Yamaha FZS8WC Manuals

Manuals and User Guides for Yamaha FZS8WC. We have 1 Yamaha FZS8WC manual available for free PDF download: Service Manual

Yamaha FZS8WC Service Manual

Yamaha FZS8WC Service Manual (394 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.64 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
  - Important Information
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking the Connections
    18
  - Special Tools
    19
Specifications

23
- General Specifications
  24
- Engine Specifications
  25
- Chassis Specifications
  32
- Electrical Specifications
  35
- Tightening Torques
  38
- Lubrication Points and Lubricant Types
  45
  - Engine
    45
  - Chassis
    46
- Lubrication System Chart and Diagrams
  48
  - Engine Oil Lubrication Chart
    48
  - Lubrication Diagrams
    50
- Cooling System Diagrams
  62
- Cable Routing
  70
Periodic Checks and Adjustments

83
- Periodic Maintenance
  
  86
  - Introduction
    86
- Engine
  
  89
  - Adjusting the Valve Clearance
    89
  - Synchronizing the Throttle Bodies
    91
  - Adjusting the Engine Idling Speed
    93
  - Adjusting the Throttle Cable Free Play
    93
  - Checking the Spark Plugs
    94
  - Measuring the Compression Pressure
    95
  - Checking the Engine Oil Level
    97
  - Changing the Engine Oil
    97
  - Measuring the Engine Oil Pressure
    98
  - Adjusting the Clutch Cable Free Play
    99
  - Cleaning the Air Filter Element
    100
  - Checking the Throttle Body Joints
    101
  - Checking the Fuel Line
    101
  - Checking the Crankcase Breather Hose
    101
  - Checking the Exhaust System
    102
  - Checking the Coolant Level
    102
  - Checking the Cooling System
    103
  - Changing the Coolant
    103
- Chassis
  
  106
  - Adjusting the Front Disc Brake
    106
    
    Adjusting the Rear Disc Brake
    106
    
    Checking the Brake Fluid Level
    107
    
    Checking the Front Brake Pads
    107
    
    Checking the Rear Brake Pads
    108
    
    Checking the Front Brake Hoses
    108
    
    Checking the Rear Brake Hose
    108
    
    Adjusting the Rear Brake Light Switch
    108
    
    Bleeding the Hydraulic Brake System
    109
    
    Adjusting the Shift Pedal
    110
    
    Adjusting the Drive Chain Slack
    110
    
    Lubricating the Drive Chain
    111
    
    Checking and Adjusting the Steering Head
    111
    
    Checking the Front Fork
    113
    
    Adjusting the Rear Shock Absorber Assembly
    113
    
    Checking the Tires
    113
    
    Checking the Wheels
    116
    
    Checking and Lubricating the Cables
    116
    
    Lubricating the Levers
    116
    
    Lubricating the Pedal
    116
    
    Lubricating the Sidestand
    116
    
    Lubricating the Centerstand
    116
    
    Lubricating the Rear Suspension
    116
Chassis

119
- General Chassis
  
  122
- Front Wheel
  
  126
  - Removing the Front Wheel
    128
  - Checking the Front Wheel
    128
  - Adjusting the Front Wheel Static Balance
    129
  - Installing the Front Wheel
    130
- Rear Wheel
  
  131
  - Removing the Rear Wheel
    134
  - Checking the Rear Wheel
    134
  - Checking the Rear Wheel Drive Hub
    134
  - Checking and Replacing the Rear Wheel Sprocket
    135
  - Adjusting the Rear Wheel Static Balance
    135
  - Installing the Rear Wheel
    135
- Front Brake
  
  136
- Rear Brake
  
  148
  - Introduction
    153
  - Checking the Rear Brake Disc
    153
  - Replacing the Rear Brake Pads
    153
  - Removing the Rear Brake Caliper
    154
  - Disassembling the Rear Brake Caliper
    154
  - Checking the Rear Brake Caliper
    155
  - Assembling the Rear Brake Caliper
    155
  - Installing the Rear Brake Caliper
    156
  - Removing the Rear Brake Master Cylinder
    157
  - Checking the Rear Brake Master Cylinder
    157
  - Assembling the Rear Brake Master Cylinder
    158
  - Installing the Rear Brake Master Cylinder
    158
- Handlebar
  
