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Yamaha 2007 FZ6-N Service Manual

Summary of 2007 FZ6-N

  • Page 1

    2007 fz6-n/s 4s8-28197-e0 service manual fz6-na/sa fz6-nhg(w) fz6-shg(w) fz6-nahg/sahg.

  • Page 2

    Eas20040 fz6-n/s fz6-na/sa fz6-nhg(w)/shg(w) fz6-nahg/sahg service manual ©2006 by yamaha motor co., ltd. First edition, august 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3

    Eas20070 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 4

    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. • the manual is di...

  • Page 5

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Note: the following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. El...

  • Page 7: Table of Contents

    1 2 3 4 5 6 7 8 9 eas20110 table of contents general information specifications periodic checks and adjustments chassis engine cooling system fuel system electrical system troubleshooting.

  • Page 9: General Information

    1 general information identification .......................................................................................... 1-1 vehicle identification number................................................... 1-1 model label ..........................................................................

  • Page 10: Identification

    Identification 1-1 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 1-2 eas20170 features eas4s81003 outline of fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor s...

  • Page 12: Features

    Features 1-3 eas4s81004 fi system the fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kpa (2.5 kg/cm 2 ). Accordingly, when the energiz- ing signal from the ecu energizes the injector, the fue...

  • Page 13: Features

    Features 1-4 eas4s81005 instrument functions multi-function meter unit warning ewa4s81002 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a speedometer (which shows the riding speed) • a t...

  • Page 14: Features

    Features 1-5 the electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. When the key is turned to “on”, the tachome- ter needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit. Caution: e...

  • Page 15: Features

    Features 1-6 odometer and tripmeter modes (fz6-nhg(w)/ fz6-nahg/fz6-shg(w)/fz6-sahg) push the “select” button to switch the dis- play between the odometer mode “odo” and the tripmeter modes “trip a” and “trip b” in the following order: “trip a” → “trip b” → “odo” → “trip a” when the fuel amount in t...

  • Page 16: Features

    Features 1-7 coolant temperature mode (fz6-nhg(w)/fz6- nahg/fz6-shg(w)/fz6-sahg) the coolant temperature display indicates the temperature of the coolant. Push the “reset” button to switch the coolant temperature display to the air intake tempera- ture display. Note: when the coolant temperature dis...

  • Page 17: Features

    Features 1-8 if any of the immobilizer system circuits are defective, the immobilizer system indicator light will flash, and then the display will indicate a two-digit error code (e.G., 51, 52, 53). Note: if the display indicates error code 52, this could be caused by transponder interference. If th...

  • Page 18: Features

    Features 1-9 eas4s81007 outline of the abs 1 the yamaha abs (anti-lock brake system) features a dual electronic control system, which acts on the front and rear brakes independently. 2 the abs features a compact and lightweight design to help maintain the basic maneuverability of the vehicle. 3 the ...

  • Page 19: Features

    Features 1-10 • brake force: the force applied by braking to reduce the wheel speed. • wheel lock: a condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle continues to travel. • side force: the force on the tires which supports the vehicle when cornering. ...

  • Page 20: Features

    Features 1-11 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed ...

  • Page 21: Features

    Features 1-12 warning ewa4s81004 the braking of the vehicle, even in the worst case, is principally executed when the vehicle is advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of the tires. Even in vehicles equipped with abs, overturning of the vehicle ...

  • Page 22: Features

    Features 1-13 abs block diagram eas4s81008 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor is composed of a permanent magnet and a hall ic. The wheel sensors are i...

  • Page 23: Features

    Features 1-14 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...

  • Page 24: Features

    Features 1-15 hydraulic unit the hydraulic unit “1” is composed of three hydraulic control valves (each with a solenoid valve and flow control valve), two buffer chambers, two hydraulic pumps, and an abs motor. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the w...

  • Page 25: Features

    Features 1-16 • buffer chamber the buffer chamber accumulates the brake fluid that is depressurized while the abs is operating. 1. Orifice 2. Solenoid valve 3. Spool 4. Flow control valve 1. Buffer chamber (pressurized) 2. Buffer chamber (depressurized) 3. Raised piston.

  • Page 26: Features

    Features 1-17 abs ecu (electronic control unit) the abs ecu “1” controls the abs and is installed under the fuel tank. To protect the abs ecu from water damage, it is protected by a cover “2”. As shown in the block following diagram, the abs ecu receives wheel sensor signals from the front and rear ...

  • Page 27: Features

    Features 1-18 the necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit and abs motor relay. Abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diag...

  • Page 28: Features

    Features 1-19 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...

  • Page 29: Features

    Features 1-20 therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper via port a “7” and port b “9”. At this time, the inlet and outlet check valves of the pump close the lines and brake fluid is not ...

  • Page 30: Features

    Features 1-21 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...

  • Page 31: Features

    Features 1-22 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”. Brake fluid that has entered through port a “7” is further restricted b...

  • Page 32: Features

    Features 1-23 eas4s81010 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the meter assembly. 1. Brake master cylinder 2. Brake light switch 3. Abs motor 4. Hydraulic pump 5. Buffer chamber 6. ...

  • Page 33: Features

    Features 1-24 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. 2.The abs warning light comes on whi...

  • Page 34: Features

    Features 1-25 4.The abs warning light “1” flashes and a malfunction code “2” is indicated on the multi-function dis- play when the test coupler adapter “3” is connected to the abs test coupler “4” for troubleshooting the abs. The abs test coupler can be accessed by removing the left inner panel (fro...

  • Page 35: Features

    Features 1-26 • 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 s...

  • Page 36: Features

    Features 1-27 • the braking of the vehicle, even in the worst case, is principally executed when the vehicle is advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of the tires. Even vehicles equipped with abs cannot be prevented from falling over if braked ...

  • Page 37: Important Information

    Important information 1-28 eas20180 important information eas20190 preparation for removal and disas- sembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to "special tools" on page 1-31. 3. When disasse...

  • Page 38: Important Information

    Important information 1-29 eas20230 bearings and oil seals install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if a...

  • Page 39: Checking The Connections

    Checking the connections 1-30 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect severa...

  • Page 40: Special Tools

    Special tools 1-31 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...

  • Page 41: Special Tools

    Special tools 1-32 steering nut wrench 90890-01403 spanner wrench yu-33975 3-29, 4-74 damper rod holder 90890-01294 damping rod holder set ym-01300 4-66, 4-68 t-handle 90890-01326 ym-01326 4-66, 4-68 oil filter wrench 90890-01426 yu-38411 3-15 fork seal driver weight 90890-01367 replacement hammer y...

  • Page 42: Special Tools

    Special tools 1-33 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-30, 5-38, 8- 111, 8-112, 8- 113, 8-114, 8- 117, 8-118, 8- 119, 8-120, 8- 121, 8-122, 8- 123, 8-124, 8- 125, 8-126, 8- 127, 8-128, 8- 129, 8-130 pressure gauge 90890-03153 yu-03153 3-16, 7-6 oil pressure adapter h 90890-03...

  • Page 43: Special Tools

    Special tools 1-34 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-12 universal clutch holder 90890-04086 ym-91042 5-49, 5-51 valve lapper 90890-04101 valve lapping tool ym-a8998 3-5 valve guide remover (ø4) 90890-04111 valve guide remover (4.0 mm) ym-04111 5-23 valve gu...

  • Page 44: Special Tools

    Special tools 1-35 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 7-7 test coupler adapter 90890-03149 1-25, 4-57, 4-58 thickness gauge 90890-03079 narrow gauge set ym-34483 4-21 tool name/tool no. Illustration reference pages.

  • Page 45: Specifications

    2 specifications general specifications ...................................................................... 2-1 engine specifications..........................................................................2-2 chassis specifications...................................................................

  • Page 46: General Specifications

    General specifications 2-1 eas20280 general specifications model model 1b3d (europe) fz6-n (standard) 5s31 (europe) fz6-na (abs) 5s51 (europe) fz6-nhg (high-grade) 5s52 (aus) fz6-nhgw (high-grade) 5s41 (europe) fz6-nahg (high-grade+abs) 5vxl (europe) fz6-s (standard) 4p53 (europe) fz6-sa (abs) 4p54 ...

  • Page 47: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 600.0 cm³ cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) compression ratio 12.20:1 standard compression pressure (at sea leve...

  • Page 48: Engine Specifications

    Engine specifications 2-3 cooling system radiator capacity (including all routes) 2.00 l (2.11 us qt) (1.76 imp.Qt) radiator capacity 0.60 l (0.63 us qt) (0.53 imp.Qt) coolant reservoir capacity (up to the maximum level mark) 0.25 l (0.26 us qt) (0.22 imp.Qt) radiator cap opening pressure 93–123 kpa...

  • Page 49: Engine Specifications

    Engine specifications 2-4 camshaft runout limit 0.060 mm (0.0024 in) timing chain model/number of links 92rh2015/120 tensioning system automatic valve clearance (cold) intake 0.13–0.20 mm (0.0051–0.0079 in) exhaust 0.23–0.30 mm (0.0091–0.0118 in) valve dimensions valve head diameter a (intake) 24.90...

  • Page 50: Engine Specifications

    Engine specifications 2-5 valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) limit 0.080 mm (0.0032 in) valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) limit 0.100 mm (0.0039 in) valve stem runout 0.040 mm (0.0016 in) cylinder head valve se...

  • Page 51: Engine Specifications

    Engine specifications 2-6 piston piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) limit 0.05 mm (0.0020 in) diameter d 65.475–65.490 mm (2.5778–2.5783 in) height h 4.0 mm (0.16 in) offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 16.002–16.013 mm ...

  • Page 52: Engine Specifications

    Engine specifications 2-7 oil ring dimensions (b × t) 1.50 × 2.00 mm (0.06 × 0.08 in) end gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) connecting rod oil clearance (using plastigauge®) 0.028–0.052 mm (0.0011–0.0020 in) limit 0.08 mm (0.0032 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green cr...

  • Page 53: Engine Specifications

    Engine specifications 2-8 transmission transmission type constant mesh 6-speed primary reduction system spur gear primary reduction ratio 86/44 (1.955) secondary reduction system chain drive secondary reduction ratio 46/16 (2.875) operation left foot operation gear ratio 1st 37/13 (2.846) 2nd 37/19 ...

  • Page 54: Chassis Specifications

    Chassis specifications 2-9 eas20300 chassis specifications chassis frame type diamond caster angle 25.00 ° trail 97.5 mm (3.84 in) front wheel wheel type cast wheel rim size 17m/c x mt3.50 rim material aluminum wheel travel 130.0 mm (5.12 in) radial wheel runout limit 1.0 mm (0.04 in) lateral wheel ...

  • Page 55: Chassis Specifications

    Chassis specifications 2-10 6.0 mm (0.24 in) (fz6-s/fz6-sa/fz6-n/fz6- na) limit 0.5 mm (0.02 in) (fz6-shg(w)/fz6-sahg/ fz6-nhg(w)/fz6-nahg) 0.8 mm (0.03 in) (fz6-s/fz6-sa/fz6-n/fz6- na) brake pad lining thickness (outer) 4.5 mm (0.18 in) (fz6-shg(w)/fz6-sahg/ fz6-nhg(w)/fz6-nahg) 6.0 mm (0.24 in) (f...

  • Page 56: Chassis Specifications

    Chassis specifications 2-11 rear suspension type swingarm (monocross) spring/shock absorber type coil spring/gas-oil damper rear shock absorber assembly travel 50.0 mm (1.97 in) spring free length 185.0 mm (7.28 in) installed length 172.0 mm (6.77 in) spring rate k1 127.40 n/mm (727.45 lb/in) (12.99...

  • Page 57: Electrical Specifications

    Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) ignition system type dc. Tci advancer type digital ignition timing (b.T.D.C.) 5.0 °/1300 r/min engine control unit model/manufacturer f...

  • Page 58: Electrical Specifications

    Electrical specifications 2-13 12 v, 5.0 w × 2 (fz6-s/fz6-sa/fz6-shg(w)/ fz6-sahg) tail/brake light 12 v, 5.0 w/21.0 w × 1 front turn signal light 12 v, 10.0 w × 2 rear turn signal light 12 v, 10.0 w × 2 license plate light 12 v, 5.0 w × 1 meter lighting led (fz6-shg(w)/fz6-sahg/fz6-nhg(w)/ fz6-nahg...

  • Page 59: Electrical Specifications

    Electrical specifications 2-14 fuel gauge model/manufacturer 5vx/denso sender unit resistance (full) 19.0–21.0 Ω sender unit resistance (empty) 139.0–141.0 Ω starting circuit cut-off relay model/manufacturer g8r-30y-v3/omron coil resistance 162–198 Ω radiator fan motor relay model/manufacturer acm33...

  • Page 60: Tightening Torques

    Tightening torques 2-15 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 cha...

  • Page 61: Tightening Torques

    Tightening torques 2-16 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plugs m10 4 18 nm (1.8 m·kg, 13 ft·lb) cylinder head bolt m10 10 see note cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft caps bolt m6 20 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder...

  • Page 62: Tightening Torques

    Tightening torques 2-17 catalyst pipe and catalyst pipe stay bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) muffler joint bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) see note catalyst joint bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) see note exhaust pipe stay bolt m8 2 20 nm (2.0 m·kg, 14 ft·lb) catalyst pipe stay bolt m8...

  • Page 63: Tightening Torques

    Tightening torques 2-18 note: • cylinder head bolt 1 first, tighten the bolts to approximately 19 nm (1.9 m·kg, 14 ft·lb) with a torque wrench following the tightening order. 2 retighten the bolts 50 nm (5.0 m·kg, 36 ft·lb) with a torque wrench. • crankcase bolt (main journal) 1 first, tighten the b...

  • Page 64: Tightening Torques

    Tightening torques 2-19 cylinder head tightening sequence. Crankcase tightening sequence..

  • Page 65: Tightening Torques

    Tightening torques 2-20 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks upper bracket pinch bolt m8 2 30 nm (3.0 m·kg, 22 ft·lb) steering stem nut m22 1 110 nm (11 m·kg, 80 ft·lb) upper bracket and upper handle- bar holder m8 4 23 nm (2.3 m·kg, 17 ft·lb) lower bra...

