 83.Left radiator fan motor fuse 84.Right radiator fan motor fuse 85.Left radiator fan motor 86.Right radiator fan motor 8-28...
Page 398 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 8-139.
Page 399 COOLING SYSTEM 8-30...
Page 400: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
Page 401 FUEL INJECTION SYSTEM 1. Main switch 4. Buckup fuse 6. Main fuse 7. Battery 8. Fuse injection system fuse 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...
Page 402 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 1. Check the fuses. NG→...
Page 403 FUEL INJECTION SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the immobilizer kit. SWITCHES” on page 8-135. OK↓ NG→ 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-135. OK↓...
Page 404 FUEL INJECTION SYSTEM 17.Checking the atmospheric pres- NG→ sure sensor. Replace the atmospheric pressure Refer to “CHECKING THE ATMO- sensor. SPHERIC PRESSURE SENSOR” on page 8-155. OK↓ 18.Check the injector. NG→ Refer to “CHECKING THE INJEC- Replace the injector. TORS” on page 7-7. OK↓...
Page 405 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 406 FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 407 FUEL INJECTION SYSTEM d. Engine trouble warning light on for 1.4 sec- a. Main switch “OFF” onds b. Main switch “ON” c. Engine trouble warning light off EAS27362 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 408 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Coolant temperature Coolant temperature sensor: sensor Able Able open or short circuit detected. (open or short circuit) Intake air temperature Intake air temperature sensor: sensor Able Able...
Page 409 FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Able Able (depend- (depend- ing on ing on Injector Injector: the num- the num- (open circuit) open circuit detected. ber of ber of faulty faulty cylin- cylin-...
Page 410 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 Unable Unable within the specified duration. (output signal error) ECU internal malfunc- Data from the ECU cannot be received Er-3 tion...
Page 411 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 412 FUEL INJECTION SYSTEM The data representing the operating conditions of the sensor appears on the odometer/ tripmeter/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 413 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Atmospheric pressure sensor hose is clogged. When the main switch is • Intake air pressure sensor hose is clogged, turned to “ON”, the atmo- kinked, or pinched. spheric pressure sensor •...
Page 414 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Open circuit detected in the • Malfunction in ignition coil. primary lead of the cylinder- • Malfunction in a component of ignition cut- #4 ignition coil.
Page 415 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. •...
Page 416 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 417 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction code reinstate • No malfunction code — • Malfunction code exists Fault code 24 To reinstate, set the engine • (If more than one code stop switch to “ ”.
Page 418 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the injector #3 five times at one-second inter- Check the operating sound Injector #3 vals. of the injector #3 five times. Illuminates the engine trou- ble warning light. Actuates the injector #4 five times at one-second inter- Check the operating sound Injector #4...
Page 419 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuate the servo motor turns to close side and to open Check the operating sound side. Sub-throttle servo motor of the Sub-throttle servo Illuminates the engine trou- motor. ble warning light only while the motor is running.
Page 420 FUEL INJECTION SYSTEM No normal signals are received from the crankshaft Fault code No. Symptom position sensor. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
Page 421 FUEL INJECTION SYSTEM Intake air pressure sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any Turn the main •...
Page 422 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 423 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 424 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 425 FUEL INJECTION SYSTEM When the main switch is turned to “ON”, the atmo- Fault code No. Symptom spheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Atmospheric pressure sensor Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstatement Order Check or maintenance job...
