1. DL manuals
  2. Yamaha
  3. Motorcycle
  4. FAZER FZ1-S
  5. Service Manual

Yamaha FAZER FZ1-S Service Manual

Manual is about: 2008 Motorcycle

Summary of FAZER FZ1-S

  • Page 1

    2006 2d1-28197-e0 fz1-n(v) fz1-s(v) service manual.

  • Page 2

    Eas20040 fz1-n (v)/fz1-s (v) service manual ©2005 by yamaha motor co., ltd. First edition, december 2005 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Notice

    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: How To Use This Manual

    Eas20090 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 5: Symbols

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

  • Page 12: Fi System

    Fi system 1-3 et2d1001 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm 2 , 46.1 psi). Accordingly, when the energizing signal from the ecu energizes the...

  • Page 13: Instrument Functions

    Instrument functions 1-4 et2d1002 instrument functions multi-function meter unit warning ew2d1005 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 spee...

  • Page 14: Instrument Functions

    Instrument functions 1-5 3. When the hour digits start flashing, push the “reset” button to set the hours. 4. Push the “select” button, and the minute digits will start flashing. 5. Push the “reset” button to set the min- utes. 6. Push the “select” button and then release it to start the clock. Odom...

  • Page 15: Instrument Functions

    Instrument functions 1-6 air intake temperature mode the air intake temperature display indicates the temperature of the air drawn into the air fil- ter case. Push the “reset” button to switch the coolant temperature display to the air intake temperature display. Note: • even if the air intake tempe...

  • Page 16: Instrument Functions

    Instrument functions 1-7 1. Turn the key to “off”. 2. Push and hold the “select” button. 3. Turn the key to “on”, and then release the “select” button after five seconds. 4. Push the “reset” button to select the desired brightness level. 5. Push the “select” button to confirm the selected brightness...

  • Page 17: Important Information

    Important information 1-8 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 1-11. 3. When disassem...

  • Page 18: Important Information

    Important information 1-9 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if ...

  • Page 19: Checking The Connections

    Checking the connections 1-10 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 20: Special Tools

    Special tools 1-11 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 21: Special Tools

    Special tools 1-12 oil filter wrench 90890-01426 yu-38411 3-13 rod holder 90890-01434 damper rod holder double ended ym-01434 4-50, 4-55 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-54 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a87...

  • Page 22: Special Tools

    Special tools 1-13 compression gauge 90890-03081 engine compression tester yu-33223 3-11 valve spring compressor 90890-04019 ym-04019 5-23, 5-29 valve spring compressor attachment 90890-04108 valve spring compressor adapter (22 mm) ym-04108 5-23, 5-29 valve spring compressor attachment 90890-04114 v...

  • Page 23: Special Tools

    Special tools 1-14 valve guide remover (ø4) 90890-04111 valve guide remover (4.0 mm) ym-04111 5-25 valve guide remover (ø4.5) 90890-04116 valve guide remover (4.5 mm) ym-04116 5-25 valve guide installer (ø4) 90890-04112 valve guide installer (4.0 mm) ym-04112 5-25 valve guide installer (ø4.5) 90890-...

  • Page 24: Special Tools

    Special tools 1-15 yamaha bond no.1215 (three bond no.1215®) 90890-85505 5-67, 6-12 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 7-9, 7-10 pivot shaft wrench 90890-01518 frame spanner socket ym-01518 5-7 pivot shaft wrench adapter 90890-01476 5-7 pocket tester 9089...

  • Page 25: Special Tools

    Special tools 1-16 vacuum/pressure pump gauge set 90890-06756 7-8 valve lapper 90890-04101 valve lapping tool ym-a8998 3-5 fuel pressure adapter 90890-03176 ym-03176 7-8 pressure gauge 90890-03153 yu-03153 3-14, 7-8 camshaft wrench 90890-04143 ym-04143 5-11, 5-16 tool name/tool no. Illustration refe...

  • Page 26: Special Tools

    Special tools 1-17.