  • Page 66: Tightening Torques

    Tightening torques 2-21 seat lock and frame m6 2 7 nm (0.7 m·kg, 5.0 ft·lb) licence plate light screw m5 2 4 nm (0.4 m·kg, 2.9 ft·lb) rear reflector bolt m5 2 4 nm (0.4 m·kg, 2.9 ft·lb) flap and bracket 6 m6 2 7 nm (0.7 m·kg, 5.0 ft·lb) bracket 6 and rear frame m6 2 19 nm (1.9 m·kg, 14 ft·lb) tail/b...

  • Page 67: Tightening Torques

    Tightening torques 2-22 note: • lower ring nut 1. First, tighten the ring nut to approximately 52 nm (5.2 m·kg, 38 ft·lb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut to specification. • engine mount bolts and engine mount self locking nut refer to "inst...

  • Page 68

    Lubrication points and lubricant types 2-23 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings and bushes crankshaft pins piston surfaces piston pins connecting rod bolts crankshaft journals camshaft lobes camshaft journals valv...

  • Page 69

    Lubrication points and lubricant types 2-24 eas20380 chassis lubrication point lubricant steering bearings and bearing races (upper and lower) front wheel oil seal (right and left) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating surface rear brake pedal shaft sidestand ...

  • Page 70

    Lubrication system chart and diagrams 2-25 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 71

    Lubrication system chart and diagrams 2-26 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main axle 7. Mission cooler 8. Drive axle 9. Main gallery 10.Piston cooler 11.Intake camshaft 12.Exhaust camshaft.

  • Page 72

    Lubrication system chart and diagrams 2-27 eas20410 lubrication diagrams.

  • Page 73

    Lubrication system chart and diagrams 2-28 1. Oil level switch 2. Oil cooler 3. Relief valve.

  • Page 74

    Lubrication system chart and diagrams 2-29.

  • Page 75

    Lubrication system chart and diagrams 2-30 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer.

  • Page 76

    Lubrication system chart and diagrams 2-31.

  • Page 77

    Lubrication system chart and diagrams 2-32 1. Oil cooler 2. Oil strainer 3. Oil level switch 4. Oil pump.

  • Page 78

    Lubrication system chart and diagrams 2-33.

  • Page 79

    Lubrication system chart and diagrams 2-34 1. Main axle 2. Oil pump 3. Relief valve.

  • Page 80

    Lubrication system chart and diagrams 2-35.

  • Page 81

    Lubrication system chart and diagrams 2-36 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft.

  • Page 82

    Lubrication system chart and diagrams 2-37.

  • Page 83

    Lubrication system chart and diagrams 2-38 1. Main axle 2. Drive axle.

  • Page 84: Cooling System Diagrams

    Cooling system diagrams 2-39 eas20420 cooling system diagrams.

  • Page 85: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Radiator 2. Oil cooler.

  • Page 86: Cooling System Diagrams

    Cooling system diagrams 2-41.

  • Page 87: Cooling System Diagrams

    Cooling system diagrams 2-42 1. Water pump 2. Oil cooler 3. Radiator.

  • Page 88: Cooling System Diagrams

    Cooling system diagrams 2-43.

  • Page 89: Cooling System Diagrams

    Cooling system diagrams 2-44 1. Oil cooler 2. Water pump.

  • Page 90: Cooling System Diagrams

    Cooling system diagrams 2-45.

  • Page 91: Cooling System Diagrams

    Cooling system diagrams 2-46 1. Radiator 2. Thermostat.

  • Page 92: Cable Routing

    Cable routing 2-47 eas20430 cable routing fz6-s/fz6-shg(w)/fz6-sa/fz6-sahg.

  • Page 93: Cable Routing

    Cable routing 2-48 fz6-s/fz6-shg(w)/fz6-sa/fz6-sahg 1. Left handlebar switch lead 2. Main switch and immobilizer lead 3. Clutch cable 4. Throttle cables 5. Right handlebar switch lead a. Clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of t...

  • Page 94: Cable Routing

    Cable routing 2-49 fz6-n/fz6-na.

  • Page 95: Cable Routing

    Cable routing 2-50 fz6-n/fz6-na 1. Left handlebar switch lead 2. Main switch and immobilizer lead 3. Clutch cable 4. Throttle cables 5. Right handlebar switch lead 6. Handlebar 7. Headlight stay a. Clamp the right handlebar switch lead and handlebars. Point the tip of the clamp downward in front of ...

  • Page 96: Cable Routing

    Cable routing 2-51 fz6-nhg(w)/fz6-nahg.

  • Page 97: Cable Routing

    Cable routing 2-52 fz6-nhg(w)/fz6-nahg 1. Left handlebar switch lead 2. Main switch and immobilizer lead 3. Clutch cable 4. Wire harness 5. Throttle cables 6. Right handlebar switch lead 7. Handlebar 8. Headlight stay a. Clamp the right handlebar switch lead and handlebars. Point the tip of the clam...

  • Page 98: Cable Routing

    Cable routing 2-53 fz6-s/fz6-shg(w).

  • Page 99: Cable Routing

    Cable routing 2-54 fz6-s/fz6-shg(w) 1. Rear brake light switch lead 2. Neutral switch lead 3. Fuel tank breather hose 4. Crankshaft position sensor lead 5. Right handlebar switch lead 6. O 2 sensor lead 7. Bracket 8. Fuel tank drain hose 9. Rear brake reservoir hose a. Pass the fuel tank breather ho...

  • Page 100: Cable Routing

    Cable routing 2-55 fz6-sa/fz6-sahg.

  • Page 101: Cable Routing

    Cable routing 2-56 fz6-sa/fz6-sahg 1. Rear brake light switch lead 2. Rear wheel sensor lead 3. Neutral switch lead 4. Abs motor coupler 5. Fuel tank breather hose 6. Crankshaft position sensor lead 7. Right handlebar switch lead 8. O 2 sensor lead 9. Bracket 10.Fuel tank drain hose 11.Hydraulic uni...

  • Page 102: Cable Routing

    Cable routing 2-57 fz6-n/fz6-nhg(w).

  • Page 103: Cable Routing

    Cable routing 2-58 fz6-n/fz6-nhg(w) 1. Rear brake light switch lead 2. Neutral switch lead 3. Fuel tank breather hose 4. Crankshaft position sensor lead 5. Throttle cables 6. Meter and left handlebar switch lead 7. Right handlebar switch lead 8. Wire harness 9. O 2 sensor lead 10.Bracket 11.Fuel tan...

  • Page 104: Cable Routing

    Cable routing 2-59 fz6-na/fz6-nahg.

  • Page 105: Cable Routing

    Cable routing 2-60 fz6-na/fz6-nahg 1. Rear brake light switch lead 2. Rear wheel sensor lead 3. Neutral switch lead 4. Hydraulic unit motor coupler 5. Fuel tank breather hose 6. Crankshaft position sensor lead 7. Throttle cables 8. Meter and left handlebar switch lead 9. Right handlebar switch lead ...

  • Page 106: Cable Routing

    Cable routing 2-61 fz6-s/fz6-shg(w).

  • Page 107: Cable Routing

    Cable routing 2-62 fz6-s/fz6-shg(w) 1. Main switch and immobilizer lead 2. Stay assembly 3. Left handlebar switch lead 4. Clutch cable 5. Throttle cables 6. Battery negative lead coupler 7. Starter relay lead 8. Battery negative lead 9. Fuel tank drain hose 10.Rectifier/regulator 11.Turn signal rela...

  • Page 108: Cable Routing

    Cable routing 2-63 fz6-sa/fz6-sahg.

  • Page 109: Cable Routing

    Cable routing 2-64 fz6-sa/fz6-sahg 1. Main switch and immobilizer lead 2. Stay assembly 3. Left handlebar switch lead 4. Clutch cable 5. Throttle cables 6. Battery negative lead coupler 7. Starter relay lead 8. Battery negative lead 9. Fuel tank drain hose 10.Hydraulic unit lead 11.Rectifier/regulat...

  • Page 110: Cable Routing

    Cable routing 2-65 fz6-n/fz6-nhg(w).

  • Page 111: Cable Routing

    Cable routing 2-66 fz6-n/fz6-nhg(w) 1. Main switch and immobilizer lead 2. Meter and left handlebar switch lead 3. Clutch cable 4. Battery negative lead coupler 5. Starter motor relay lead 6. Battery negative lead 7. Fuel tank drain hose 8. Rectifier/regulator 9. Turn signal relay 10.Radiator fan mo...

  • Page 112: Cable Routing

    Cable routing 2-67 fz6-na/fz6-nahg.

  • Page 113: Cable Routing

    Cable routing 2-68 fz6-na/fz6-nahg 1. Main switch and immobilizer lead 2. Meter and left handlebar switch lead 3. Clutch cable 4. Battery negative lead coupler 5. Starter motor relay lead 6. Battery negative lead 7. Fuel tank drain hose 8. Hydraulic unit lead 9. Rectifier/regulator 10.Turn signal re...

  • Page 114: Cable Routing

    Cable routing 2-69 fz6-s/fz6-shg(w).

  • Page 115: Cable Routing

    Cable routing 2-70 fz6-s/fz6-shg(w) 1. Right handlebar switch lead 2. Throttle cables 3. Battery positive lead 4. Battery cover 5. Connector cover 6. Fuel tank breather hose 7. Lean angle sensor 8. Fuse box 9. Rear right turn signal light lead 10.License plate light lead 11.Rear left turn signal lig...

  • Page 116: Cable Routing

    Cable routing 2-71 fz6-sa/fz6-sahg.

  • Page 117: Cable Routing

    Cable routing 2-72 fz6-sa/fz6-sahg 1. Right handlebar switch lead 2. Throttle cables 3. Battery positive lead 4. Battery cover 5. Connector cover 6. Fuel tank breather hose 7. Lean angle sensor 8. Fuse box 9. Rear right turn signal light lead 10.License plate light lead 11.Rear left turn signal ligh...

  • Page 118: Cable Routing

    Cable routing 2-73.

  • Page 119: Cable Routing

    Cable routing 2-74 as.Route the spark plug lead #3 under the air cut-off valve hose. At. Route the spark plug lead #2 behind the air cut-off valve hose. Au.Route the spark plug lead #4 by the front side of the spark plug leads #2 and #3. Av.Route the spark plug leads #2 and #3 behind the air cut-off...

  • Page 120: Cable Routing

    Cable routing 2-75 fz6-n/fz6-nhg(w).

  • Page 121: Cable Routing

    Cable routing 2-76 fz6-n/fz6-nhg(w) 1. Right handlebar switch lead 2. Throttle cables 3. Battery positive lead 4. Battery cover 5. Connector cover 6. Fuel tank breather hose 7. Lean angle sensor 8. Fuse box 9. Rear right turn signal light lead 10.License plate light lead 11.Rear left turn signal lig...

  • Page 122: Cable Routing

    Cable routing 2-77.

  • Page 123: Cable Routing

    Cable routing 2-78 av.Route the spark plug lead #4 behind the air cut-off valve hose. Aw.Point the spark plug caps of #1 to #4 to the direction as shown in the illustration. Ax.Route the spark plug lead #3 under the air cut-off valve hose. Ay.Route the spark plug lead #2 behind the air cut-off valve...

  • Page 124: Cable Routing

    Cable routing 2-79 fz6-na/fz6-nahg.

  • Page 125: Cable Routing

    Cable routing 2-80 fz6-na/fz6-nahg 1. Right handlebar switch lead 2. Throttle cables 3. Battery positive lead 4. Battery cover 5. Connector cover 6. Fuel tank breather hose 7. Lean angle sensor 8. Fuse box 9. Rear right turn signal light lead 10.License plate light lead 11.Rear left turn signal ligh...

  • Page 126: Cable Routing

    Cable routing 2-81.

  • Page 127: Cable Routing

    Cable routing 2-82 ar.Route the throttle cables behind the #1 and #4 spark plug lead. As.Pass the spark plug leads #1 and #4 through the slit of the cover 2. At. Route the throttle cables by the front side of the #2 and #3 spark plug lead. Au.Route the throttle cables under the vent hose of the air-...

  • Page 128: Cable Routing

    Cable routing 2-83.

  • Page 129: Cable Routing

    Cable routing 2-84 1. Fuel pump assembly 2. Fuel tank breather hose 3. Fuel tank drain hose 4. Fuel hose 5. Clip 6. Clamp 7. Fuel tank protector a. Air opening. B. Install the o-ring with its lip pointed upward. C. Fuel tank breather hose has a white point mark. (fuel tank breather hose side) d. Poi...

  • Page 130: Cable Routing

    Cable routing 2-85.

  • Page 131

    3 periodic checks and adjustments periodic maintenance .........................................................................3-1 introduction ....................................................................................3-1 engine................................................................

  • Page 132

    Electrical system.............................................................................. 3-35 replacing the headlight bulbs............................................... 3-35 adjusting the headlight beams .............................................. 3-35.

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and redu...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-2 13 drive chain • check chain slack, alignment and condition. • adjust and lubricate chain with a special o-ring chain lubricant thor- oughly. Every 1000 km and after wash- ing the vehicle or riding in the rain 14 * steering bear- ings • check bearing play and steering for ro...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-3 note: • air filter • this model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • the air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas....

  • Page 137: Engine

    Engine 3-4 eas20470 engine eas20490 adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead ce...

  • Page 138: Engine

    Engine 3-5 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at tdc, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: • camshafts note: • refer to "camshafts" on page 5-8. • when removing the timing...

  • Page 139: Engine

    Engine 3-6 • since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original. C. Round off the original valve pad number according to the following table. Example: original valve pad number = 148 (thickness...

  • Page 140: Engine

    Engine 3-7 • air filter case refer to "general chassis" on page 4- 1. 3. Install: • vacuum gauge “1” (onto the synchronizing hose “2”) 4. Install: • air filter case refer to "general chassis" on page 4- 1. • fuel tank refer to "fuel tank" on page 7-1. 5. Start the engine and let it warm up for sev- ...

  • Page 141: Engine

    Engine 3-8 11. Install: • fuel tank refer to "fuel tank" on page 7-1. • seat refer to "general chassis" on page 4- 1. Eas4s81012 adjusting the exhaust gas volume (fz6-n/fz6-na/fz6-s/fz6-sa) note: be sure to set the co density level to stan- dard, and then adjust the exhaust gas volume. 1. Turn the m...