Page 426 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 427 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 428 FUEL INJECTION SYSTEM Fault code No. 30 Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method The vehicle has overturned. Raise the vehicle upright. Turning the main switch to Installed state of the lean angle sen-...
Page 429 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 430 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 •...
Page 431 FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 36 Symptom #4 ignition coil Diagnostic code No. Cylinder-#4 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •...
Page 432 FUEL INJECTION SYSTEM Fault code No. 39 Symptom Open circuit detected in a injector. Injector #1 Injector #2 Diagnostic code No. Injector #3 Injector #4 Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Start the engine •...
Page 433 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
Page 434 FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. 42 Symptom B. Open circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstate- Order Check or maintenance job cause...
Page 435 FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. 42 Symptom B. Open circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause...
Page 436 FUEL INJECTION SYSTEM Power supply to the injectors and fuel pump is not nor- Fault code No. Symptom mal. Diagnostic code No. Fuel system voltage (battery voltage) Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •...
Page 437 FUEL INJECTION SYSTEM An error is detected while reading or writing on Fault code No. Symptom EEPROM (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Item/components and probable Reinstatement Order Check or maintenance job cause method Malfunction in ECU •...
Page 438 FUEL INJECTION SYSTEM Power supply to the fuel injection system relay is not nor- Fault code No. 46 Symptom mal. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections. • Check the coupler for any pins Starting the •...
Page 439 FUEL INJECTION SYSTEM Sub-throttle position sensor: open or short circuit Fault code No. 47 Symptom detected. Diagnostic monitor- Sub-throttle servo motor ing code No. Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of sub-throttle position •...
Page 440 FUEL INJECTION SYSTEM Fault code No. 48 Symptom Sub-throttle servo motor: stuck. Diagnostic code No. Sub-throttle servo motor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the • Sub-throttle servo motor coupler that may be pulled out.
Page 441 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
Page 442 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •...
Page 443 FUEL INJECTION SYSTEM 8-74...
Page 444: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-75...
Page 445 FUEL PUMP SYSTEM 1. Main switch 6. Main fuse 7. Battery 8. Fuel injection system fuse 13.Fuel pump relay 16.Fuel pump 23.ECU (engine control unit) 46.Multi-function meter 56.Engine stop switch 78.Ignition fuse 8-76...
Page 446 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. 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 fuel injection system) Replace the fuse(s).
Page 447 FUEL PUMP SYSTEM 8-78...
Page 448: Immobilizer System
IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-79...
Page 449 IMMOBILIZER SYSTEM 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 23.ECU (engine control unit) 41.Immobilizer indicator 46.Multi-function meter 78.Ignition fuse 8-80...
Page 450 IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following. • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
Page 451 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration Acces- bilizer unit Standard requirement sory lock* Main Immobi- and key switch lizer unit √ Standard key is lost New standard key All keys have been Code re-registering √ √ √...
Page 452 IMMOBILIZER SYSTEM e. Standby mode on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. NOTE: Do not start the engine with a standard key that has not been registered.
Page 453 IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the lost standard key.
Page 454 IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turn “ON”, the indicator light does not come on or flashing. 1. Check the fuses. NG→ (Main, ignition and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-139. OK↓...