  • Page 27: Specifications

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

  • Page 28: General Specifications

    General specifications 2-1 eas20280 general specifications model model 2d11 (eur) 2d13 (aus) 3c31 (eur) 3c33 (aus) 3c37 (eur) 3c39 (aus) dimensions overall length 2140 mm (84.3 in) overall width 770 mm (30.3 in) overall height 1060 mm (41.7 in) (fz1-n) 1205 mm (47.4 in) (fz1-s) seat height 815 mm (3...

  • Page 29: Engine Specifications

    Engine specifications 2-2 inner-rotor-to-outer-rotor-tip clearance 0.010–0.100 mm (0.0004–0.0039 in) limit 0.18 mm (0.0071 in) outer-rotor-to-oil-pump-housing clearance 0.090–0.150 mm (0.0035–0.0059 in) limit 0.22 mm (0.0087 in) oil-pump-housing-to-inner-and-outer-rotor clearance 0.06–0.13 mm (0.002...

  • Page 30: Engine Specifications

    Engine specifications 2-3 camshaft runout limit 0.030 mm (0.0012 in) timing chain model/number of links rh2020/122 tensioning system automatic valve, valve seat, valve guide valve clearance (cold) intake 0.11–0.20 mm (0.0043–0.0079 in) exhaust 0.21–0.25 mm (0.0083–0.0098 in) valve dimensions valve h...

  • Page 31: Engine Specifications

    Engine specifications 2-4 limit 4.425 mm (0.1742 in) valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) limit 4.050 mm (0.1594 in) valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in) limit 4.550 mm (0.1791 in) valve-stem-to-valve-guide clearance (intake) 0.010...

  • Page 32: Engine Specifications

    Engine specifications 2-5 offset 0.50 mm (0.0197 in) offset direction intake side piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in) piston ring top ring ring type barrel dimensions (b × t) 0.90 × 2.75 mm (0.04 × 0.11 i...

  • Page 33: Engine Specifications

    Engine specifications 2-6 journal oil clearance (using plastigauge®) 0.014–0.037 mm (0.0006–0.0015 in) bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green clutch clutch type wet, multiple-disc clutch release method outer pull, rack and pinion pull clutch lever free play 10.0–15.0 mm (0.39–0.59...

  • Page 34: Engine Specifications

    Engine specifications 2-7 idling condition engine idling speed 1100–1300 r/min intake vacuum 30.0 kpa (8.9 inhg) (225 mmhg) water temperature 95.0–105.0 °c (203.00–221.00 °f) oil temperature 80.0–90.0 °c (176.00–194.00 °f) throttle cable free play 3.0–5.0 mm (0.12–0.20 in).

  • Page 35: Chassis Specifications

    Chassis specifications 2-8 eas20300 chassis specifications chassis frame type diamond caster angle 25.00 ° trail 109.0 mm (4.29 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 36: Chassis Specifications

    Chassis specifications 2-9 master cylinder inside diameter 16.00 mm (0.63 in) caliper cylinder inside diameter 30.20 mm (1.19 in) caliper cylinder inside diameter 27.00 mm (1.06 in) recommended fluid dot 4 rear brake type single disc brake operation right foot operation brake pedal free play 4.3–9.3...

  • Page 37: Electrical Specifications

    Electrical specifications 2-10 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) ignition timing (b.T.D.C.) 5.0 °/1200 r/min engine control unit model/manufacturer tbdf20/denso transistorized coil ignition crankshaft...

  • Page 38: Electrical Specifications

    Electrical specifications 2-11 coolant temperature warning light led engine trouble warning light led immobilizer system indicator light led electric starting system system type constant mesh starter motor model/manufacturer sm13/mitsuba power output 0.80 kw armature coil resistance 0.0250–0.0350 Ω ...