  • Page 142: Engine

    Engine 3-9 2. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch to “on”, and continue to press the buttons for 8 seconds or more. Note: “di” appears on the clock lcd. 3. Press the “select” button to select the co adjustment mode “co” “1” or the diag- nostic mode “d...

  • Page 143: Engine

    Engine 3-10 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the idle adjusting screw “1” in direction “a” or “b” until the specified engine idling speed is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Adjust: • throttle cable free play refer to "adjusting the throttle cable free play" on page 3-10. Eas20630 a...

  • Page 144: Engine

    Engine 3-11 b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. C. Tighten the locknut ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • battery refer to "general chassis" on page 4- 1 and "checking and charging the battery" on page 8-114. • air...

  • Page 145: Engine

    Engine 3-12 normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure: • spark plug gap “a” (with a wire thickness gauge) out of specification → regap. 8. Install: • spark plugs note: before installing the spark plug, clean the spark plug and ga...

  • Page 146: Engine

    Engine 3-13 out of specification → refer to steps (c) and (d). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes. Warning ewa4s81003 to prevent sparking, ground all spark plug leads ...

  • Page 147: Engine

    Engine 3-14 caution: eca4s81007 • engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of cd “a” or higher and do not use oils labeled “energy con- serving ii” “b” or highe...

  • Page 148: Engine

    Engine 3-15 b. Lubricate the o-ring “3” of the new oil filter cartridge with a thin coat of engine oil. Caution: eca13390 make sure the o-ring “3” is positioned cor- rectly in the groove of the oil filter car- tridge. C. Tighten the new oil filter cartridge to speci- fication with an oil filter wren...

  • Page 149: Engine

    Engine 3-16 4. Install: • oil pressure gauge “1” • adapter “2” 5. Measure: • engine oil pressure (at the following conditions) out of specification → adjust. 6. Install: • main gallery bolt “1” eas20870 adjusting the clutch cable free play 1. Check: • clutch cable free play “a” out of specification ...

  • Page 150: Engine

    Engine 3-17 note: if the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ engine side a. Loosen the locknuts “1”. B. Turn the adjusting nut “2” in direction ...

  • Page 151: Engine

    Engine 3-18 refer to "general chassis" on page 4- 1. Eas21010 checking the throttle body joints the following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: • throttle bodies refer to "throttle bodies" on page 7- 4. 2. Check: • throttle body joints “1” cracks/d...

  • Page 152: Engine

    Engine 3-19 • seat refer to "general chassis" on page 4- 1. Eas21080 checking the exhaust system the following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • radiator refer to "radiator" on page 6-1. 2. Check: • exhaust pipe “1” • catalytic converter pipe “2” • muffler “3” c...

  • Page 153: Engine

    Engine 3-20 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: • coolant level note: before checking the coolant level, wait a few minutes until it settles. Eas21120 checking the cooling system 1. Check: • radiator “1” • radiator inlet hose “2” • radiator outlet hos...

  • Page 154: Engine

    Engine 3-21 warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury. When the engine has cooled, open the radiator cap as follows: place a thick rag or a tow...

  • Page 155: Engine

    Engine 3-22 12. Install: • coolant reservoir cap 13. Start the engine, warm it up for several minutes, and then stop it. 14. Check: • coolant level refer to "checking the coolant level" on page 3-19. Note: before checking the coolant level, wait a few minutes until the coolant has settled..

  • Page 156: Chassis

    Chassis 3-23 eas21140 chassis eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) note: • while pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • be sure to a...

  • Page 157: Chassis

    Chassis 3-24 warning ewa4s81005 a soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance. Caution: eca...

  • Page 158: Chassis

    Chassis 3-25 eas21260 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • rear brake pad wear indicators “b” almost touch the brake disc → replace the brake pads as a set. Refer to "rear brake" on page 4-41. Eas21280 checking the f...

  • Page 159: Chassis

    Chassis 3-26 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21340 bleeding the hydraulic brake sys- tem warning ewa13100 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. • brake operation is fault...

  • Page 160: Chassis

    Chassis 3-27 warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ bleeding the abs brake warning ewa14010 bleed the abs whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid lev...

  • Page 161: Chassis

    Chassis 3-28 warning ewa14020 after bleeding the abs, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21370 adjusting the shift pedal 1. Check: • shift pedal position align the center of shift pedal “1” and cen- ter of footrest bracket bolt “2” in a straight line. Incorrect → adjust. 2....

  • Page 162: Chassis

    Chassis 3-29 note: to maintain the proper wheel alignment, adjust both sides evenly. D. Tighten both locknuts to specification. E. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21440 lubricating the drive chain the drive chain consists of many interacting parts. If t...

  • Page 163: Chassis

    Chassis 3-30 c. Loosen the lower ring nut “4” completely and then tighten it to specification with a steering nut wrench. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any bindi...

  • Page 164: Chassis

    Chassis 3-31 warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Check: • inner tube “1” damage/scratches → replace. • oil seal “2” oil leakage → replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • front fork operation push down har...

  • Page 165: Chassis

    Chassis 3-32 warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • the tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the antic...

  • Page 166: Chassis

    Chassis 3-33 warning ewa14080 • do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • when using a tube tire, be sure to install the correct tube. • always replace a new tube tire and a new tube as a set. • to avoid pinc...

  • Page 167: Chassis

    Chassis 3-34 eas21670 checking the wheels the following procedure applies to both of the wheels. 1. Check: • wheel damage/out-of-round → replace. Warning ewa13260 never attempt to make any repairs to the wheel. Note: after a tire or wheel has been changed or replaced, always balance the wheel. Eas21...

  • Page 168: Electrical System

    Electrical system 3-35 eas21750 electrical system eas21790 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler “1” 2. Remove: • headlight bulb cover “2” 3. Remove: • headlight bulb holder “1” 4. Remove: • headlight bulb “2”...

  • Page 169: Electrical System

    Electrical system 3-36 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Fz6-s/fz6-shg(w)/fz6-sa/fz6-sahg b. Fz6-n/fz6-nhg(w)/fz6-na/fz6-nahg direction “a...

  • Page 170: Electrical System

    Electrical system 3-37.

  • Page 171: Chassis

    4 chassis general chassis....................................................................................4-1 front wheel ............................................................................................ 4-7 removing the front wheel ........................................................

  • Page 172

    Abs (anti-lock brake system) ........................................................ 4-53 [d-5] maintenance of the hydraulic unit..............................4-55 hydraulic unit operation test ................................................ 4-56 [d-6-5] trial run ....................................

  • Page 174: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat order job/parts to remove q’ty remarks 1 seat 1 for installation, reverse the removal proce- dure..

  • Page 175: General Chassis

    General chassis 4-2 removing the cowlings (fz6-n/fz6-nhg(w)/fz6-na/fz6-nahg) order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. 1 side cover 2 2 rear cowling 1 for installation, reverse the removal proce- dure..

  • Page 176: General Chassis

    General chassis 4-3 removing the cowlings (fz6-s/fz6-sa) order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. 1 left front cowling inner panel (with cowling) 1 2 right front cowling inner panel (with cowling) 1 3 front turn signal light coupler 2 disconnect. 4 front co...

  • Page 177: General Chassis

    General chassis 4-4 removing the cowlings (fz6-shg(w)/fz6-sahg) order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. 1 left front cowling inner panel (with cowling) 1 2 right front cowling inner panel (with cowling) 1 3 front turn signal light coupler 2 disconnect. 4 f...

  • Page 178: General Chassis

    General chassis 4-5 removing the air filter case and battery order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chas...

  • Page 179: General Chassis

    General chassis 4-6 removing the battery box order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chassis" on page 4-1...

  • Page 180: Front Wheel

    Front wheel 4-7 eas21880 front wheel * fz6-nhg(w)/fz6-shg(w) removing the front wheel and brake discs (fz6-n/fz6-nhg(w)/fz6-s/fz6-shg(w)) order job/parts to remove q’ty remarks 1 brake hose holder 2 2 brake hose holder 1 3 front brake caliper 2 4 front wheel axle pinch bolt 1 loosen. 5 front wheel a...

  • Page 181: Front Wheel

    Front wheel 4-8 * fz6-nahg/fz6-sahg removing the front wheel sensor and sensor rotor (fz6-na/fz6-nahg/fz6-sa/fz6-sahg) order job/parts to remove q’ty remarks 1 brake hose holder 2 2 brake hose holder 1 3 front brake caliper 2 4 front wheel sensor 1 5 front wheel axle pinch bolt 1 loosen. 6 front whe...

  • Page 182: Front Wheel

    Front wheel 4-9 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 183: Front Wheel

    Front wheel 4-10 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • left brake caliper • ...

  • Page 184: Front Wheel

    Front wheel 4-11 c. Remove the wheel bearings “3” with a gen- eral bearing puller. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Caution: eca14130 do not contact the wheel bearing inner race “4” or balls “5”. Contact should be made only with the outer race “6”....

  • Page 185: Front Wheel

    Front wheel 4-12 2. Check: • front wheel sensor rotor “2” cracks/damage → replace the front wheel assembly. Note: the wheel sensor rotor of the vehicle is inserted under pressure by a special process and cannot be replaced as a single unit. To replace the sensor rotor, replace the wheel assembly. In...

  • Page 186: Front Wheel

    Front wheel 4-13 3. Check: • front wheel sensor installation check if the wheel sensor housing is installed properly. Refer to "[d-3] maintenance of the front wheel sensor and sensor rotor" on page 4-11. Eas21970 adjusting the front wheel static balance note: • after replacing the tire, wheel or bot...

  • Page 187: Front Wheel

    Front wheel 4-14 c. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure ...

  • Page 188: Rear Wheel

    Rear wheel 4-15 eas22030 rear wheel removing the rear wheel (fz6-n/fz6-nhg(w)/fz6-s/fz6-shg(w)) order job/parts to remove q’ty remarks 1 rear brake caliper 1 2 locknut 2 loosen. 3 adjusting nut 2 loosen. 4 rear wheel axle nut 1 5 washer 1 6 rear wheel axle 1 7 washer 1 8 drive chain puller 2 9 rear ...

  • Page 189: Rear Wheel

    Rear wheel 4-16 removing the rear wheel sensor and sensor rotor (fz6-na/fz6-nahg/fz6-sa/fz6-sahg) order job/parts to remove q’ty remarks 1 rear wheel sensor 1 2 rear brake caliper 1 3 lock nut 2 loosen. 4 adjusting nut 2 loosen. 5 wheel axle nut 1 6 washer 1 7 rear wheel axle 1 8 washer 1 9 drive ch...

  • Page 190: Rear Wheel

    Rear wheel 4-17 removing the rear brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 rear wheel sprocket 1 3 collar 2 4 oil seal 2 5 bearing 2 6 rear wheel drive hub 1 7 rear wheel drive hub damper 6 8 rear wheel 1 for installation, reverse the removal pr...

  • Page 191: Rear Wheel

    Rear wheel 4-18 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 192: Rear Wheel

    Rear wheel 4-19 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • brake caliper “1” note: ...

  • Page 193: Rear Wheel

    Rear wheel 4-20 eas22120 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → replace the rear wheel sprocket. Bent teeth → replace the rear wheel sprocket. 2. Replace: • rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-lo...

  • Page 194: Rear Wheel

    Rear wheel 4-21 • rear wheel refer to "removing the rear wheel" on page 4-19. 5. Remove: • sensor rotor “5” checking the rear wheel sensor and sensor rotor 1. Check: • rear wheel sensor cracks/bends/distortion → replace. Iron powder/dust → clean. 2. Check: • rear wheel sensor rotor cracks/damage → r...

  • Page 195: Rear Wheel

    Rear wheel 4-22 5. Connect: • rear wheel sensor lead holder “3” • clamp “4” • rear wheel sensor coupler “5” caution: eca14500 to route the rear wheel sensor lead, refer to "cable routing" on page 2-47. 6. Check: • rear wheel sensor installation check if the wheel sensor housing is installed properly...

  • Page 196: Front Brake

    Front brake 4-23 eas22210 front brake removing the front brake pads (fz6-n/fz6-na/fz6-s/fz6-sa) order job/parts to remove q’ty remarks 1 front brake caliper 1 2 brake pad 2 3 brake pad spring 2 4 bleed screw 1 for installation, reverse the removal proce- dure..

  • Page 197: Front Brake

    Front brake 4-24 * fz6-nahg/fz6-sahg removing the front brake pads (fz6-nhg(w)/fz6-nahg/fz6-shg(w)/fz6-sahg) order job/parts to remove q’ty remarks 1 brake hose holder 2 2 front brake caliper 2 3 brake pad clip 2 4 brake pad pin 1 5 brake pad spring 1 6 brake pad 2 7 bleed screw 1 8 clamp 1 for inst...

  • Page 198: Front Brake

    Front brake 4-25 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-26. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm holder 1 3 brake master cylinder reserv...

  • Page 199: Front Brake

    Front brake 4-26 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 master cylinder kit 1 4 spring 1 5 master cylinder 1 6 push rod 1 for assembly, reverse the disassembly pro- cedure..

  • Page 200: Front Brake

    Front brake 4-27 removing the front brake calipers (fz6-n/fz6-na/fz6-s/fz6-sa) order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-26. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 brake caliper 1 5 brake pad 2 6 brake caliper bracke...

  • Page 201: Front Brake

    Front brake 4-28 * fz6-nahg/fz6-sahg removing the front brake calipers (fz6-nhg(w)/fz6-nahg/fz6-shg(w)/fz6-sahg) order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-26. 1 union bolt 2 2 copper washer 5 3 brake hose 2 4 brake caliper 1 5 ...

  • Page 202: Front Brake

    Front brake 4-29 disassembling the front brake calipers (fz6-n/fz6-na/fz6-s/fz6-sa) order job/parts to remove q’ty remarks 1 brake pad 2 2 brake caliper piston 2 3 brake caliper piston seal 4 4 brake pad spring 1 5 bleed screw 1 for assembly, reverse the disassembly pro- cedure..

  • Page 203: Front Brake

    Front brake 4-30 disassembling the front brake calipers (fz6-nhg(w)/fz6-nahg/fz6-shg(w)/fz6-sahg) order job/parts to remove q’ty remarks 1 brake pad clip 2 2 brake pad pin 1 3 brake pad spring 1 4 brake pad 2 5 brake caliper piston 4 6 brake caliper piston seal 8 7 bleed screw 1 for assembly, revers...