Page 455 IMMOBILIZER SYSTEM EAS27720 SELF-DIAGNOSIS FAULT CODE INDICATION When the system failure occurred, the error code number is indicated in the immobilizer system indi- cator light blinks at the same time. The pattern of blinking also shows the error code. Error Detection Symptoms Trouble...
Page 456 IMMOBILIZER SYSTEM Error Detection Symptoms Trouble Measures code IMMOBILIZER Key code registra- Same standard key was Prepare the new UNIT tion error. attempted to continu- standard key and ously two times register. register it. Undefinition code is Noise interference or dis- 1.
Page 457 IMMOBILIZER SYSTEM 8-88...
Page 458 ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM (FZ1-SA) 8-89...
Page 459 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-SA 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 12.Starting circuit cut-off relay 14.Neutral switch 46.Multi-function meter 53.ABS warning light 56.Front brake light switch 57.Engine stop switch 58.Start switch 59.Rear brake light switch 76.Tail/brake light 82.Signal fuse 84.ABS fuse...
Page 460 ABS (ANTI-LOCK BRAKE SYSTEM) EAS22C1001 CIRCUIT DIAGRAM (FZ1-NA) 8-91...
Page 461 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 12.Starting circuit cut-off relay 14.Neutral switch 46.Multi-function meter 53.ABS warning light 56.Front brake light switch 57.Engine stop switch 58.Start switch 59.Rear brake light switch 76.Tail/brake light 81.Signal fuse 83.ABS fuse...
Page 462 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART FZ1-SA 8-93...
Page 463 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-SA 1. ABS warning light 2. ABS test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. ABS ECU 9. ABS motor relay 10.Fuse box 8-94...
Page 464 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 8-95...
Page 465 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 1. ABS warning light 2. ABS test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. ABS ECU 9. ABS motor relay 10.Fuse box 8-96...
Page 466 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS CONNECTOR LOCATION CHART FZ1-SA 8-97...
Page 467 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-SA 1. ABS ECU coupler 2. Front wheel sensor coupler 3. Rear wheel sensor coupler 4. Hydraulic unit coupler 5. ABS motor relay 6. ABS test coupler 7. Multi-function coupler 8-98...
Page 468 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 8-99...
Page 469 ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 1. Front wheel sensor coupler 2. Rear wheel sensor coupler 3. Hydraulic unit coupler 4. ABS ECU coupler 5. ABS motor relay 6. ABS test coupler 7. Multi-function coupler 8-100...
Page 470 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27760 ABS ECU AND ABS MOTOR RELAY Removing the ABS ECU and ABS motor relay (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Right front cowling inner panel Refer to “GENERAL CHASSIS” on page 4-1. Refer to “ABS (ANTI-LOCK BRAKE SYS- Under cover TEM)”...
Page 471 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the ABS ECU and ABS motor relay (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Right front cowling inner panel Refer to “GENERAL CHASSIS” on page 4-1. Refer to “ABS (ANTI-LOCK BRAKE SYS- Under cover TEM)” on page 4-50. Rear fender lower cover ABS motor relay ABS motor relay coupler...
Page 472 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 [D-1] MAINTENANCE OF THE ABS ECU Removing the ABS ECU 1. Remove: • ABS ECU “1” NOTE: When removing the ABS ECU, take care not to damage the ABS ECU or ABS ECU couplers. A. FZ1-SA B.
Page 473 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27780 [D-2] MAINTENANCE OF THE ABS MOTOR RELAY Removing the ABS motor relay 1. Remove: • ABS motor relay coupler NOTE: Do not pull the ABS motor relay leads to remove the ABS motor relay coupler. Always press on the lock to disconnect the ABS motor relay coupler from the ABS motor relay.
Page 474 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27790 ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light on the meter assembly indicates a malfunction.
Page 475 ABS (ANTI-LOCK BRAKE SYSTEM) Differences between the normal handling and services on a vehicle • Care should be taken not to damage components by shocks and pulling too much since the ABS components are precisely adjusted. • ABS ECU, HU, Wheel sensors and ABS motor relay cannot be disassembled. •...
Page 476 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-107...
Page 477: Meter Coupler
ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. EWA14050 WARNING Always execute the “final check” when the components related to ABS are checked and ser- viced.
Page 478 ABS (ANTI-LOCK BRAKE SYSTEM) EAS4S81020 [B-3] THE ABS WARNING LIGHT FLASHES NOTE: Check the battery voltage before proceeding. Check the test coupler located in the left inner panel (front cowling). Is the T/C terminal ground? 1. Yes → Disconnect the grounding lead from the T/C terminal and install the protective cap onto the test coupler.
Page 479 ABS (ANTI-LOCK BRAKE SYSTEM) B. FZ1-NA A. FZ1-SA 1. Indicate the malfunction code (Example: malfunction code 11) 2. ABS warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5] If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS).
Page 480 ABS (ANTI-LOCK BRAKE SYSTEM) 7. ABS warning light terminal (White/Red) 1. ABS test coupler 8. Test coupler adapter 2. Lock plate 9. Light green 3. Protective cap 10.Black 4. Grounding 11.White/Red 5. T/C terminal 6. T/F terminal As an example, “10 digits/1 digit pattern” of tester reading is shown below. 8-111...
Page 481: Meter Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) C. Time (second) A. This example is the pattern which shows malfunction code 12. B. This example is the pattern which shows malfunction code 21. EAS4S81021 [C] DETERMINING THE CAUSE AND LOCATION OF THE MALFUNCTION EAS4S81022 [C-1] ONLY THE ABS WARNING LIGHT DOES NOT COME ON WHEN THE MAIN SWITCH IS SET TO “ON”...
Page 482: Rectifier/Regulator
ABS (ANTI-LOCK BRAKE SYSTEM) EAS4S81024 [C-3] ABS WARNING LIGHT FLASHES 1. When the warning light flashes “ON” for 0.25 seconds and “OFF” for 0.75 seconds, check the stop switch or 3-4), 5). 2. When the warning light flashes “ON” for 0.75 seconds and “OFF” for 0.25 seconds, the starter motor monitor is defective.
Page 483 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27880 [C-5] DIAGNOSIS BY THE MALFUNCTION CODE Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “[B-4] MAL- FUNCTION CHECK BY THE ABS SELF-DIAGNOSIS (PAST MALFUNCTION)” and “[B-5] MAL- FUNCTION CHECK BY THE ABS SELF-DIAGNOSIS (PRESENT MALFUNCTION)”.) The malfunction codes are explained in the following table.
Page 484 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Stop light failure • Adjust the brake light switch. Malfunction (Brake system circuit has failure.) • Brake light switch code 24 • Bulb has burned out. • Check the wire harness for the brake light system circuit.
Page 485 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Disconnection is detected between • ABS harness circuit (from ABS Malfunction the ABS ECU and solenoid sys- ECU to the solenoid) code 35 tem. • Solenoid coupler Downstream side of the solenoid •...
Page 486 ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Sensor power supply failure • Wire harness circuit Malfunction • Battery terminal is disconnected code 63 63 (front) • Replace the ABS ECU (front) and 64 64 (rear) (rear) Present ABS ECU may be malfunctioning •...
Page 487 ABS (ANTI-LOCK BRAKE SYSTEM) • ABS ECU coupler terminal is disconnected. → [D-1] 2. ABS warning light goes on for 2 seconds then goes off. 1. With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is not a malfunction.
Page 488 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Check the wheel sensor signal Measure the wheel sensor signal output voltage. Refer to “CHECKING THE WHEEL SENSOR” on page 8-149. 2. Check the appearance. 3. Check the wire harness. 1. Disconnection of the ABS ECU coupler terminal 2.
Page 489 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Front solenoid 1. ABS ECU 6. Rear solenoid 2. Red 7. Green 3. Red 8. White/Red 4. Red *Continuity between: “A”–“B”, “A”–“C”, “D”–“G”, “E”–“F” • Check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal. 4.
Page 490 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Yellow 1. Front brake light switch 6. Brake light 2. Rear brake light switch 7. Yellow 3. Green/Yellow 8. ABS ECU 4. Yellow *Continuity between: “A”–“B” Malfunction code 25 (At the beginning of running, there is no pulse from the front wheel sen- sor.) •...
Page 491 ABS (ANTI-LOCK BRAKE SYSTEM) 4. When the items 1 to 3 are normal, replace the ABS ECU. Malfunction code 32 (Circuit malfunction of ABS ECU is detected. Upstream side of the sole- noid relay.) NOTE: Check following the steps in sequence. 1.