  • Page 39: Tightening Torques

    Tightening torques 2-12 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 40: Tightening Torques

    Tightening torques 2-13 eas20340 engine tightening torques item thread size q’ty tightening torque remarks spark plug m10 4 13 nm (1.3 m·kg, 9.4 ft·lb) cylinder head nut m10 10 see note cylinder head bolt m6 2 12 nm (1.2 m·kg, 8.7 ft·lb) camshaft caps bolt m6 28 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder ...

  • Page 41: Tightening Torques

    Tightening torques 2-14 cylinder head and exhaust pipe nut m8 8 20 nm (2.0 m·kg, 14 ft·lb) exhaust pipe and muffler bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) exup pulley and shaft arm nut m6 1 7 nm (0.7 m·kg, 5.1 ft·lb) exup valve pulley cover bolt m6 2 14 nm (1.4 m·kg, 10 ft·lb) exup cable nut m6 2 6 nm...

  • Page 42: Tightening Torques

    Tightening torques 2-15 note: • cylinder head nut 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 67 nm (6.7 m•kg, 48 ft•lb) with a torque wrench. • connecting rod cap bolt 1 tighten the connecting rod ...

  • Page 43: Tightening Torques

    Tightening torques 2-16.

  • Page 44: Tightening Torques

    Tightening torques 2-17 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks upper bracket pinch bolt m8 2 26 nm (2.6 m·kg, 19 ft·lb) steering stem nut m28 1 113 nm (11.3 m·kg, 82 ft·lb) upper handlebar holder bolt m8 4 24 nm (2.4 m·kg, 17 ft·lb) lower handlebar holder...

  • Page 45: Tightening Torques

    Tightening torques 2-18 rear brake hose holder screw m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank bolt (front) m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank bolt (rear) m6 1 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank bracket screw m6 4 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank cap bolt m5 5 6 nm (0.6 m·kg, 4.3 ft·lb)...

  • Page 46: Tightening Torques

    Tightening torques 2-19 note: 1 first, tighten the ring nut to approximately 52 nm (5.2 m•kg, 38 ft•lb) with a torque wrench, then loosen the lower ring nut completely. 2 retighten the lower ring nut 18 nm (1.8 m•kg, 13 ft•lb). Clutch cable adjust nut m8 1 7 nm (0.7 m·kg, 5.1 ft·lb) item thread size...

  • Page 47: 2-20

    Lubrication points and lubricant types 2-20 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins crankshaft journals camshaft lobes camshaft journals valve stems (intake and exhaust) val...

  • Page 48: 2-21

    Lubrication points and lubricant types 2-21 pickup rotor cover yamaha bond no. 1215 lubrication point lubricant.

  • Page 49: 2-22

    Lubrication points and lubricant types 2-22 eas20380 chassis lubrication point lubricant steering bearings and bearing races (upper and lower) throttle grip inner surface brake lever pivoting point and metal-to-metal moving parts clutch lever pivoting point and metal-to-metal moving parts engine mou...

  • Page 50: 2-23

    Lubrication system chart and diagrams 2-23 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.

  • Page 51: 2-24

    Lubrication system chart and diagrams 2-24 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. Ac magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.Ac magneto axle 13.Piston cooler 14.Chain tensioner 15.Intake camsh...

  • Page 52: 2-25

    Lubrication system chart and diagrams 2-25 eas20410 lubrication diagrams.

  • Page 53: 2-26

    Lubrication system chart and diagrams 2-26 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch.

  • Page 54: 2-27

    Lubrication system chart and diagrams 2-27.

  • Page 55: 2-28

    Lubrication system chart and diagrams 2-28 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump.

  • Page 56: 2-29

    Lubrication system chart and diagrams 2-29.

  • Page 57: 2-30

    Lubrication system chart and diagrams 2-30 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler.

  • Page 58: 2-31

    Lubrication system chart and diagrams 2-31.

  • Page 59: 2-32

    Lubrication system chart and diagrams 2-32 1. Main axle 2. Oil delivery pipe 3. Drive axle.

  • Page 60: 2-33

    Lubrication system chart and diagrams 2-33.