  • Page 204: Front Brake

    Front brake 4-31 eas22220 introduction warning ewa14100 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 ent...

  • Page 205: Front Brake

    Front brake 4-32 d. Measure the brake disc deflection. E. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas...

  • Page 206: Front Brake

    Front brake 4-33 5. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-26. Fz6-nhg(w)/fz6-nahg/fz6-shg(w)/fz6- sahg 1. Measure: • brake pad wear limit “a” out of specification → replace the brake pads as a set. 2. ...

  • Page 207: Front Brake

    Front brake 4-34 5. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-26. Eas22300 removing the front brake calipers the following procedure applies to both of the brake calipers. Note: before removing the brake c...

  • Page 208: Front Brake

    Front brake 4-35 fz6-nhg(w)/fz6-nahg/fz6-shg(w)/fz6- sahg 1. Remove: • brake caliper pistons “1” • brake caliper piston seals “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the brake caliper pistons with a piece of wood “a”. B. Blow compressed air into the brake hose joint opening “b” to force out the...

  • Page 209: Front Brake

    Front brake 4-36 eas22410 assembling the front brake cali- pers warning ewa13620 • 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 as they will cause the piston seals to swell and d...

  • Page 210: Front Brake

    Front brake 4-37 • brake system refer to "bleeding the hydraulic brake system" on page 3-26. 4. Check: • brake fluid level below the minimum level mark “c” → add the recommended brake fluid to the proper level. Refer to "checking the brake fluid level" on page 3-24. 5. Check: • brake lever operation...

  • Page 211: Front Brake

    Front brake 4-38 5. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-26. Eas22490 removing the front brake master cylinder note: before removing the front brake master cylin- der, drain the brake fluid from the e...

  • Page 212: Front Brake

    Front brake 4-39 eas22520 assembling the front brake mas- ter cylinder warning ewa13520 • 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. 1. Install: • master cylinder kit • circli...

  • Page 213: Front Brake

    Front brake 4-40 boiling point of the brake fluid and could cause vapor lock. Caution: eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system refer to "bleeding the hydraulic brake system" on page 3-2...

  • Page 214: Rear Brake

    Rear brake 4-41 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 rear brake caliper 1 4 brake pad shim 4 5 brake pad 2 6 brake screw 1 7 brake pad spring 1 for installation, reverse the removal proce- dure..

  • Page 215: Rear Brake

    Rear brake 4-42 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-26. 1 brake fluid reservoir cap 1 2 rear brake fluid reservoir diaphragm holder 1 3 rear brake fluid reservoir diaphragm 1 4 brak...

  • Page 216: Rear Brake

    Rear brake 4-43 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 spring 1 5 brake master cylinder body 1 for installation, reverse the removal proce- dure..

  • Page 217: Rear Brake

    Rear brake 4-44 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydraulic brake system" on page 3-26. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 rear brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 218: Rear Brake

    Rear brake 4-45 disassembling the rear brake caliper order job/parts to remove q’ty remarks 1 screw plug 1 2 brake pad pin 1 3 brake pad 2 4 brake pad shim 4 5 brake pad spring 1 6 brake caliper piston 1 7 brake caliper piston seal 2 8 bleed screw 1 for assembly, reverse the disassembly pro- cedure..

  • Page 219: Rear Brake

    Rear brake 4-46 eas22560 introduction warning ewa14100 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 enti...

  • Page 220: Rear Brake

    Rear brake 4-47 b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. C. Tighten the bleed screw. D. Install a new brake pad shim “3” onto each new brake pad “4”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • brake caliper • brake pad pin • screw plug 4...

  • Page 221: Rear Brake

    Rear brake 4-48 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. Warning ewa13550 • cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper...

  • Page 222: Rear Brake

    Rear brake 4-49 1. Install: • brake caliper seals • brake caliper piston eas22670 installing the rear brake caliper 1. Install: • brake caliper “1” (temporarily) • copper washers • brake hose “2” • union bolt “3” warning ewa13530 proper brake hose routing is essential to insure safe vehicle operatio...

  • Page 223: Rear Brake

    Rear brake 4-50 7. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-26. Eas22700 removing the rear brake master cylinder 1. Remove: • union bolt “1” • copper washers “2” • brake hose “3” note: to collect any rema...

  • Page 224: Rear Brake

    Rear brake 4-51 eas22730 assembling the rear brake master cylinder warning ewa13520 • 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. 1. Install: • master cylinder kit • circlip ea...

  • Page 225: Rear Brake

    Rear brake 4-52 6. Adjust: • rear brake light operation timing refer to "adjusting the rear brake light switch" on page 3-25. Brake pedal position 25.8 mm (1.02 in).

  • Page 226: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-53 eas22760 abs (anti-lock brake system) removing the hydraulic unit order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Abs ecu refer to "abs ecu and abs motor relay" on page 8-77. Hydraulic u...

  • Page 227: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-54 10 brake hose (hydraulic unit to front brake cali- pers) 1 11 union bolt 1 12 copper washer 2 13 brake hose (rear brake master cylinder to hydraulic unit) 1 14 union bolt 1 15 copper washer 2 16 brake hose (hydraulic unit to rear brake caliper) 1 17 hydraulic unit 1...

  • Page 228: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-55 eas22770 [d-5] maintenance of the hydraulic unit caution: eca15060 do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fl...

  • Page 229: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-56 installing the hydraulic unit proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit bracket note: tighten the nuts in the proper sequence. 2. Install: • hydraulic unit note: do not allow any foreign materials...

  • Page 230: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-57 • hydraulic unit operation test 1: this test gen- erates the same reaction-force pulsating action that is generated in the brake lever and brake pedal when the abs is activated. • hydraulic unit operation test 2: this test checks the function of the abs after the sy...

  • Page 231: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-58 caution: eca14810 • check that the brake lever returns to its home position before the brake pedal returns to its home position. • if the brake pedal returns to its home position before the brake lever does, check that the brake hoses are connected correctly to the ...

  • Page 232: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-59 note: after setting the main switch to “on”, wait (approximately 2 seconds) until the abs warn- ing light goes off. 8. Push the start switch for at least 4 seconds. Caution: eca14790 do not operate the brake lever or the brake pedal. 9. After releasing the start swi...

  • Page 233: Handlebar

    Handlebar 4-60 eas22840 handlebar * fz6-nhg(w)/fz6-nahg/fz6-shg(w)/fz6-sahg removing the handlebar order job/parts to remove q’ty remarks 1 grip end 2 2 handlebar grip 1 3 clutch switch connector 1 disconnect. 4 left handlebar switch 1 5 clutch cable 1 6 clutch lever 1 7 right handlebar switch 1 8 t...

  • Page 234: Handlebar

    Handlebar 4-61 eas22860 removing the handlebars 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the left handle- bar and the handlebar grip, and gra...

  • Page 235: Handlebar

    Handlebar 4-62 2. Install: • handlebar “1” • upper handlebar holders “2” • upper handlebar holder caps “3” (stan- dard) caution: eca14250 • first, tighten the bolts on the front side of the handlebar holder, and then on the rear side. • turn the handlebar all the way to the left and right. If there ...

  • Page 236: Handlebar

    Handlebar 4-63 • clutch cable note: align the slit on the clutch lever holder with the punch mark “a” on the handlebar. 6. Install: • left handlebar switch note: align the projection “a” on the left handlebar switch with the hole “b” on the handlebar. 7. Install: • handlebar grip • grip end ▼▼▼▼▼▼▼▼...

  • Page 237: Front Fork

    Front fork 4-64 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks front wheel refer to "front wheel" on page 4-7. Front brake calipers refer to "front brake" on page 4-23. 1 front fender 1 2 cap bolt 1 loosen. 3 upper bracket pinch bolt 1 loosen. 4 under bracket...

  • Page 238: Front Fork

    Front fork 4-65 disassembling the front fork legs order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 spacer 1 4 washer 1 5 front fork spring 1 6 dust seal 1 7 oil seal clip 1 8 damper rod assembly bolt 1 9 copper washer 1 10 damper rod assembly 1 11 oil seal 1 12 washer 1 13 inner tube...

  • Page 239: Front Fork

    Front fork 4-66 eas22970 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 240: Front Fork

    Front fork 4-67 caution: eca14190 • excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. • avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas2301...

  • Page 241: Front Fork

    Front fork 4-68 eas23020 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning ewa13660 • make sure the oil levels in both front fork legs are equal. • uneven oil levels can result in poor han- dling and a loss of stability. Note: • when assembling th...

  • Page 242: Front Fork

    Front fork 4-69 5. Install: • washer • oil seal “1” (with the fork seal driver and adapter) caution: eca14220 make sure the numbered side of the oil seal faces up. Note: • before installing the oil seal, lubricate its lips with lithium soap base grease. • lubricate the outer surface of the inner tub...

  • Page 243: Front Fork

    Front fork 4-70 9. Measure: • front fork leg oil level “a” out of specification → correct. Note: • while filling the front fork leg, keep it upright. • after filling, slowly pump the front fork leg up and down to distribute the fork oil. 10. Install: • spring “1” • spring seat “2” • spacer “3” • cap...

  • Page 244: Front Fork

    Front fork 4-71.

  • Page 245: Steering Head

    Steering head 4-72 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front wheel refer to "front wheel" on page 4-7. Front fender refer to "front fork" on page 4-64. Front fork refer to "front fork" on page 4-64. Handlebar refer to "handlebar" on page 4-60. Fro...

  • Page 246: Steering Head

    Steering head 4-73 13 bearing inner race 2 14 upper bearing 1 15 lower bearing 1 16 dust seal 1 17 bearing outer race 2 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty remarks.

  • Page 247: Steering Head

    Steering head 4-74 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • steering stem nut • washer • upper ring nut • lock washer • rubber washer • lower ring nut “1” (wi...

  • Page 248: Steering Head

    Steering head 4-75 • upper bracket • lower bracket (along with the steering stem) bends/cracks/damage → replace. Eas23140 installing the steering head 1. Lubricate: • upper bearing • lower bearing • bearing races 2. Install: • lower bracket • lower ring nut “1” • rubber washer “2” • upper ring nut “...

  • Page 249: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-76 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Side cover refer to "general chassis" on page 4-1. Rear brake caliper refer to "rear brake" on page 4-...

  • Page 250: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-77 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held respo...

  • Page 251: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-78 • bushings damage/wear → replace. • dust seals damage/wear → replace. • bolts bends/damage/wear → replace. Eas23300 installing the rear shock absorber assembly 1. Lubricate: • collar • bearings • oil seals 2. Install: • rear shock absorber assembly note: when instal...

  • Page 252: Swingarm

    Swingarm 4-79 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks muffler assembly refer to "engine removal" on page 5-1. Catalyst assembly refer to "engine removal" on page 5-1. Exhaust pipe assembly refer to "engine removal" on page 5-1. Rear brake caliper refer to "rear...

  • Page 253: Swingarm

    Swingarm 4-80 for installation, reverse the removal proce- dure. Removing the swingarm order job/parts to remove q’ty remarks.

  • Page 254: Swingarm

    Swingarm 4-81 eas23340 removing the swingarm 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • swingarm side play • swinga...

  • Page 255: Swingarm

    Swingarm 4-82 eas23380 installing the swingarm 1. Lubricate: • bearings • spacers • dust covers • pivot shaft “1” 2. Install: • swingarm • pivot shaft nut “2” 3. Install: • rear shock absorber assembly refer to "installing the rear shock absorber assembly" on page 4-78. • rear wheel refer to "instal...

  • Page 256: Chain Drive

    Chain drive 4-83 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket cover refer to "engine removal" on page 5-1. Swingarm refer to "removing the swingarm" on page 4-81. 1 rear fender 1 2 drive chain 1 3 chain protector 1 for installation, reverse the ...

  • Page 257: Chain Drive

    Chain drive 4-84 eas23410 removing the drive chain 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain (with the ...

  • Page 258: Chain Drive

    Chain drive 4-85 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • o-rings “1” damage → replace the drive chain. • drive chain rollers “2” damage/wear → replace the drive chain. • drive chain side plates “3” damage/wear → replace the drive chain. Cracks → replace the drive chain and make sure the battery b...

  • Page 259: Engine

    5 engine engine removal ......................................................................................5-1 installing the engine .................................................................... 5-6 camshafts.....................................................................................

  • Page 260

    Checking the oil nozzles .......................................................... 5-44 assembling the oil pump ............................................................ 5-44 installing the oil pump ...............................................................5-45 installing the oil strainer ....

  • Page 262: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the drive sprocket order job/parts to remove q’ty remarks drive chain loosen refer to "adjusting the shift pedal" on page 3-28. 1 locknut 1 2 shift rod 1 3 shift arm 1 4 drive sprocket cover 1 5 drive sprocket nut 1 6 lock washer 1 7 drive sprocket...

  • Page 263: Engine Removal

    Engine removal 5-2 removing the exhaust pipe order job/parts to remove q’ty remarks 1 exhaust pipe assembly 1 2 exhaust pipe gasket 4 3 catalytic converter pipe 1 4 muffler cover 1 5 muffler 1 for installation, reverse the removal proce- dure..

  • Page 264: Engine Removal

    Engine removal 5-3 disconnecting the leads and hoses order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on ...

  • Page 265: Engine Removal

    Engine removal 5-4 5 starter motor lead 1 disconnect. 6 stator coil assembly coupler 1 disconnect. 7 oil level switch connector 1 disconnect. 8 neutral switch coupler 1 disconnect. 9 speed sensor coupler 1 disconnect. For assembly, reverse the removal proce- dure. Disconnecting the leads and hoses o...

  • Page 266: Engine Removal

    Engine removal 5-5 removing the engine order job/parts to remove q’ty remarks 1 right front engine mounting bolt 1 2 left front engine mounting bolt 2 3 self-locking nut 2 4 rear engine mounting bolt 2 5 engine 1 for installation, reverse the removal proce- dure..

  • Page 267: Engine Removal

    Engine removal 5-6 eas23720 installing the engine 1. Install: • rear engine mounting bolts “1” note: lubricate the rear engine mounting bolt threads with engine oil. 2. Install: • right front engine mounting bolt “2” • left front engine mounting bolts “3” note: do not fully tighten the bolts. 3. Tig...