  160
  - Removing the Handlebars
    161
  - Checking the Handlebar
    161
  - Installing the Handlebar
    161
- Front Fork
  
  164
  - Removing the Front Fork Legs
    166
  - Disassembling the Front Fork Legs
    166
  - Checking the Front Fork Legs
    167
  - Assembling the Front Fork Legs
    168
  - Installing the Front Fork Legs
    170
- Steering Head
  
  172
  - Removing the Lower Bracket
    174
  - Checking the Steering Head
    174
  - Installing the Steering Head
    175
- Rear Shock Absorber Assembly
  
  176
- Swingarm
  
  179
  - Removing the Swingarm
    181
  - Checking the Swingarm
    181
  - Installing the Swingarm
    182
- Chain Drive
  
  183
  - Removing the Drive Chain
    184
  - Checking the Drive Chain
    184
  - Checking the Drive Sprocket
    185
  - Checking the Rear Wheel Sprocket
    185
  - Checking the Rear Wheel Drive Hub
    185
  - Installing the Drive Chain
    185
Engine

187
- Engine Removal
  
  190
  - Installing the Engine
    195
- Camshafts
  
  197
  - Removing the Camshafts
    199
  - Checking the Camshafts
    200
  - Checking the Timing Chain and Camshaft Sprocket
    201
  - Checking the Timing Chain Guides
    201
  - Checking the Timing Chain Tensioner
    202
  - Installing the Camshafts
    202
- Cylinder Head
  
  205
  - Removing the Cylinder Head
    206
  - Checking the Cylinder Head
    206
  - Installing the Cylinder Head
    206
- Valves and Valve Springs
  
  209
  - Removing the Valves
    210
  - Checking the Valves and Valve Guides
    211
  - Checking the Valve Seats
    212
  - Checking the Valve Springs
    214
  - Checking the Valve Lifters
    215
  - Installing the Valves
    215
- Generator and Starter Clutch
  
  217
  - Removing the Generator
    219
  - Removing the Starter Clutch
    219
  - Checking the Starter Clutch
    220
  - Installing the Starter Clutch
    220
  - Installing the Generator
    221
  - Pickup Rotor
    222
- Removing the Pickup Rotor
  
  223
  - Installing the Pickup Rotor
    223
- Electric Starter
  
  225
  - Checking the Starter Motor
    227
  - Assembling the Starter Motor
    228
  - Installing the Starter Motor
    228
- Oil Pump
  
  229
  - Removing the Oil Pan
    232
  - Checking the Oil Pump
    232
  - Checking the Relief Valve
    232
  - Checking the Oil Delivery Pipes
    233
  - Checking the Oil Strainer
    233
  - Checking the Oil Nozzles
    233
  - Assembling the Oil Pump
    233
  - Installing the Oil Pump
    234
  - Installing the Oil Strainer
    234
  - Installing the Oil Pan
    234
- Clutch
  
  235
  - Removing the Clutch
    238
  - Checking the Friction Plates
    238
  - Checking the Clutch Plates
    239
  - Checking the Clutch Springs
    239
  - Checking the Clutch Housing
    239
  - Checking the Clutch Boss
    239
  - Checking the Pressure Plate
    240
  - Checking the Pull Lever Shaft and Pull Rod
    240
  - Installing the Clutch
    240
- Shift Shaft
  
  242
  - Checking the Shift Shaft
    243
  - Checking the Stopper Lever
    243
  - Installing the Shift Shaft
    243
- Crankcase
  
  244
  - Disassembling the Crankcase
    246
  - Checking the Crankcase
    246
  - Checking the Bearings and Oil Seals
    246
  - Checking the Oil Pump Drive Chain
    246
  - Assembling the Crankcase
    247
- Crankshaft
  
  249
  - Removing the Connecting Rods and Pistons
    251
  - Removing the Crankshaft Assembly
    251
  - Checking the Cylinder and Piston
    252
  - Checking the Piston Rings
    252
  - Checking the Piston Pins
    253
  - Checking the Big End Bearings
    254
  - Installing the Connecting Rod and Piston
    257
  - Checking the Crankshaft
    259
  - Checking the Crankshaft Journal Bearings
    259
  - Installing the Crankshaft
    261
- Transmission
  