  • Page 61: 2-34

    Lubrication system chart and diagrams 2-34 1. Cylinder head 2. Crankshaft.

  • Page 62: Cooling System Diagrams

    Cooling system diagrams 2-35 eas20420 cooling system diagrams.

  • Page 63: Cooling System Diagrams

    Cooling system diagrams 2-36 1. Water pump 2. Radiator 3. Radiator fan.

  • Page 64: Cooling System Diagrams

    Cooling system diagrams 2-37.

  • Page 65: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat.

  • Page 66: Cable Routing

    Cable routing 2-39 eas20430 cable routing.

  • Page 67: Cable Routing

    Cable routing 2-40 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Horn stay assembly 7. Throttle cable (pull side) 8. Throttle cable (return side) 9. Wire harness 10.Brake hose 11.Throttle cables 12.Right handlebar switch lead a. Wire is connect...

  • Page 68: Cable Routing

    Cable routing 2-41.

  • Page 69: Cable Routing

    Cable routing 2-42 1. Wire harness 2. Right handlebar switch lead 3. Throttle cable 4. Radiator inlet hose 5. Wire guide 6. Brake fluid reservoir hose 7. Fuel tank breather hose 8. Exup cable wire bending attachment 9. Exup cables 10.Rear brake light switch lead 11.Radiator fan motor lead (right) 12...

  • Page 70: Cable Routing

    Cable routing 2-43.

  • Page 71: Cable Routing

    Cable routing 2-44 1. Clutch cable 2. Water pump breather hose 3. Oil level switch lead 4. Sidestand switch lead 5. O 2 sensor lead 6. Coolant reservoir tank drain hose 7. Wire harness 8. Battery negative lead 9. Seat lock cable 10.Ac magneto lead 11.Rectifier/regulator lead 12.Water pump inlet pipe...

  • Page 72: Cable Routing

    Cable routing 2-45.

  • Page 73: Cable Routing

    Cable routing 2-46 af.The coolant reservoir tank drain hose shall cross with the speed sensor lead under the rear arm bracket. The coolant reservoir tank drain hose shall be positioned above the vehicle..

  • Page 74: Cable Routing

    Cable routing 2-47.

  • Page 75: Cable Routing

    Cable routing 2-48 1. Throttle cables 2. Right handlebar switch lead 3. Wire harness 4. Throttle cable (pull side) 5. Throttle cable (return side) 6. Radiator fan motor lead (right) 7. Coolant reservoir tank hose 8. Radiator inlet hose 9. Air filter drain hose 10.Crankshaft position sensor lead 11.D...

  • Page 76: Cable Routing

    Cable routing 2-49.

  • Page 77: Cable Routing

    Cable routing 2-50 q. Pass the turn signal light lead (right) and license plate light lead under the rear fender bracket and route between the ribs of the battery box. R. Pass the turn signal light lead (left) and tail/ brake light lead under the rear fender bracket and route between the ribs of the...

  • Page 78: Cable Routing

    Cable routing 2-51.

  • Page 79: Cable Routing

    Cable routing 2-52 fz1-s 1. Clutch cable 2. Left handlebar switch lead 3. Immobilizer lead 4. Main switch lead 5. Protector 6. Throttle cables 7. Right handlebar switch lead 8. Throttle cable (pull side) 9. Throttle cable (return side) 10.Bracket 11.Wire harness 12.Turn signal light lead 13.Seat loc...

  • Page 80: Cable Routing

    Cable routing 2-53.

  • Page 81: Cable Routing

    Cable routing 2-54 1. Fuel tank 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Clip 5. Air filter bracket 6. 3 way connector 7. Hose 8. Fuel hose 9. Damper 10.Collar 11.Fuel tank bracket 12.O-ring 13.Fuel pump a. Hook the cover pawl to the fuel tank bracket. B. The knob of the clip can be pos...

  • Page 82: Cable Routing

    Cable routing 2-55.