  • Page 268: Engine Removal

    Engine removal 5-7 note: • before installing, make sure to align the punch mark “a” of the shift shaft with the punch mark “b” of the shift arm. • align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket..

  • Page 269: Camshafts

    Camshafts 5-8 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks battery refer to "general chassis" on page 4-1. Air filter case refer to "general chassis" on page 4-1. Battery box refer to "fuel tank" on page 7-1. Battery box bracket refer to "general chassis...

  • Page 270: Camshafts

    Camshafts 5-9 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to "pickup rotor" on page 5-33. 1 camshaft sprocket bolt 4 2 timing chain tensioner 1 3 timing chain tensioner gasket 1 4 timing chain guide (exhaust side) 1 5 intake camshaft cap 3 6 dowel pin 6 7 e...

  • Page 271: Camshafts

    Camshafts 5-10 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to "pickup rotor" on page 5-33. 2. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on th...

  • Page 272: Camshafts

    Camshafts 5-11 8. Remove: • camshaft sprockets eas23850 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → replace the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the cam- shaft. 3. Measure: • camshaft runout out o...

  • Page 273: Camshafts

    Camshafts 5-12 note: • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clear- ance with the plastigauge®. D. Remove the camshaft caps and then mea- sure the width of ...

  • Page 274: Camshafts

    Camshafts 5-13 damage/wear → replace the defective part(s). Eas23970 checking the timing chain ten- sioner 1. Check: • timing chain tensioner cracks/damage → replace. 2. Check: • one-way cam rough movement → replace the timing chain tensioner assembly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Lightly press...

  • Page 275: Camshafts

    Camshafts 5-14 3. Install: • dowel pins • intake camshaft caps • exhaust camshaft caps note: • make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “i1”, “i2”: intake side camshaft cap mark “e1”, “e2”: exhaust side camshaft cap mark • make sur...

  • Page 276: Camshafts

    Camshafts 5-15 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Turn: • crankshaft (several full turns clockwise) 8. Check: • “t” mark “a” make sure the “t” mark on the pickup rotor is aligned with the crankcase mating sure face “b”. • camshaft sprocket match mark “c” make sure the match marks on the cam- shaft sp...

  • Page 277: Cylinder Head

    Cylinder head 5-16 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks intake camshaft refer to "camshafts" on page 5-8. Exhaust camshaft refer to "camshafts" on page 5-8. 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation, reverse the remo...

  • Page 278: Cylinder Head

    Cylinder head 5-17 eas24120 removing the cylinder head 1. Remove: • cylinder head bolts note: • loosen the bolts in the proper sequence as shown. • loosen each bolts 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. Eas24160 checking the cylinder head 1. Eliminate: • c...

  • Page 279: Cylinder Head

    Cylinder head 5-18 note: pass the timing chain through the timing chain cavity. 3. Tighten: • cylinder head bolts “1” – “10” • cylinder head bolts “11” “12” note: • lubricate the cylinder head bolts with engine oil. • tighten the cylinder head bolts in the proper tightening sequence as shown and tor...

  • Page 280: Valves and Valve Springs

    Valves and valve springs 5-19 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to "cylinder head" on page 5-16. 1 intake valve lifter 8 2 intake valve pad 8 3 intake valve cotter 16 4 intake valve upper spring seat 8 5...

  • Page 281: Valves and Valve Springs

    Valves and valve springs 5-20 for installation, reverse the removal proce- dure. Removing the valves and valve springs order job/parts to remove q’ty remarks.

  • Page 282: Valves and Valve Springs

    Valves and valve springs 5-21 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve l...

  • Page 283: Valves and Valve Springs

    Valves and valve springs 5-22 eas24290 checking the valves and valve guides the following procedure applies to all of the valves and valve guides. 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 2. Replace: • valve guide note: to ease valve guide rem...

  • Page 284: Valves and Valve Springs

    Valves and valve springs 5-23 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Mea...

  • Page 285: Valves and Valve Springs

    Valves and valve springs 5-24 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear impression. D. Measure the valve seat width. N...

  • Page 286: Valves and Valve Springs

    Valves and valve springs 5-25 h. Install the valve into the cylinder head. I. Press the valve through the valve guide and onto the valve seat to make a clear impression. J. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. ▲▲▲▲▲▲▲...

  • Page 287: Valves and Valve Springs

    Valves and valve springs 5-26 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lifters and cylinder head....

  • Page 288: Valves and Valve Springs

    Valves and valve springs 5-27 4. Install: • valve cotters “1” note: install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attach- ment “3”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a so...

  • Page 289: Generator and Starter Clutch

    Generator and starter clutch 5-28 eas4s81014 generator and starter clutch removing the generator and starter clutch order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Coolant drain refer to "changing the coolant" on page 3-...

  • Page 290: Generator and Starter Clutch

    Generator and starter clutch 5-29 11 idler gear shaft 1 12 idler gear 1 13 starter clutch drive gear 1 for installation, reverse the removal proce- dure. Removing the generator and starter clutch order job/parts to remove q’ty remarks.

  • Page 291: Generator and Starter Clutch

    Generator and starter clutch 5-30 eas24490 removing the generator 1. Remove: • seat refer to "general chassis" on page 4- 1. • fuel tank refer to "fuel tank" on page 7-1. 2. Drain: • coolant refer to "changing the coolant" on page 3-20. • engine oil refer to "changing the engine oil" on page 3-14. 3...

  • Page 292: Generator and Starter Clutch

    Generator and starter clutch 5-31 eas24570 checking the starter clutch 1. Check: • starter clutch rollers “1” damage/wear → replace. 2. Check: • starter clutch idle gear “1” • starter clutch drive gear “2” burrs/chips/roughness/wear → replace the defective part(s). 3. Check: • starter clutch gear’s ...

  • Page 293: Generator and Starter Clutch

    Generator and starter clutch 5-32 eas24500 installing the generator 1. Install: • generator rotor • washer • generator rotor bolt note: • clean the tapered portion of the crankshaft and the generator rotor hub. • replace the washer with a new one. 2. Tighten: • generator rotor bolt “1” note: • while...

  • Page 294: Pickup Rotor

    Pickup rotor 5-33 eas4s81015 pickup rotor removing the pickup rotor order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "gener...

  • Page 295: Pickup Rotor

    Pickup rotor 5-34 eas4s81041 removing the pickup rotor 1. Remove: • pickup rotor cover “1” note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • pickup rotor bolt “1” • washer “2” • pickup rotor “3”...

  • Page 296: Pickup Rotor

    Pickup rotor 5-35 3. Apply: • sealant (onto the crankshaft position sensor lead grommet) 4. Install: • pickup rotor cover gasket • pickup rotor cover note: • when installing the pickup rotor cover, align the timing chain guide (intake side) pin “1” with the hole “2” in the pickup rotor cover. • tigh...

  • Page 297: Electric Starter

    Electric starter 5-36 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to...

  • Page 298: Electric Starter

    Electric starter 5-37 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 starter motor front cover 1 3 lock washer 1 4 oil seal 1 5 bearing 1 6 washer set 1 7 starter motor rear cover 1 8 washer set 1 9 o-ring 2 10 brush holder 1 11 armature assembly 1 12 starter mot...

  • Page 299: Electric Starter

    Electric starter 5-38 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 300: Electric Starter

    Electric starter 5-39 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • brush seat “1” 2. Install: • armature “2” • o-ring “3” note: align the tab “a” on the brush sea...

  • Page 301: Oil Pump

    Oil pump 5-40 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to "changing the engine oil" on page 3-14. Coolant drain. Refer to "changing the coolant" on page 3-20. Exhaust pipe assembly refer to "engine removal" on page 5-1. Water ...

  • Page 302: Oil Pump

    Oil pump 5-41 13 relief valve assembly 1 for installation, reverse the removal proce- dure. Removing the oil pan and oil pump order job/parts to remove q’ty remarks.

  • Page 303: Oil Pump

    Oil pump 5-42 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump cover 1 2 pin 2 3 oil pump inner rotor 1 4 oil pump outer rotor 1 5 pin 1 6 washer 1 7 oil pump rotor housing 1 8 oil pump driven sprocket 1 for assembly, reverse the removal proce- dure..

  • Page 304: Oil Pump

    Oil pump 5-43 eas24930 removing the oil pan 1. Remove: • oil level switch “1” • oil pan “2” • oil pan gasket • dowel pins 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. Eas24960 checking the oil pump 1. C...

  • Page 305: Oil Pump

    Oil pump 5-44 eas24980 checking the oil delivery pipes 1. Check: • oil delivery pipe “1” • oil pipe “2” damage → replace. Obstruction → wash and blow out with compressed air. Eas24990 checking the oil strainer 1. Check: • oil strainer “1” damage → replace. Contaminants → clean with solvent. Eas4s810...

  • Page 306: Oil Pump

    Oil pump 5-45 3. Check: • oil pump operation refer to "checking the oil pump" on page 5-43. Eas25030 installing the oil pump 1. Install: • oil pump drive chain • gear cover • oil pump • oil pump bolts caution: eca4s81018 after tightening the bolts, make sure the oil pump turns smoothly. Eas25040 ins...

  • Page 307: Clutch

    Clutch 5-46 eas25060 clutch * yamaha bond no.1215 (three bond no.1215®) removing the clutch cover order job/parts to remove q’ty remarks engine oil drain refer to "changing the engine oil" on page 3-14. Coolant drain refer to "changing the coolant" on page 3-20. 1 coolant hose 1 2 clutch cable 1 3 c...

  • Page 308: Clutch

    Clutch 5-47 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 2 2 washer 1 3 pull lever 1 4 pull lever spring 1 5 washer 1 6 oil seal 1 7 bearing 2 8 pull lever shaft 1 9 washer 1 for installation, reverse the removal proce- dure..

  • Page 309: Clutch

    Clutch 5-48 removing the clutch order job/parts to remove q’ty remarks 1 compression spring 6 2 pressure plate 1 3 pull rod 1 4 bearing 1 5 friction plate 1 6 6 clutch plate 1 7 7 friction plate 2 2 8 clutch plate 2 1 9 clutch boss nut 1 10 lock washer 1 11 clutch boss 1 12 thrust plate 1 for assemb...

  • Page 310: Clutch

    Clutch 5-49 eas25070 removing the clutch 1. Remove: • clutch cable holder “1” • clutch cover “2” • gasket note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts “1” • compres...

  • Page 311: Clutch

    Clutch 5-50 eas25110 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: • clutch plate damage → replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clut...

  • Page 312: Clutch

    Clutch 5-51 note: pitting on the clutch boss splines will cause erratic clutch operation. Eas25170 checking the pressure plate 1. Check: • pressure plate “1” cracks/damage → replace. • bearing “2” damage/wear → replace. Eas25220 checking the pull lever shaft and pull rod 1. Check: • pull lever shaft...

  • Page 313: Clutch

    Clutch 5-52 5. Install: • friction plates • clutch plates note: first, install a friction plate and then alternate between a clutch plate and a friction plate. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the clutch plate and friction plate as shown in the illustration. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6...

  • Page 314: Shift Shaft

    Shift shaft 5-53 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks drive sprocket cover refer to "engine removal" on page 5-1. 1 shift shaft cover 1 2 shift shaft cover gasket 1 3 dowel pin 2 4 oil seal 1 5 shift shaft 1 6 shift shaft spring 1 7 c...

  • Page 315: Shift Shaft

    Shift shaft 5-54 eas25420 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear → replace. • shift shaft spring “2” damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever “1” bends/damage → replace. Roller turns roughly → replace the stopper lever. Eas2...

  • Page 316: Crankcase

    Crankcase 5-55 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to "engine removal" on page 5-1. Cylinder head refer to "cylinder head" on page 5-16. Generator refer to "generator and starter clutch" on page 5-28. Starter clutch refer to "generator and ...

  • Page 317: Crankcase

    Crankcase 5-56 8 plate 1 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks.

  • Page 318: Crankcase

    Crankcase 5-57 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts 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. • loosen the bolts in decreasing numerica...

  • Page 319: Crankcase

    Crankcase 5-58 eas25660 assembling the crankcase 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) 2. Apply: • sealant (onto the crankcase mating surfaces) note: do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not app...

  • Page 320: Crankcase

    Crankcase 5-59.

  • Page 321: Crankshaft

    Crankshaft 5-60 eas25950 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to "crankcase" on page 5-55. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 piston pin 4 6 piston 4 7 connecting...

  • Page 322: Crankshaft

    Crankshaft 5-61 removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to "crankcase" on page 5-55. Connecting rods caps refer to "crankshaft" on page 5-60. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft journal upper bearing 5 for installation, re...

  • Page 323: Crankshaft

    Crankshaft 5-62 eas26030 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap “1” • big end bearings note: identify the position of each big end bearing so that it can be reinstalled in its original place....

  • Page 324: Crankshaft

    Crankshaft 5-63 eas24390 checking the cylinder and piston 1. Check: • piston wall • cylinder wall vertical scratches → replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “c” with t...

  • Page 325: Crankshaft

    Crankshaft 5-64 2. Install: • piston ring (into the cylinder) note: level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s...

  • Page 326: Crankshaft

    Crankshaft 5-65 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas4s81037 checking the big end bearings 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼...

  • Page 327: Crankshaft

    Crankshaft 5-66 e. Tighten the connecting rod bolts. Note: install by carrying out the following procedures in order to assemble in the most suitable con- dition. • connecting rod bolts f. Replace the connecting rod bolts with new ones. G. Clean the connecting rod bolts. H. After installing the big ...

  • Page 328: Crankshaft

    Crankshaft 5-67 p. After the installation, check that the section show “a” is flush with each other by touch- ing the surface. • side machined face “a” warning ewa4s81014 • when the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a...

  • Page 329: Crankshaft

    Crankshaft 5-68 eas26190 installing the connecting rod and piston the following procedure applies to all of the connecting rods and pistons. 1. Install: • top ring “1” • 2nd ring “2” • upper oil ring rail “3” • oil ring expander “4” • lower oil ring rail “5” note: be sure to install the piston rings...

  • Page 330: Crankshaft

    Crankshaft 5-69 6. Install: • big end bearings • connecting rod cap (onto the connecting rod) note: • align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. • make sure that the characters “a” on both the connecting rod and connecting rod cap a...

  • Page 331: Crankshaft

    Crankshaft 5-70 9. Tighten: • connecting rod bolts ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ caution: eca14980 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 corner of the con- n...