Page 492 ABS (ANTI-LOCK BRAKE SYSTEM) • Check for continuity between the positive battery terminal and the battery end of the ABS motor fuse terminal (terminal “B” shown in the above illustration). • Remove the ABS ECU and the ABS motor relay from the wire harness (ABS), and then check for continuity between the white/black lead terminals of ABS ECU coupler and the white/red lead terminals of ABS motor coupler.
Page 493 • Check the brake hose lines for kinks and deterioration. EWA4S81009 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the front brake caliper from the hydraulic unit are correct.
Page 494 EWA4S81011 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the rear brake caliper from the hydraulic unit are correct.
Page 495 ABS (ANTI-LOCK BRAKE SYSTEM) Terminal color Solenoid side Wire harness side (ABS) Front Red, Green Red, Green Rear Red, Blue Red, White/Red 6. Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be sure to connect the brake hose lines and couplers correctly and securely.
Page 496 ABS (ANTI-LOCK BRAKE SYSTEM) Refer to “Malfunction code 42”. 6. Hydraulic unit Refer to “Malfunction code 42”. 7. Battery voltage Measure the battery voltage. Malfunction code 61 (front), 62 (rear) (Sensor power supply is low) 1. Battery voltage low Charge, check or replace the battery. 2.
Page 497 ABS (ANTI-LOCK BRAKE SYSTEM) EAS5D01005 [D-6-4] DELETING THE MALFUNCTION CODE 1. Connect the test coupler adapter “1” to the test coupler “2”. Refer to “[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)” A. FZ1-SA B. FZ1-NA 2. Turn the main switch on. •...
Page 498 ABS (ANTI-LOCK BRAKE SYSTEM) e. Flashing a. ABS warning light f. 2 seconds b. ON g. 3 seconds c. Main switch on h. 0.5 seconds d. Main switch off 7. Turn the main switch off. 8. Disconnect the test coupler adapter from the test coupler, and install the protective cap with the test coupler adapter.
Page 499 ABS (ANTI-LOCK BRAKE SYSTEM) 6. Check: • ECU-to-start-switch-lead continuity Connect the pocket tester (Ω × 1) to the ECU coupler and start switch coupler. Tester positive probe → Blue/White “1” (start switch) Tester negative probe → Green/White “2” (ECU) No continuity → Replace or repair the wire harness. 7.
Page 500: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-131...
Page 501 ELECTRICAL COMPONENTS 1. Main switch (immobilizer unit) 2. Front brake light switch 3. Battery 4. Fuse box 5. Starter relay 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Ignition coil 11.Radiator fan motor 12.Horn 8-132...
Page 502 ELECTRICAL COMPONENTS 8-133...
Page 503 ELECTRICAL COMPONENTS 1. ABS ECU (FZ1-SA), (FZ1-NA) 2. ECU (engine control unit) 3. Intake air temperature sensor 4. Fuel pump 5. Headlight relay (on/off) 6. Radiator fan motor relay 7. Lean angle sensor 8. Starting circuit cut-off relay 9. Turn signal relay 10.Rear wheel sensor (FZ1-SA), (FZ1-NA) 11.Rectifier/regulator 12.ABS motor relay (FZ1-SA), (FZ1-NA)
Page 504 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-135...
Page 505 7. Turn signal switch 8. Hazard switch 9. Clutch switch 10.Sidestand switch 11.Engine stop switch 12.Front brake light switch 13.Start switch 14.Oil level switch 15.Neutral switch 16.Rear brake light switch 17.Fuse box 18.Left handlebar switch lead (FZ1-N(X)/FZ1- 19.Left handlebar switch lead (FZ1-S(X)/FZ1- 8-136...
Page 506 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “1”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 507 ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely Check each bulb and bulb socket for damage hot, keep flammable products and your or wear, proper connections, and also for conti- hands away from the bulb until it has nuity between the terminals.
Page 508 YU-03112-C Amperage Fuses Q’ty rating NOTE: Main 50 A Check each bulb socket for continuity in the Headlight (FZ1-N(X), same manner as described in the bulb section; 15 A FZ1-SA) however, note the following. Headlight (FZ1-S(X), 25 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ FZ1-SA) a.
Page 509 ELECTRICAL COMPONENTS EWA13310 ferent from those of conventional batter- WARNING ies. The MF battery should be charged as explained in the charging method illustra- Never use a fuse with an amperage rating other than that specified. Improvising or tions. If the battery is overcharged, the electrolyte level will drop considerably.
Page 510 ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- • As shown in the following illustration, the cuit voltage equals or exceeds 12.8 V. open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging b. Check the charge of the battery, as shown has been completed.