  • Page 83

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

  • Page 84

    Lubricating the centerstand (fz1-s) ..................................... 3-34 lubricating the rear suspension .......................................... 3-34 electrical system.............................................................................. 3-35 checking and charging the battery..........

  • Page 86: 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 87: 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 motorcycle or riding in the rain 14 * steering bear- ings • check bearing play and steering for...

  • Page 88: 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 89: 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 90: 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: • camshaft note: • refer to "camshafts" on page 5-10. • when removing the timing...

  • Page 91: Engine

    Engine 3-6 if the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062in) d. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad number. Example: 1.58 mm (0.062 in) + 0.05 mm (0.002 in) = 1.63 mm (0.064 in) the valve...

  • Page 92: Engine

    Engine 3-7 refer to "general chassis" on page 4- 1. • fuel tank refer to "fuel tank" on page 7-1. 3. Remove: • synchronizing hoses “1” 4. Install: • vacuum gauge “1” (onto the synchronizing hose) • digital tachometer (near the spark plug) 5. Install: • fuel tank refer to "fuel tank" on page 7-1. 6. ...

  • Page 93: Engine

    Engine 3-8 make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: • throttle cable free play refer to "adjusting the throttle cable free play" on page 3-9. 12. Install: • synchronizing hoses • fuel tank refer to "fuel tank" on ...

  • Page 94: Engine

    Engine 3-9 8. Simultaneously press the “select” and “reset” buttons to return to the cylinder selection (step 5). 9. Turn the main switch to “off” to cancel the mode. Eas20610 adjusting the engine idling speed note: prior to adjusting the engine idling speed, the throttle bodies’ synchronization sho...

  • Page 95: Engine

    Engine 3-10 c. Tighten the locknut. Warning ew2d1001 after adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas20680 checking the spark pl...

  • Page 96: Engine

    Engine 3-11 caution: eca13340 before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 4. Install: • compression gauge “1” • extension 5. Measure: • compression pressure out of specification → ref...

  • Page 97: Engine

    Engine 3-12 caution: eca13360 • 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 “c” or higher and do not use oils labeled “energy con- serving ii” “d” or higher....

  • Page 98: Engine

    Engine 3-13 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “3” of the new oil filter cartridge with a thin coat of engine oil. Caution...

  • Page 99: Engine

    Engine 3-14 to measure the engine oil pressure after warming up the engine. 3. Remove: • oil gallery bolt “1” warning ewa12980 the engine, muffler and engine oil are extremely hot. 4. Install: • oil pressure gauge “1” • adapter “2” 5. Measure: • engine oil pressure (at the following conditions) note...

  • Page 100: Engine

    Engine 3-15 2. Adjust • clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ handlebar side a. Turn the adjusting dial “1” in direction “b” or “c” until the specified clutch cable free play is obtained. Note: if the specified clutch cable free play cannot be obtained on the handlebar side of the ca...

  • Page 101: Engine

    Engine 3-16 4. Install: • air filter case cover caution: eca14400 never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle bodies ...

  • Page 102: Engine

    Engine 3-17 refer to "fuel tank" on page 7-1. 2. Check: • crankcase breather hose “1” cracks/damage → replace. Loose connection → connect properly. Caution: eca13450 make sure the crankcase breather hose is routed correctly. 3. Install: • fuel tank refer to "fuel tank" on page 7-1. • rider and passe...

  • Page 103: Engine

    Engine 3-18 2. Check: • exup system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”. Refer to "fuel injection system" on page 8-31. B. Set the engine stop switch to “ ”. C. Check that the exup valve operates prop- erly. ▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 104: Engine

    Engine 3-19 • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → add the recommended coolant to the proper level. Caution: eca13470 • adding water instead of coolant lowers the antifreeze content of the coolant. If ...

  • Page 105: Engine

    Engine 3-20 4. Drain: • coolant (from the coolant reservoir) 5. Remove: • radiator cap “1” 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 ...