  263
  - Removing the Transmission
    267
  - Checking the Shift Forks
    267
  - Checking the Shift Drum Assembly
    267
  - Checking the Transmission
    268
  - Installing the Transmission
    268
Cooling System

271
- Radiator
  
  274
  - Checking the Radiator
    274
    
    Installing the Radiator
    274
- Oil Cooler
  
  276
  - Checking the Oil Cooler
    276
  - Installing the Oil Cooler
    276
- Thermostat
  
  277
  - Checking the Thermostat
    278
  - Installing the Thermostat Assembly
    278
- Water Pump
  
  280
  - Disassembling the Water Pump
    282
  - Checking the Water Pump
    282
  - Assembling the Water Pump
    283
  - Installing the Water Pump
    284
Fuel System

285
- Fuel Tank
  
  287
  - Checking the Fuel Pump Body
    287
  - Checking the Fuel Pump Operation
    287
  - Installing the Fuel Pump
    287
  - Removing the Fuel Pump
    287
  - Removing the Fuel Tank
    287
  - Installing the Fuel Tank
    288
- Throttle Bodies
  
  290
  - Checking the Injectors
    291
  - Checking the Throttle Bodies
    291
  - Checking the Fuel Pressure
    291
  - Adjusting the Throttle Position Sensor
    291
- Air Induction System
  
  294
  - Checking the Air Induction System
    297
  - Installing the Air Induction System
    297
Electrical System

299
- Ignition System
  
  302
  - Circuit Diagram
    302
  - Troubleshooting
    304
- Electric Starting System
  
  306
  - Circuit Diagram
    306
  - Starting Circuit Cut-Off System Operation
    308
  - Troubleshooting
    309
- Charging System
  
  312
  - Circuit Diagram
    312
  - Troubleshooting
    314
- Lighting System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Signaling System
  
  320
  - Circuit Diagram
    320
  - Troubleshooting
    322
- Cooling System
  
  328
  - Circuit Diagram
    328
  - Troubleshooting
    330
- Fuel Injection System
  
  332
  - Circuit Diagram
    332
  - Ecu Self-Diagnostic Function
    334
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    335
  - Troubleshooting Method
    337
  - Diagnostic Mode
    338
  - Troubleshooting Details
    344
- Fuel Pump System
  
  356
  - Circuit Diagram
    356
  - Troubleshooting
    358
- Electrical Components
  
  360
  - Checking the Switches
    364
  - Checking the Bulbs and Bulb Sockets
    367
  - Checking the Leds
    368
  - Checking the Fuses
    368
  - Checking and Charging the Battery
    369
  - Checking the Relays
    372
  - Checking the Turn Signal/Hazard Relay
    373
  - Checking the Relay Unit (Diode)
    373
  - Checking the Spark Plug Caps
    374
  - Checking the Ignition Coils
    375
  - Checking the Crankshaft Position Sensor
    376
  - Checking the Lean Angle Sensor
    376
  - Checking the Startor Motor Operation
    376
  - Checking the Stator Coil
    377
  - Checking the Rectifier/Regulator
    377
  - Checking the Horn
    378
  - Checking the Engine Oil Level Gauge
    378
  - Checking the Fuel Sender
    379
  - Checking the Speed Sensor
    379
  - Checking the Radiator Fan Motor
    380
  - Checking the Coolant Temperature Sensor
    380
  - Checking the Throttle Position Sensor
    380
  - Checking the Fuel Pump
    381
  - Checking the Air Induction System Solenoid
    382
  - Checking the Intake Air Pressure Sensor
    382
  - Checking the Intake Air Temperature Sensor
    382
Troubleshooting

385
- General Information
  385
- General Information
  386
- Incorrect Engine Idling Speed
  386
- Starting Failures
  386
- Troubleshooting
  386
- Faulty Clutch
  387
- Faulty Gear Shifting
  387
- Jumps out of Gear
  387
- Overheating
  387
- Poor Medium-And-High-Speed Performance
  387
- Shift Pedal Does Not Move
  387
- Faulty Front Fork Legs
  388
- Overcooling
  388
- Poor Braking Performance
  388
- Unstable Handling
  388
- Faulty Lighting or Signaling System
  389
  - Wiring Diagram
    390

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