Page 511 ELECTRICAL COMPONENTS g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 512 2. Negative battery terminal Continuity/No continuity 3. Positive tester probe (between “3” to “4”) 4. Negative tester probe Relay unit (starting circuit cut-off relay) Result FZ1-N(X)/FZ1-S(X)/FZ1-NA Continuity/No continuity (between “3” to “4”) Headlight relay (on/off) (FZ1-N(X))/FZ1-NA FZ1-SA 1. Positive battery terminal 2.
Page 513 ELECTRICAL COMPONENTS Headlight relay (dimmer) ABS motor relay resistance FZ1-S(X)/FZ1-SA) 50–150 Ω Pocket tester 90890-03112 Analog Pocket tester YU-03112-C • Tester positive probe →Terminal “2” • Tester negative probe → Terminal “1” Tester reading is “∞”. → Replace the ABS motor relay.
Page 514 ELECTRICAL COMPONENTS EAS5D01009 CHECKING THE SOLENOID VALVES AND Pocket tester MOTOR 90890-03112 Analog Pocket tester ECA4S81023 CAUTION: YU-03112-C When check the hydraulic unit solenoid • Positive tester probe → relay and ABS motor, do not remove the terminal “3” brake hoses. •...
Page 515 ELECTRICAL COMPONENTS EAS5D01028 CHECKING THE TURN SIGNAL/HAZARD Pocket tester RELAY 90890-03112 1. Check: Analog Pocket tester • Turn signal/hazard relay input voltage YU-03112-C Out of specification → The wiring circuit • Positive tester probe → from the main switch to the turn signal/ hazard relay coupler is faulty and must be Brown/White “1”...
Page 516 ELECTRICAL COMPONENTS FZ1-N(X)/FZ1-S(X)/FZ1-NA Continuity Positive tester probe → Sky blue “1” Negative tester probe → Yel- low/Black “2” (FZ1-N(X)/FZ1- S(X)/FZ1-NA) Black/Yellow “2” (FZ1-SA) No continuity Positive tester probe → Yel- low/Black “2” (FZ1-N(X)/FZ1- FZ1-SA S(X)/FZ1-NA) Black/Yellow “2” (FZ1-SA) Negative tester probe → Sky blue “1”...
Page 517 ELECTRICAL COMPONENTS 3. Check: • Positive tester probe • Ignition spark gap “a” Ignition coil terminal Out of specification → Replace. • Negative tester probe Ignition coil terminal Minimum ignition spark gap 6.0 mm (0.24 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the spark plug.
Page 518 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the crankshaft position sensor coupler as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Gray “1” c. When turn the lean angle sensor to 65°. •...
Page 519 CHECKING THE STARTER MOTOR OPERA- Stator coil resistance 0.144–0.176 Ω at 20 °C (68 °F) TION 1. Check: (FZ1-S(X), FZ1-N(X), FZ1-SA) 0.153–0.187 Ω at 20 °C (68 °F) • Starter motor operation Does not operate → Perform the electric (FZ1-NA) starting system troubleshooting, starting ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 520 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe a. Set the engine tachometer to the ignition Horn terminal “1” coil of cylinder #1. • Negative tester probe b. Connect the pocket tester (AC 20 V) to the Horn terminal “2” rectifier/regulator coupler as shown. Pocket tester 90890-03112 Analog pocket tester...
Page 521 ELECTRICAL COMPONENTS Fuel sender resistance Full position of the float 19–21Ω at 20 °C (68 °F) Empty position of the float 139–141 Ω at 20 °C (68 °F) b. Set the main switch to “ON”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 10) to the c.
Page 522 ELECTRICAL COMPONENTS 2. Check: d. Slowly heat the coolant, and then let it cool • Coolant temperature sensor resistance to the specified temperature indicated in Out of specification → Replace. the table. e. Check the coolant temperature sensor for Coolant temperature sensor continuity at the temperatures indicated in...
Page 523 ELECTRICAL COMPONENTS d. While slowly opening the throttle, check • Tester positive lead → that the throttle position sensor resistance Blue “1” is within the specified range. • Tester negative lead → The resistance does not change or it Black/Blue “2” changes abruptly →...
Page 524 ELECTRICAL COMPONENTS c. Measure the Air induction system solenoid ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ resistance. 3. Install: • Sub-throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE: EAS28380 When installing the throttle position sensor, CHECKING THE ATMOSPHERIC PRES- adjust its angle properly. Refer to “CHECKING SURE SENSOR THE SUB-THROTTLE POSITION SENSOR” 1.
Page 525 ELECTRICAL COMPONENTS EAS28390 CHECKING THE CYLINDER IDENTIFICA- Intake air pressure sensor out- TION SENSOR put voltage 1. Check: 3.75–4.25 V • Cylinder identification sensor output volt- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the Out of specification → Replace. intake air pressure sensor coupler (wire Cylinder identification...