  • Page 106: Engine

    Engine 3-21 coolant is potentially harmful and should be handled with special care. Warning ewa13040 • if coolant splashes in your eyes, thor- oughly wash them with water and consult a doctor. • if coolant splashes on your clothes, quickly wash it away with water and then with soap and water. • if c...

  • Page 107: Chassis

    Chassis 3-22 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 108: Chassis

    Chassis 3-23 eas21240 checking the brake fluid level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Warni...

  • Page 109: Chassis

    Chassis 3-24 eas21280 checking the front brake hoses the following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose “1” cracks/damage/wear → replace. 2. Check: • brake hose clamp “2” loose → tighten the clamp bolt. 3. Hold the vehicle upright and apply the fr...

  • Page 110: Chassis

    Chassis 3-25 nut “2” in direction “a” or “b” until the rear brake light comes on at the proper time. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21350 bleeding the hydraulic brake sys- tem warning ewa13100 bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, d...

  • Page 111: Chassis

    Chassis 3-26 warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ et2d1006 adjusting the shift pedal 1. Adjust: • shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. B. Turn the shift rod “2” in direction “...

  • Page 112: Chassis

    Chassis 3-27 d. Tighten both locknuts to specification. E. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ et2d1008 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. T...

  • Page 113: Chassis

    Chassis 3-28 d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to "steering head" on page 4-57. E. Install the rubber washer “3”. F. Install the ...

  • Page 114: Chassis

    Chassis 3-29 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 115: Chassis

    Chassis 3-30 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ rebound damping (right side front fork) caution: ec2d1006 • never go beyond the maximum or mini- mum adjustment positions. • when assembling the front forks, be care- ful not to assemble them to the opposite position because there are two kinds of forks (f...

  • Page 116: Chassis

    Chassis 3-31 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21620 adjusting the rear shock absorber assembly warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Spring preload caution: eca13590 never go beyond the maximum or minimum adjustment positions. 1. Adjust: • spri...

  • Page 117: Chassis

    Chassis 3-32 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21650 checking the tires the following procedure applies to both of the tires. 1. Check: • tire pressure out of specification → regulate. Warning ewa13180 • the tire pressure should only be checked and regulated when the tire temperature equals the ambi...

  • Page 118: 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 119: 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 120: Electrical System

    Electrical system 3-35 eas21750 electrical system eas21760 checking and charging the battery refer to "electrical components" on page 8-89. Eas21770 checking the fuses refer to "electrical components" on page 8-89. Eas21780 replacing the headlight bulbs 1. Remove: • headlight side cover bolts “1” (f...

  • Page 121: Electrical System

    Electrical system 3-36 warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 7. Install: • headlight bulb secure the new headlight bulb with the headlight bulb holder. Caution: eca13690 avoid touching the gla...

  • Page 122: Electrical System

    Electrical system 3-37 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Fz1-n b. Fz1-s.

  • Page 123: Chassis

    4 chassis general chassis.................................................................................... 4-1 removing the cover....................................................................... 4-7 installing the cover ..................................................................... 4...

  • Page 124

    Removing the handlebar ........................................................... 4-45 checking the handlebar............................................................ 4-45 installing the handlebar .......................................................... 4-45 front fork............................

  • Page 126: General Chassis

    General chassis 4-1 eas21830 general chassis removing the seat and battery order job/parts to remove q’ty remarks 1 passenger seat 1 2 rider seat 1 3 battery band 1 4 battery cover 1 5 battery negative lead 1 6 battery positive lead 1 7 battery 1 8 battery seat 1 for installation, reverse the remova...

  • Page 127: General Chassis

    General chassis 4-2 removing the headlight and meter assembly (fz1-n) order job/parts to remove q’ty remarks 1 headlight side cover bolt (left and right) 4 2 headlight coupler 1 disconnect. 3 headlight sub-wire harness coupler 1 disconnect. 4 headlight assembly 1 5 headlight bracket 2 6 headlight si...