  • Page 332: Crankshaft

    Crankshaft 5-71 out of specification → replace the crank- shaft journal bearings. Caution: eca4s81028 do not interchange the crankshaft journal bearings. To obtain the correct crankshaft journal- to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must ...

  • Page 333: Crankshaft

    Crankshaft 5-72 refer to "crankcase" on page 5-55. G. Remove the lower crankcase and the crankshaft journal lower bearings. H. Measure the compressed plastigauge® width “c” on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specifica- tion, sele...

  • Page 334: Crankshaft

    Crankshaft 5-73 note: • align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • be sure to install each crankshaft journal upper bearing in its original place. 2. Install: • crankshaft 3. Install: • lower crankcase refer to "crankcase" on pag...

  • Page 335: Transmission

    Transmission 5-74 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks lower crankcase 1 refer to "crankcase" on page 5-55. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 bearing 1 5 shift drum retainer 1 6 shift fork guide ...

  • Page 336: Transmission

    Transmission 5-75 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 bearing 1 2 2nd pinion gear 1 3 toothed lock washer 1 4 toothed lock washer retainer 1 5 6th pinion gear 1 6 collar 1 7 washer 1 8 circlip 1 9 3rd pinion gear 1 10 circlip 1 11 washer 1 12 5th pinion gear...

  • Page 337: Transmission

    Transmission 5-76 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 1st wheel gear 1 3 collar 1 4 5th wheel gear 1 5 circlip 1 6 washer 1 7 collar 1 8 3rd wheel gear 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 338: Transmission

    Transmission 5-77 for installation, reverse the removal proce- dure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks.

  • Page 339: Transmission

    Transmission 5-78 eas26250 removing the transmission 1. Remove: • main axle assembly “1” (with the torx® wrench) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts “2” of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten the bolts until they conta...

  • Page 340: Transmission

    Transmission 5-79 eas26300 checking the transmission 1. Measure: • main axle runout (with a centering device and dial gauge “1”) out of specification → replace the main axle. 2. Measure: • drive axle runout (with a centering device and dial gauge “1”) out of specification → replace the drive axle. 3...

  • Page 341: Transmission

    Transmission 5-80 3. Install: • shift fork-r “1” • shift fork-l “2” • drive axle “3” • shift fork guide bar • shift drum retainer note: • install shift fork-l into the groove in the 6th wheel gear and shift fork-r into the groove in the 5th wheel gear on the drive axle. • make sure that the drive ax...

  • Page 342: Transmission

    Transmission 5-81.

  • Page 343: Cooling System

    6 cooling system radiator.................................................................................................... 6-1 checking the radiator..................................................................6-3 installing the radiator ..........................................................

  • Page 344: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chassis" on ...

  • Page 345: Radiator

    Radiator 6-2 13 coolant reservoir drain hose 1 for installation, reverse the removal proce- dure. Removing the radiator order job/parts to remove q’ty remarks.

  • Page 346: Radiator

    Radiator 6-3 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. 2. Check: • radiator hoses • radiator pipes cracks/damage ...

  • Page 347: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks radiator assembly refer to "radiator" on page 6-1. Coolant reservoir refer to "radiator" on page 6-1. Engine oil drain. Refer to "changing the engine oil" on page 3-14. 1 oil cooler outlet hose 1 2 unio...

  • Page 348: Oil Cooler

    Oil cooler 6-5 eas26420 checking the oil cooler 1. Check: • oil cooler cracks/damage → replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose cracks/damage/wear → replace. Eas26430 installing the oil cooler 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth da...

  • Page 349: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling)+ refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chass...

  • Page 350: Thermostat

    Thermostat 6-7 eas26450 checking the thermostat 1. Check: • thermostat “1” does not open at 71–85 °c (160–185°f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container “4” filled with water. B. Slowly heat the water “2”. C. Place a thermometer “1” in the water. D. Whi...

  • Page 351: Thermostat

    Thermostat 6-8 refer to "checking the radiator" on page 6-3..

  • Page 352: Water Pump

    Water pump 6-9 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks it is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Coolant drain. Refer to "changing the coolant" on page 3-20. 1 radiator outlet ...

  • Page 353: Water Pump

    Water pump 6-10 disassembling the water pump order job/parts to remove q’ty remarks 1 water pump cover 1 2 o-ring 1 3 impeller shaft 1 4 circlip 1 5 water pump seal 1 6 oil seal 1 7 bearing 1 8 water pump housing 1 9 o-ring 1 10 copper washer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 354: Water Pump

    Water pump 6-11 eas26510 disassembling the water pump 1. Remove: • water pump cover • o-ring • circlip • impeller shaft 2. Remove: • water pump seal “1” note: remove the water pump seal from the inside of the water pump housing “2”. 3. Remove: • oil seal “3” (with a thin, flat-head screwdriver) note...

  • Page 355: Water Pump

    Water pump 6-12 3. Check: • water pump outlet pipe • radiator outlet hose cracks/damage/wear → replace. Eas26560 assembling the water pump 1. Install: • bearing • oil seal “1” (into the water pump housing “2”) note: • before installing the oil seal, apply tap water or coolant onto its out surface. •...

  • Page 356: Water Pump

    Water pump 6-13 5. Install: • impeller shaft • circlip • o-ring • water pump cover eas26590 installing the water pump 1. Install: • o-ring • copper washer • water pump assembly “1” note: • align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft. • lubricate the o-ring ...

  • Page 357: Fuel System

    7 fuel system fuel tank ..................................................................................................7-1 removing the fuel tank ................................................................7-2 removing the fuel pump................................................................

  • Page 358: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to "general chassis" ...

  • Page 359: Fuel Tank

    Fuel tank 7-2 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel return hose • fuel hose caution: eca4s81003 • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel...

  • Page 360: Fuel Tank

    Fuel tank 7-3 eas4s81001 installing the fuel tank 1. Install: • fuel hose caution: eca4s81001 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. Note: install th...

  • Page 361: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer to ...

  • Page 362: Throttle Bodies

    Throttle bodies 7-5 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor coupler 1 disconnect. 2 intake air pressure sensor coupler 1 disconnect. 3 cylinder #1 injector coupler 1 disconnect. 4 cylinder #2 injector coupler 1 disconnect. 5 cylinder #3 injector coupl...

  • Page 363: Throttle Bodies

    Throttle bodies 7-6 eas26980 checking the injectors 1. Check: • injectors damage → replace. Eas26990 checking the throttle bodies 1. Check: • throttle bodies cracks/damage → replace the throttle bodies as a set. 2. Check: • fuel passages obstructions → clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash t...

  • Page 364: Throttle Bodies

    Throttle bodies 7-7 c. Measure the throttle position sensor volt- age. D. Adjust the throttle position sensor angle so that the voltage is within the specified range. E. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • ...

  • Page 365: Throttle Bodies

    Throttle bodies 7-8.

  • Page 366: Air Induction System

    Air induction system 7-9 eas27040 air induction system.

  • Page 367: Air Induction System

    Air induction system 7-10 1. Air cut-off valve 2. Reed valve 3. To air filter case a. To cylinder #1 and #2 b. To cylinder #3 and #4.

  • Page 368: Air Induction System

    Air induction system 7-11 removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowling inner panel (with cowling) refer t...

  • Page 369: Air Induction System

    Air induction system 7-12 eas27060 checking the air induction system air injection the air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is neg- ative pressure at the exhaust port, the r...

  • Page 370: Air Induction System

    Air induction system 7-13 2. Install: • reed valve cover.

  • Page 371: Electrical System

    8 electrical system ignition system.......................................................................................8-1 circuit diagram................................................................................ 8-1 troubleshooting .............................................................

  • Page 372

    Abs (anti-lock brake system) ........................................................ 8-71 abs circuit diagram ..................................................................... 8-71 abs components chart...............................................................8-73 abs connector location cha...

  • Page 373

    Checking the engine oil level gauge .................................8-125 checking the fuel sender ......................................................8-126 checking the speed sensor ...................................................8-126 checking the radiator fan motor.............................

  • Page 374: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w 16 20 21 b/l g/w...

  • Page 375: Ignition System

    Ignition system 8-2 1. Main switch 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 12.Sidestand switch 13.Neutral switch 18.Lean angle sensor 19.Crankshaft position sensor 22.Ecu (engine control unit) 29.Cylinder-#1/#4 ignition coil 30.Cylinder-#2/#3 ignition coil 31.Spark plugs 45.Engine ...

  • Page 376: Ignition System

    Ignition system 8-3 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1.Seat 2.Fuel tank 3.Side cowlings ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse...

  • Page 377: Ignition System

    Ignition system 8-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the engine stop switch. Refer to "checking the switches" on page 8-109. Replace the right handlebar switch. 9. Check the neutral switch. Refer to "checking the switches" on page 8-109. Replace the neut...

  • Page 378: Electric Starting System

    Electric starting system 8-5 eas27160 electric starting system eas27170 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/...

  • Page 379: Electric Starting System

    Electric starting system 8-6 1. Main switch 7. Main fuse 8. Starter relay 9. Starter motor 10.Battery 11.Starting circuit cut-off relay 12.Sidestand switch 13.Neutral switch 45.Engine stop switch 46.Start switch 52.Ignition fuse 59.Clutch switch.

  • Page 380: Electric Starting System

    Electric starting system 8-7 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: • the transmission is in neutr...

  • Page 381: Electric Starting System

    Electric starting system 8-8 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Left side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fus...

  • Page 382: Electric Starting System

    Electric starting system 8-9 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the neutral switch. Refer to "checking the switches" on page 8-109. Replace the neutral switch. 9. Check the sidestand switch. Refer to "checking the switches" on page 8-109. Replace the sidestand switch. 10. Che...

  • Page 383: Electric Starting System

    Electric starting system 8-10

  • Page 384: Charging System

    Charging system 8-11 eas27200 charging system eas27210 circuit diagram p b b 7 bb 10 r r/w l/w 9 r 8 5 r l/w r r/w r r 2 w w w ww w 4 r ww ww ww r br/l r/g bb br/l br/r b r/w 3 r br/l y/l g/l r/w r b w w w b y/l y/l lg r/w br/r br/r on off 1 g/l r/g.

  • Page 385: Charging System

    Charging system 8-12 2. Ac magneto 3. Rectifier/regulator 7. Main fuse 10.Battery.

  • Page 386: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to "checking the fuses" on pa...

  • Page 387: Charging System

    Charging system 8-14.

  • Page 388: Lighting System

    Lighting system 8-15 eas27240 lighting system eas27250 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w 16 20 21 b/l g/...

  • Page 389: Lighting System

    Lighting system 8-16 1. Main switch 7. Main fuse 10.Battery 22.Ecu (engine control unit) 38.High beam indicator light 51.Headlight fuse 53.Tail fuse 56.License plate light 57.Tail/brake light 60.Pass switch 61.Dimmer switch 66.Headlight relay 67.Auxiliary light 68.Headlight (high beam) 69.Headlight ...

  • Page 390: Lighting System

    Lighting system 8-17 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Note: • before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Side cover ng → ok ↓ ng → ok...

  • Page 391: Lighting System

    Lighting system 8-18 ng → ok ↓ 8. Check the entire lighting system’s wiring. Refer to "circuit diagram" on page 8-1. Properly connect or repair the lighting system’s wiring. This circuit is ok..

  • Page 392: Signaling System

    Signaling system 8-19 eas27270 signaling system eas27280 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g g/r g/r lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w 16 20...

  • Page 393: Signaling System

    Signaling system 8-20 1. Main switch 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 13.Neutral switch 14.Fuel pump 22.Ecu (engine control unit) 30.Abs ecu 32.Rear wheel sensor 40.Fuel level warning light 41.Oil level warning light 42.Neutral indicator light 43.Tachometer 44.Multi-function...

  • Page 394: Signaling System

    Signaling system 8-21 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. Note: • before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Side cover ng → ok ↓ ng...

  • Page 395: Signaling System

    Signaling system 8-22 ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ 3. Check the entire signaling sys- tem’s wiring. Refer to "circuit diagram" on page 8-1. Proper...

  • Page 396: Signaling System

    Signaling system 8-23 ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 3. Check the hazard switch. Refer to "checking the switches" on page 8-109. Replace the left handlebar switch. 4. Check the turn signal/hazard relay. Refer to "checking the re...

  • Page 397: Signaling System

    Signaling system 8-24 ng → ok ↓ the oil level warning light fails to come. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come. Ng → ok ↓ ng → ok ↓ 4. Check the entire signaling sys- tem’s wiring. Refer to "circuit diagram" on page 8-1. Properly connect or repair the signal- ing...

  • Page 398: Signaling System

    Signaling system 8-25 ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ note: repair or replace if there is an open or short circuit. • between rear wheel sensor and abs ecu coupler. (yellow/white-yellow/white) (black-black) • between abs ecu coupler and ecu coupler. (white/yellow-whit...

  • Page 399: Signaling System

    Signaling system 8-26.

  • Page 400: Cooling System

    Cooling system 8-27 eas27300 cooling system eas27310 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w 16 20 21 b/l g/w ...

  • Page 401: Cooling System

    Cooling system 8-28 1. Main switch 7. Main fuse 10.Battery 21.Coolant temperature sensor 22.Ecu (engine control unit) 37.Multi-function meter 47.Radiator fan motor fuse 48.Radiator fan motor relay 49.Radiator fan motor 52.Ignition fuse.

  • Page 402: Cooling System

    Cooling system 8-29 eas27320 troubleshooting note: • before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel 3.Fuel tank 4.Side cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and radiator fan motor) refer to "che...

  • Page 403: Cooling System

    Cooling system 8-30 ng → ok ↓ 7. Check the entire cooling system’s wiring. Refer to "circuit diagram" on page 8-1. Properly connect or repair the cooling system’s wiring. This circuit is ok..

  • Page 404: Fuel Injection System

    Fuel injection system 8-31 eas27330 fuel injection system eas27340 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g g/r g/r lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l...

  • Page 405: Fuel Injection System

    Fuel injection system 8-32 1. Main switch 3. Backup fuse 5. Fuel injection system fuse 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 12.Sidestand switch 13.Neutral switch 14.Fuel pump 15.Throttle position sensor 16.Intake air pressure sensor 17.O 2 sensor 18.Lean angle sensor 19.Cranksha...