Page 526 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Brown/White “1” • Negative tester probe Black/Blue “2” b. Measure the intake air temperature sensor resistance.
Page 527: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2 OVER COOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3...
Page 528 TROUBLESHOOTING EAS28450 • Sucked-in air TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery NOTE: • Faulty battery The following guide for troubleshooting does 2. Fuse(s) not cover all the possible causes of trouble. It • Blown, damaged or incorrect fuse should be helpful, however, as a guide to basic •...
Page 529 TROUBLESHOOTING • Improper throttle cable free play EAS28550 JUMPS OUT OF GEAR • Flooded throttle body • Faulty air induction system Shift shaft • Incorrect shift pedal position Electrical system • Improperly returned stopper lever 1. Battery • Discharged battery Shift forks •...
Page 530 TROUBLESHOOTING • Incorrect oil viscosity • Damaged brake hose • Inferior oil quality • Oil or grease on the brake disc • Oil or grease on the brake pad Cooling system • Incorrect brake fluid level 1. Coolant • Low coolant level EAS28660 FAULTY FRONT FORK LEGS 2.
Page 531 TROUBLESHOOTING 7. Wheel(s) Turn signal blinks slowly • Incorrect wheel balance • Faulty turn signal relay • Deformed cast wheel • Faulty main switch • Damaged wheel bearing • Faulty turn signal switch • Bent or loose wheel axle • Incorrect turn signal bulb •...
Page 532 TROUBLESHOOTING • Defective starter motor monitor • Other defective ABS warning light flashes every 0.5 sec- onds • Voltage drop (Less than 10 V) • Battery • Rectifier/regulator • AC magneto • Strong radio waves or static electricity • Test coupler adapter is connected to test coupler ABS Warning light continues to come on •...
Page 533 TROUBLESHOOTING...
Page 534: Wiring List
55. Front brake light switch Br/W Brown/White WIRING DIAGRAM 56. Engine stop switch Br/Y Brown/Yellow 57. Start switch FZ1-N(X) 2008 Green/Black 58. Rear brake light switch 1. Main switch Green/Red 59. Left handlebar switch 2. Rectifier/regulator Green/White 60. Clutch switch 3.
Page 535 FZ1-S(X) 2008 59. Left handlebar switch Green/White 60. Clutch switch 1. Main switch Green/Yellow 61. Pass switch 2. Rectifier/regulator Gy/G Gray/Green 62. Dimmer switch 3. AC magneto Gy/R Gray/Red 63. Hazard switch 4. Backup fuse Blue/Black 64. Turn signal switch 5.
Page 536 FZ1-SA 2008 59. Rear brake light switch Black/White 60. Left handlebar switch 1. Main switch Black/Yellow 61. Clutch switch 2. Rectifier/regulator Br/G Brown/Green 62. Pass switch 3. AC magneto Br/L Brown/Blue 63. Dimmer switch 4. Backup fuse Br/R Brown/Red 64. Hazard switch 5.
Page 537 FZ1-NA 2008 59. Rear brake light switch Black/White 60. Left handlebar switch 1. Main switch Black/Yellow 61. Clutch switch 2. Rectifier/regulator Br/G Brown/Green 62. Pass switch 3. AC magneto Br/L Brown/Blue 63. Dimmer switch 4. Backup fuse Br/R Brown/Red 64. Hazard switch 5.
Page 538 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 539: Wiring Diagrams
FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N(X) 2008...
Page 540 FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-S(X) 2008...
Page 541 FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-SA 2008...
Page 542 FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-NA 2008 G/B R/B R/L Gy/R Gy/R O R/B O/G L/R Dg B/G L O/B L/B Y/R Gy/G Br/R W/B Br/R L Gy/G B Ch B/Y Br/W G/Y Br/W Y Y/W...
Page 543 FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N(X) 2008...
Page 544 FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-S(X) 2008...
Page 545 FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-SA 2008...
Page 546 FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-NA 2008...

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Yamaha 2008 Fazer FZ1-N Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshafts

Cylinder Head

Valves and Valve Springs

Generator

Starter Clutch

Crankshaft Position Sensor

Electric Starter

Clutch

Shift Shaft

Oil Pump

Crankcase

Crankshaft

Transmission

Cooling System

Radiator

Oil Cooler

Thermostat

Water Pump

Quick Links

Chapters

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Summary of Contents for Yamaha 2008 Fazer FZ1-N