  • Page 128: General Chassis

    General chassis 4-3 removing the front cowling (fz1-s) order job/parts to remove q’ty remarks 1 inner panel 2 2 headlight assembly coupler 1 disconnect. 3 meter coupler 1 disconnect. 4 front cowling assembly 1 5 rear view mirror 2 6 cowling stay 1 7 meter assembly 1 8 headlight unit 1 for installati...

  • Page 129: General Chassis

    General chassis 4-4 removing the rear fender (fz1-n) order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. 1 licence plate light lead coupler 1 disconnect. 2 turn signal light lead coupler 1 disconnect. 3 mud guard assembly 1 4 rear fender 1 5 tail/b...

  • Page 130: General Chassis

    General chassis 4-5 removing the rear fender (fz1-s) order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. 1 licence plate light lead coupler 1 disconnect. 2 turn signal light lead coupler 1 disconnect. 3 mud guard assembly 1 4 rear fender 1 5 tail/b...

  • Page 131: General Chassis

    General chassis 4-6 removing the air filter case order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. 1 intake air temperature sensor lead cou- pler 1 disconnect. 2 intake air temperature sensor 1 3 air fi...

  • Page 132: General Chassis

    General chassis 4-7 eas21840 removing the cover 1. Remove: • tail cover • rear fender note: to remove the quick fastener, push its center with a screwdriver, then pull the fastener out. Eas21850 installing the cover 1. Install: • rear fender • tail cover note: to install the quick fastener, push its...

  • Page 133: Front Wheel

    Front wheel 4-8 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 brake hose holder (left and right) 2 2 front brake caliper (left and right) 2 3 front wheel axle pinch bolt 1 4 front wheel axle 1 5 collar (left and right) 2 6 dust cover 2 7 front...

  • Page 134: Front Wheel

    Front wheel 4-9 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal (left and right) 2 2 wheel bearing (left and right) 2 3 spacer 1 for assembly, reverse the disassem- bly procedure..

  • Page 135: 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 136: 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 “1” or balls “2”. Contact should be made only with the outer race “3”....

  • Page 137: Front Wheel

    Front wheel 4-12 a. Install a balancing weight “1” onto the rim exactly opposite the heavy spot “x”. Note: start with the lightest weight. B. Turn the front wheel 90 ° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. R...

  • Page 138: Front Wheel

    Front wheel 4-13 warning ewa13490 make sure the brake cable is routed prop- erly. Note: make sure that there is enough space between the brake pads before installing the brake cali- pers onto the brake discs..

  • Page 139: Rear Wheel

    Rear wheel 4-14 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks 1 rear brake caliper 1 2 locknut (left and right) 2 loosen. 3 adjusting bolt (left and right) 2 loosen. 4 wheel axle nut 1 5 washer 1 6 rear wheel axle 1 7 adjusting block (left) 1 8 adjusting block (r...

  • Page 140: Rear Wheel

    Rear wheel 4-15 removing the 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 coller (left and right) 2 4 dust cover 2 5 oil seal 1 6 bearing 1 7 rear wheel drive hub 1 8 rear wheel drive hub damper 6 9 rear wheel 1 for installat...

  • Page 141: Rear Wheel

    Rear wheel 4-16 disassembling the rear wheel order job/parts to remove q’ty remarks 1 coller 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassem- bly procedure..

  • Page 142: Rear Wheel

    Rear wheel 4-17 eas22040 removing the rear wheel (disc) 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”...

  • Page 143: Rear Wheel

    Rear wheel 4-18 damage/wear → replace. 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 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 144: Rear Wheel

    Rear wheel 4-19 warning ewa13500 make sure the brake hose is routed prop- erly..

  • Page 145: Front Brake

    Front brake 4-20 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks 1 brake hose holder 1 2 front brake caliper 1 3 brake pad clip 2 4 brake pad pin 1 5 brake pad spring 1 6 brake pad 2 7 bleed screw 1 for installation, reverse the removal procedure..

  • Page 146: Front Brake

    Front brake 4-21 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydrau- lic brake system" on page 3- 25. 1 right rearview mirror (fz1-n) 1 2 brake master cylinder reservoir cap 1 3 brake master cylinder reservoir dia- phragm ...