  • Page 406: Fuel Injection System

    Fuel injection system 8-33 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 char...

  • Page 407: Fuel Injection System

    Fuel injection system 8-34 eas27362 fail-safe actions (substitute characteristics operation control) if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc-...

  • Page 408: Fuel Injection System

    Fuel injection system 8-35 communication error with the meter 34 ignition coil (#2, #3) (faulty ignition) malfunction detected in the pri- mary wire of the ignition coil (#2, #3). Able (depending on the num- ber of faulty cylinders) able (depending on the num- ber of faulty cylinders) 41 lean angle ...

  • Page 409: Fuel Injection System

    Fuel injection system 8-36 eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code number displayed on the meter. B. Identify the system with the malfunction...

  • Page 410: Fuel Injection System

    Fuel injection system 8-37 eas27411 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch t...

  • Page 411: Fuel Injection System

    Fuel injection system 8-38 8. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating conditions of the sensor appears on the trip lcd. • actuator operation set the engine stop switch to “ ” to operate the actuator. Note: if the engine stop switch is se...

  • Page 412: Fuel Injection System

    Fuel injection system 8-39 14 intake air pressure sensor- pipe system malfunction (clogged or detached hose). • detected hose • clogged hose • intake air pressure sensor hose is detached, clogged, kinked, or pinched. • malfunction in ecu. 03 15 throttle position sensor- open or short circuit detecte...

  • Page 413: Fuel Injection System

    Fuel injection system 8-40 sensor operation table 42 no normal signals are received from the speed sensor. Open or short circuit is detected in the neutral switch. • open or short circuit in wire harness. • defective speed sensor. • malfunction in vehicle speed sensor detected unit. • defective neut...

  • Page 414: Fuel Injection System

    Fuel injection system 8-41 03 pressure difference (intake air pressure) displays the intake air pres- sure. Turn on the engine stop switch, then operate the throttle while pressing the start switch. (if the display value changes, the perfor- mance is ok.) 05 intake air temperature displays the intak...

  • Page 415: Fuel Injection System

    Fuel injection system 8-42 * if it is not possible to check the intake temperature, use the ambient temperature as reference (use the compared values for reference). Actuator operation table 61 malfunction history code display — • no history 00 • history exists 12-50 (fault detection code) • (if cod...

  • Page 416: Fuel Injection System

    Fuel injection system 8-43 eas27451 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfu...

  • Page 417: Fuel Injection System

    Fuel injection system 8-44 diagnostic code number to be used when the diagnostic mode is operated. Refer to "diagnostic mode" on page 8-37. Fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. Order item/components and probable cause che...

  • Page 418: Fuel Injection System

    Fuel injection system 8-45 fault code no. 14 symptom a. Intake air pressure sensor-pipe system malfunction (clogged or detached hose). B. Intake air pressure sensor-open or short circuit detected. C. Stuck throttle position sensor detected. Diagnostic code no. 03 intake air pressure sensor order ite...

  • Page 419: Fuel Injection System

    Fuel injection system 8-46 fault code no. 15 symptom throttle position sensor-open or short circuit detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstate- ment method 1 installed condition of throttle position sensor. Ch...

  • Page 420: Fuel Injection System

    Fuel injection system 8-47 fault code no. 19 symptom open circuit is detected in the input line from the side- stand switch to the ecu. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • ma...

  • Page 421: Fuel Injection System

    Fuel injection system 8-48 fault code no. 22 symptom intake air temperature sensor-open or short circuit detected. Diagnostic code no. 05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstate- ment method 1 installed condition of intake air tem- pe...

  • Page 422: Fuel Injection System

    Fuel injection system 8-49 fault code no. 30 symptom latch up detected. No normal signal is received from the lean angle sensor. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstate- ment method 1 the vehicle has overturned. Raise the v...

  • Page 423: Fuel Injection System

    Fuel injection system 8-50 fault code no. 34 symptom malfunction detected in the primary wire of the ignition coil (#2/#3). Diagnostic code no. 31 ignition coil (#2/#3) order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • ignition ...

  • Page 424: Fuel Injection System

    Fuel injection system 8-51 fault code no. 42 symptom a. No normal signals are received from the rear wheel sensor. (with abs) b. Open or short circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch order item/components and probable cause check or mainte...

  • Page 425: Fuel Injection System

    Fuel injection system 8-52 b-1 connected state of connector • neutral switch coupler • main wire harness ecu coupler • check the coupler for any pins that may have pulled out. • check the locking condition of the coupler. • if there is a malfunction, repair it and connect the coupler securely. Start...

  • Page 426: Fuel Injection System

    Fuel injection system 8-53 fault code no. 44 symptom an error is detected while reading or writing on eeprom (co adjustment value). Diagnostic code no. 60 eeprom fault cylinder no. Order item/components and probable cause check or maintenance job reinstate- ment method 1 malfunction in ecu • set the...

  • Page 427: Fuel Injection System

    Fuel injection system 8-54 fault code no. 46 symptom power supply to the fi system relay is not normal. Diagnostic monitor- ing code no. — — order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector. • main wire harness ecu coupler • chec...

  • Page 428: Fuel Injection System

    Fuel injection system 8-55 fault code no. Er-1 symptom no signals are received from the ecu. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • main wire harness ecu coupler • main wire harness meter coupl...

  • Page 429: Fuel Injection System

    Fuel injection system 8-56 fault code no. Er-3 symptom data from the ecu cannot be received correctly. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstate- ment method 1 connected state of connector • main wire harness ecu coupler • main wire harness m...

  • Page 430: Fuel Pump System

    Fuel pump system 8-57 eas27550 fuel pump system eas27560 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g g/r g/r lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w 16 20...

  • Page 431: Fuel Pump System

    Fuel pump system 8-58 1. Main switch 5. Fuel injection system fuse 7. Main fuse 10.Battery 11.Starting circuit cut-off relay 14.Fuel pump 22.Ecu (engine control unit) 56.Engine stop switch 64.Ignition fuse.

  • Page 432: Fuel Pump System

    Fuel pump system 8-59 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1.Seat 2.Front cowling inner panel3 3.Fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition an...

  • Page 433: Fuel Pump System

    Fuel pump system 8-60

  • Page 434: Immobilizer System

    Immobilizer system 8-61 eas27640 immobilizer system eas27650 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g g/r g/r lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w 1...

  • Page 435: Immobilizer System

    Immobilizer system 8-62 1. Main switch 4. Backup fuse 6. Immobilizer unit 7. Main fuse 10.Battery 22.Ecu (engine control unit) 39.Immobilizer indicator light 44.Multi-function meter 64.Ignition fuse.

  • Page 436: Immobilizer System

    Immobilizer system 8-63 eas27671 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 437: Immobilizer System

    Immobilizer system 8-64 * accessory locks mean the seat lock and fuel tank cap. Code re-registering key registration: when the immobilizer unit or ecu is replaced, the code re-registering key must be registered to the unit. To register a code re-registering key: 1. Turn the main switch to “on” with ...

  • Page 438: Immobilizer System

    Immobilizer system 8-65 standby mode: to enable the immobilizer system, turn the ignition key to “off”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the imm...

  • Page 439: Immobilizer System

    Immobilizer system 8-66 standard key registration 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...

  • Page 440: Immobilizer System

    Immobilizer system 8-67 eas27701 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27721 self-diagnosis fault code indication when a system failure occurs, the error code number is i...

  • Page 441: Immobilizer System

    Immobilizer system 8-68 immobilizer system indicator light fault code indication digit of 10: cycles of 1 sec. On and 1.5 sec. Off. Digit of 1: cycles of 0.5 sec. On and 0.5 sec. Off. Example: fault code 52 52 immobilizer unit codes between the key and immobilizer unit do not match. 1.Signal receive...

  • Page 442: Immobilizer System

    Immobilizer system 8-69 a. Light on b. Light off.

  • Page 443: Immobilizer System

    Immobilizer system 8-70

  • Page 444: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-71 eas28790 abs (anti-lock brake system) eas27730 circuit diagram ch b p g/l y/l r/g lg b/w g/l y/l r/g g/r g/r lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b 23 r/l r/l r/l r/b r/l 24 25 26 27 r/w br/r r/w br/r 15 l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l ...

  • Page 445: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-72 1. Main switch 7. Main fuse 8. Starter relay 9. Starter motor 10.Battery 11.Starting circuit cut-off relay 13.Neutral switch 22.Ecu (engine control unit) 28.Abs motor fuse 29.Abs test coupler 30.Abs ecu 31.Front wheel sensor 32.Rear wheel sensor 33.Abs motor relay 3...

  • Page 446: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-73 eas27740 abs components chart.

  • Page 447: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-74 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.

  • Page 448: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-75 eas27750 abs connector location chart.

  • Page 449: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-76 1. Abs motor relay 2. Abs ecu coupler 3. Hydraulic unit coupler 4. Rear wheel sensor coupler 5. Front wheel sensor coupler 6. Abs test coupler 7. Multi-function coupler (fz6-sa) 8. Multi-function coupler (fz6-na) 9. Multi-function coupler (fz6-sahg) 10.Multi-functio...

  • Page 450: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-77 eas27760 abs ecu and abs motor relay removing the abs ecu and abs motor relay order job/parts to remove q’ty remarks seat refer to "general chassis" on page 4-1. Left front cowling inner panel (with cowling) refer to "general chassis" on page 4-1. Right front cowlin...

  • Page 451: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-78 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. 2. Remove: • abs ecu coupler “1” • abs ecu coupler “2” note: • do not pull the abs ecu l...

  • Page 452: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-79 (refer to "[d-6] final check" on page 8-104.) abs warning light goes on and the abs condition 1.When the abs warning light keeps going on → it works as a normal brake. • detecting the malfunction by means of the abs self diagnostic function. 2.Light goes on and off ...

  • Page 453: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-80 [a] malfunction check by the abs warning light [b] detail check of malfunction results by self diagnosis are displayed by the multifunction display or a pocket tester according to the ecu’s operation. [c] supposing the malfunction cause and position find the malfunc...

  • Page 454: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-81 eas27810 basic process for troubleshooting.

  • Page 455: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-82 note: do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. Warning ewa14050 always execute the “final check” when the components related to abs are checked and ser- viced. Eas27830 [a] abs malfu...

  • Page 456: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-83 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 ins...

  • Page 457: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-84 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). If a malfunction code is displayed on...

  • Page 458: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-85 eas27870 [b-5] malfunction check by the abs self diagnosis (present malfunction) note: before proceeding to read the part of “arrangement and the function of test coupler”. Remove the side cowling (right) and check the location of test coupler. Connect the test coup...

  • Page 459: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-86 as an example, “10 digits/1 digit pattern” of tester reading is shown below. 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” 1. Confirmation using t...

  • Page 460: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-87 2. Check that the main switch coupler is securely connected. 3. Check that the meter assembly coupler is securely connected. (refer to "abs connector location chart" on page 8-75.) when these checks are finished, return to [a] and check the abs again. Eas4s81024 [c-...

  • Page 461: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-88 malfunc- tion code problem check point reference 11* front wheel sensor signal is not received properly. • installation of the front wheel sensor • front wheel sensor lead and cou- pler • abs wire harness circuit • front wheel sensor rotor malfunction code 11 12 rea...

  • Page 462: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-89 25 at the beginning of running, there is no pulse from the front wheel sensor. • rear wheel was rotated with the vehicle on the centerstand. • rear wheel was wheel-spin. • wheelie tried • defective installation of the wheel speed sensor for the front wheel malfuncti...

  • Page 463: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-90 35 disconnection is detected between the abs ecu and solenoid sys- tem. Downstream side of the solenoid relay • abs harness circuit (from abs ecu to the solenoid) • solenoid coupler • battery terminal is disconnected. Malfunction code 35 41 front wheel will not reco...

  • Page 464: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-91 * malfunction code 11 is indicated if the rear wheel rotates for more than 20 seconds with the front wheel stopped. Note: malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor) is displayed if a defective con- nection to either the front or rear sensor i...

  • Page 465: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-92 2. Abs warning light goes on for 2 seconds then goes off. 1. With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is not a malfunction. 2. Signal is not generated at the rear wheel sensor. • rear wheel sensor is not installed...

  • Page 466: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-93 2. Check the appearance. 3. Check the wire harness. 1. Disconnection of the abs ecu coupler terminal 2. Remove the abs ecu coupler and wheel sensor coupler and check the conductivity, short- circuit to gnd and short-circuit to ssr-vcc from the wire harness. • conduc...

  • Page 467: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-94 *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. Battery • battery terminal is disconnected malfunction code 22 (starter motor monitor malfunction) 1. Disconn...

  • Page 468: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-95 *continuity between: “a”–“b” malfunction code 25 (at the beginning of running, there is no pulse from the front wheel sen- sor.) • rear wheel was rotated with the vehicle on the stand. • rear wheel was wheel-spin. • wheel tried. • defective installation of the wheel...

  • Page 469: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-96 *continuity between: “a”–“c”, “b”–“c” 3. When the items 1 to 2 are normal, replace the abs ecu. Malfunction code 33 (defective operation of the abs motor is detected. [abs motor stops and will not rotate.]) note: check following the steps in sequence. 1. Abs motor f...

  • Page 470: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-97 • check if the abs motor coupler located under the fuel tank is connected properly. • check the abs motor for continuity. → [d-5] 2. Wire harness (abs) • remove the abs motor coupler and check for continuity between the black terminal of the abs motor coupler of the...

  • Page 471: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-98 warning ewa4s81009 only use genuine yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the front brake calipe...

  • Page 472: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-99 • check that the brake fluid pressure is correctly transmitted to the brake disc when the brake pedal is operated and that the pressure decreases when the pedal is released. 3. Brake fluid • visually check the brake fluid in the brake master cylinder reservoir and c...

  • Page 473: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-100 malfunction code 51 (front wheel will not recover from the locking tendency even though the signal is continuously transmitted from the abs ecu to release the hydraulic state [when the battery voltage is low].) check the following: 1. Rotation of the front wheel re...

  • Page 474: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-101 malfunction code 61 (front), 62 (rear) (sensor power supply is low) 1. Battery voltage low charge, check or replace the battery. 2. Battery terminal is disconnected. Malfunction code 63 (front), 64 (rear) (sensor power supply failure) 1. Gnd short-circuit of the wi...

  • Page 475: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-102 2. Turn the main switch on. • the multi-function display indicates previously recorded malfunction codes. Note: the abs error code is not displayed during the diagnosis of the fuel injection. 3. Turn the engine stop switch off. Caution: eca4s81019 if the starter sw...

  • Page 476: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-103 eas4s81033 [d-6-6] delete function test 1. Place the vehicle on the sidestand. 2. Set the main switch to “off”. 3. Connect the test coupler adapter to the test coupler. 4. Set the main switch to “on”. 5. Check: • ecu voltage connect the pocket tester (dc 20 v) to t...

  • Page 477: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-104 8. If the above-mentioned check are within specification, replace the ecu. Eas4s81028 [d-6] final check checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir. Refer to "checking the brake fluid level" on...

  • Page 478: Electrical Components

    Electrical components 8-105 eas27970 electrical components.

  • Page 479: Electrical Components

    Electrical components 8-106 1. Main switch 2. Front brake light switch 3. Starter relay 4. Battery 5. Abs motor relay (fz6-na/fz6-nahg/fz6- sa/fz6-sahg) 6. Fuse box 7. Rear brake light switch 8. Neutral switch 9. Sidestand switch 10.Oil level switch 11.Radiator fan motor 12.Horn 13.Ignition coil.

  • Page 480: Electrical Components

    Electrical components 8-107.

  • Page 481: Electrical Components

    Electrical components 8-108 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air temperature sensor 4. Fuel pump 5. Intake air pressure sensor 6. Ecu (engine control unit) 7. Abs ecu (fz6-na/fz6-nahg/fz6-sa/ fz6-sahg) 8. Lean angle sensor 9. Starting circuit cut-off relay 10.Rear ...

  • Page 482: Electrical Components

    Electrical components 8-109 eas27980 checking the switches.

  • Page 483: Electrical Components

    Electrical components 8-110 1. Main switch 2. Horn switch 3. Dimmer switch (fz6-s/fz6-na/fz6-sa/ fz6-shg(w)/fz6-sahg) 4. Dimmer switch (fz6-n/fz6-nhg(w)/fz6- nahg) 5. Pass switch (fz6-s/fz6-na/fz6-sa/fz6- shg(w)/fz6-sahg) 6. Pass switch (fz6-n/fz6-nhg(w)/fz6- nahg) 7. Turn signal switch 8. Hazard sw...

  • Page 484: Electrical Components

    Electrical components 8-111 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. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the prob...

  • Page 485: Electrical Components

    Electrical components 8-112 eas27990 checking the bulbs and bulb sock- ets check each bulb and bulb socket for damage or wear, proper connections, and also for conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → properly connect. ...

  • Page 486: Electrical Components

    Electrical components 8-113 b. Connect the positive tester probe to termi- nal “1” and the negative tester probe to ter- minal “3”, and check the continuity. C. If either of the readings indicate no continu- ity, replace the bulb. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ checking the condition of the bulb soc...

  • Page 487: Electrical Components

    Electrical components 8-114 b. If the pocket tester indicates “ ∞”, replace the fuse. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Replace: • blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “off”. B. Install a new fuse of the correct amperage rating. C. Set on the switches to verify if the ...

  • Page 488: Electrical Components

    Electrical components 8-115 note: since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: ...

  • Page 489: Electrical Components

    Electrical components 8-116 minutes after charging is completed before measuring the open-circuit volt- age. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Note: voltage should be measured 30 minutes af...

  • Page 490: Electrical Components

    Electrical components 8-117 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery terminals 10. Install: • fuel tank • front cowling inner panel • seat eas28040 checking the relays check each switch for continuity with the pocket t...

  • Page 491: Electrical Components

    Electrical components 8-118 headlight relay radiator fan motor eas4s81030 checking the abs motor relay 1. Check: • abs motor relay for continuity connect the pocket tester ( Ω × 1) to the ter- minals of abs motor relay. Check for continuity between terminals “1” and “2” of the abs motor relay. Teste...

  • Page 492: Electrical Components

    Electrical components 8-119 eas4s81031 checking the solenoid valves and motor caution: eca4s81023 when check the hydraulic unit solenoid relay and abs motor, do not remove the brake hoses. 1. Check: • solenoid valve resistance (front) out of specification → replace the hydrau- lic unit. ▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 493: Electrical Components

    Electrical components 8-120 eas4s81032 checking the turn signal/hazard relay 1. Check: • turn signal/hazard relay input voltage out of specification → the wiring circuit from the main switch to the turn signal/haz- ard relay coupler is faulty and must be repaired. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. C...

  • Page 494: Electrical Components

    Electrical components 8-121 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continu- ity. ▲▲▲▲▲...

  • Page 495: Electrical Components

    Electrical components 8-122 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil connectors from the ignition coil terminals. B. Connect the pocket tester ( Ω × 1) to the ignition coil as shown. C. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • secondary co...

  • Page 496: Electrical Components

    Electrical components 8-123 2. Check: • crankshaft position sensor resistance out of specification → replace the crank- shaft position sensor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the crankshaft position sensor coupler as shown. B. Measure the crankshaft position...

  • Page 497: Electrical Components

    Electrical components 8-124 b. Turn the main switch to “on”. C. Elevate the front wheel and slowly rotate it. D. Measure the voltage with each full rotation of the front wheel, the voltage reading should cycle from lo (0.5–0.9 v) to hi (1.1– 1.7 v) to lo to hi. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas4s81...

  • Page 498: Electrical Components

    Electrical components 8-125 out of specification → replace the rectifier/ regulator. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. B. Connect the pocket tester (ac 20 v) to the rectifier/regulator coupler as shown. C. Start the engine and let it run...

  • Page 499: Electrical Components

    Electrical components 8-126 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the engine oil level gauge terminal as shown. B. Measure the pickup coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28230 checking the fuel sender 1. Remove: • fuel tank 2. Disconnect: • fuel pum...

  • Page 500: Electrical Components

    Electrical components 8-127 b. Set the main switch to “on”. C. Elevate the rear wheel and slowly rotate it. D. Measure the voltage (dc 5 v) of white/yel- low and black/blue. With each full rotation of the rear wheel, the voltage reading should cycle from 0.6 v to 4.8 v to 0.6 v to 4.8 v. ▲▲▲▲▲▲▲▲▲▲▲...

  • Page 501: Electrical Components

    Electrical components 8-128 e. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position se...

  • Page 502: Electrical Components

    Electrical components 8-129 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1) to the fuel pump coupler as shown. B. Measure the fuel pump resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28370 checking the air induction system solenoid 1. Check: • air induction system solenoid resist...

  • Page 503: Electrical Components

    Electrical components 8-130 c. Measure the intake air pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28420 checking the intake air tempera- ture sensor 1. Remove: • intake air temperature sensor (from the air filter case.) warning ewa14110 • handle the intake air temperature senso...

  • Page 504: Electrical Components

    Electrical components 8-131.

  • Page 505: Troubleshooting

    9 troubleshooting troubleshooting .................................................................................. 9-1 general information ..................................................................... 9-1 starting failures ......................................................................

  • Page 506: Troubleshooting

    Troubleshooting 9-1 eas28450 troubleshooting eas28460 general information note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative proce- dure in this manual for checks, ...

  • Page 507: Troubleshooting

    Troubleshooting 9-2 • improper throttle cable free play • flooded throttle body • faulty air induction system electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electro...

  • Page 508: Troubleshooting

    Troubleshooting 9-3 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality cooling system 1. Coolant • low coolant level 2. Radiator • damaged or leaking radiator • faulty radiator cap • bent or damaged radiator fin 3. Water pump • damaged or faulty water pump • thermos...

  • Page 509: Troubleshooting

    Troubleshooting 9-4 • faulty rear shock absorber spring • leaking oil or gas 6. Tire(s) • uneven tire pressures (front and rear) • incorrect tire pressure • uneven tire wear 7. Wheel(s) • incorrect wheel balance • deformed cast wheel • damaged wheel bearing • bent or loose wheel axle • excessive whe...

  • Page 510: Troubleshooting

    Troubleshooting 9-5 • defective connection of the meter coupler abs warning light continues to flashes • brake light switch (front or rear) is defective • brake light switch front or rear coupler has come off • defective starter motor monitor • other defective abs warning light flashes every 0.5 sec...

  • Page 511: Troubleshooting

    Troubleshooting 9-6.

  • Page 512

    Eas28740 wiring diagram fz6-n 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Starting circuit cut-off relay 12. Sidestand switch 13. Neutral switch 14. Fuel pump ...

  • Page 513

    Fz6-na 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Abs motor fuse 12. Starting circuit cut-off relay 13. Sidestand switch 14. Neutral switch 15. Fuel pump 16. ...

  • Page 514

    Fz6-nhg(w) 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Starting circuit cut-off relay 12. Sidestand switch 13. Neutral switch 14. Fuel pump 15. Throttle positi...

  • Page 515

    Fz6-nahg 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Starting circuit cut-off relay 12. Sidestand switch 13. Neutral switch 14. Fuel pump 15. Throttle position...

  • Page 516

    Fz6-s 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Starting circuit cut-off relay 12. Sidestand switch 13. Neutral switch 14. Fuel pump 15. Throttle position se...

  • Page 517

    Fz6-sa 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Abs motor fuse 12. Starting circuit cut-off relay 13. Sidestand switch 14. Neutral switch 15. Fuel pump 16. ...

  • Page 518

    Fz6-shg(w) 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Starting circuit cut-off relay 12. Sidestand switch 13. Neutral switch 14. Fuel pump 15. Throttle positi...

  • Page 519

    Fz6-sahg 2007 1. Main switch 2. Ac magneto 3. Rectifier/regulator 4. Backup fuse 5. Fuel injection system fuse 6. Immobilizer unit 7. Main fuse 8. Starter relay 9. Starter motor 10. Battery 11. Starting circuit cut-off relay 12. Sidestand switch 13. Neutral switch 14. Fuel pump 15. Throttle position...

  • Page 522

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 523

    Ch b p r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b r/l r/l r/l r/b r/l r/w br/r r/w br/r l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w b/l g/w b/l b/l l d y y c l l c r/l c g/b c r/b b/l r/l b/l g/w br/w y p/w b/l g/w br/w y p/w b/l l l p/w p/w r/b r/l g/b l b/y b/l y/g l b/r ...

  • Page 524

    Fz6-na 2007 wiring diagram fz6-na 2007 schema de cablage fz6-na 2007 schaltplan fz6-na 2007 schema elettrico diagrama de conexiones de fz6-na 2007.

  • Page 525

    Ch b p r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b r/l r/l r/l r/b r/l r/w br/r r/w br/r l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w b/l g/w b/l b/l l d y y c l l c r/l c g/b c r/b b/l r/l b/l g/w br/w y p/w b/l g/w br/w y p/w b/l l l p/w p/w r/b r/l g/b l b/y b/l y/g l b/r ...

  • Page 526

    Fz6-nahg 2007 wiring diagram fz6-nahg 2007 schema de cablage fz6-nahg 2007 schaltplan fz6-nahg 2007 schema elettrico diagrama de conexiones de fz6-nahg 2007.

  • Page 527

    Ch b p g/l y/l r/g lg b/w g/l y/l r/g lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b r/l r/l r/l r/b r/l r/w br/r r/w br/r l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w b/l g/w b/l b/l l a b/w a y/l d y y c l l c r/l c g/b c r/b b/l r/l b/l g/w br/w y p/w b/l g/w br/w y p/...

  • Page 528

    Fz6-sa 2007 wiring diagram fz6-sa 2007 schema de cablage fz6-sa 2007 schaltplan fz6-sa 2007 schema elettrico diagrama de conexiones de fz6-sa 2007.

  • Page 529

    Ch b p g/l y/l r/g lg b/w g/l y/l r/g lg b/w r/b r/l g/b r/l g/b r/l g/b r/b r/l g/b r/b r/l r/l r/l r/b r/l r/w br/r r/w br/r l y b/l d g/w g/w d br/w br/w d p/w p/w d b/l b/l b/l br/w l b/l p/w b/l g/w b/l b/l l a b/w a y/l d y y c l l c r/l c g/b c r/b b/l r/l b/l g/w br/w y p/w b/l g/w br/w y p/...

  • Page 530

    Fz6-sahg 2007 wiring diagram fz6-sahg 2007 schema de cablage fz6-sahg 2007 schaltplan fz6-sahg 2007 schema elettrico diagrama de conexiones de fz6-sahg 2007.

  • Page 531

    Fz6-n 2007 wiring diagram fz6-n 2007 schema de cablage fz6-n 2007 schaltplan fz6-n 2007 schema elettrico diagrama de conexiones de fz6-n 2007.

  • Page 532

    Fz6-na 2007 wiring diagram fz6-na 2007 schema de cablage fz6-na 2007 schaltplan fz6-na 2007 schema elettrico diagrama de conexiones de fz6-na 2007.

  • Page 533

    Fz6-nhg(w) 2007 wiring diagram fz6-nhg(w) 2007 schema de cablage fz6-nhg(w) 2007 schaltplan fz6-nhg(w) 2007 schema elettrico diagrama de conexiones de fz6-nhg(w) 2007.

  • Page 534

    Fz6-nahg 2007 wiring diagram fz6-nahg 2007 schema de cablage fz6-nahg 2007 schaltplan fz6-nahg 2007 schema elettrico diagrama de conexiones de fz6-nahg 2007.

  • Page 535

    Fz6-s 2007 wiring diagram fz6-s 2007 schema de cablage fz6-s 2007 schaltplan fz6-s 2007 schema elettrico diagrama de conexiones de fz6-s 2007.

  • Page 536

    Fz6-sa 2007 wiring diagram fz6-sa 2007 schema de cablage fz6-sa 2007 schaltplan fz6-sa 2007 schema elettrico diagrama de conexiones de fz6-sa 2007.

  • Page 537

    Fz6-shg(w) 2007 wiring diagram fz6-shg(w) 2007 schema de cablage fz6-shg(w) 2007 schaltplan fz6-shg(w) 2007 schema elettrico diagrama de conexiones de fz6-shg(w) 2007.

  • Page 538

    Fz6-sahg 2007 wiring diagram fz6-sahg 2007 schema de cablage fz6-sahg 2007 schaltplan fz6-sahg 2007 schema elettrico diagrama de conexiones de fz6-sahg 2007.