  • Page 147: Front Brake

    Front brake 4-22 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 brake master cylinder body 1 for assembly, reverse the disassem- bly procedure..

  • Page 148: Front Brake

    Front brake 4-23 removing the front brake calipers order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydrau- lic brake system" on page 3- 25. 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 brake caliper 1 for installation, reverse the removal procedure..

  • Page 149: Front Brake

    Front brake 4-24 disassembling the front brake calipers 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, reverse the disassem- bly procedure..

  • Page 150: Front Brake

    Front brake 4-25 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 151: Front Brake

    Front brake 4-26 note: tighten the brake disc bolts in stages and in a crisscross pattern. 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...

  • Page 152: Front Brake

    Front brake 4-27 note: the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • brake pad pins • brake pad clips • brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake flu...

  • Page 153: Front Brake

    Front brake 4-28 c. Remove the brake caliper piston seals. D. Repeat the previous steps to force out the right side pistons from the brake caliper. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas22390 checking the front brake calipers 1. Check: • brake caliper pistons “1” rust/scratches/wear → replace the brake ...

  • Page 154: Front Brake

    Front brake 4-29 “a” touches the projection “b” on the brake caliper. 2. Remove: • brake caliper 3. Install: • brake pads • brake pad spring • brake pad pin • brake pad clips • brake caliper • brake hose holder refer to "replacing the front brake pads" on page 4-26. 4. Fill: • brake master cylinder ...

  • Page 155: Front Brake

    Front brake 4-30 2. Remove: • union bolt “1” • copper washers “2” • brake hose “3” note: to collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. Eas22500 checking the front brake master cylinder 1. Check: • brake master cylinder damage/scratch...

  • Page 156: Front Brake

    Front brake 4-31 warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to "cable routing" on page 2-39. Note: • while holding the brake hose, tighten the union bolt as shown. • turn the handlebar to the left and right to make sure the brake hose does not tou...

  • Page 157: Rear Brake

    Rear brake 4-32 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 bleed screw 1 7 brake pad spring 1 for installation, reverse the removal procedure..

  • Page 158: Rear Brake

    Rear brake 4-33 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to "bleeding the hydrau- lic brake system" on page 3- 25. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm 1 4 brake fluid...

  • Page 159: Rear Brake

    Rear brake 4-34 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder kit 1 2 hose joint 1 3 bushing 1 4 brake master cylinder body 1 for assembly, reverse the disassem- bly procedure..

  • Page 160: Rear Brake

    Rear brake 4-35 removing the rear brake caliper order job/parts to remove q’ty remarks 1 union bolt 1 2 copper washer 2 3 brake hose 1 4 barke caliper 1 for installation, reverse the removal procedure..

  • Page 161: Rear Brake

    Rear brake 4-36 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 disassem- bly procedure..

  • Page 162: Rear Brake

    Rear brake 4-37 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 163: Rear Brake

    Rear brake 4-38 a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. 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 ...

  • Page 164: Rear Brake

    Rear brake 4-39 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 piston from the brake caliper. Warning ewa13550 • cover the brake caliper piston with a rag. Be careful not to ge...

  • Page 165: Rear Brake

    Rear brake 4-40 eas22670 installing the rear brake caliper 1. Install: • brake caliper “1” (temporarily) • copper washers “2” • brake hose “3” • union bolt “4” warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to "cable routing" on page 2-39. Caution: ec...

  • Page 166: Rear Brake

    Rear brake 4-41 7. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to "bleeding the hydraulic brake system" on page 3-25. Eas22700 removing the rear brake master cylinder 1. Remove: • union bolt “1” • copper washers “2” • brake hose “3” note: to collect any rema...

  • Page 167: Rear Brake

    Rear brake 4-42 2. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ew2d1005 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type ...

  • Page 168: Handlebar

    Handlebar 4-43 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks front cowling (fz1-s) refer to "general chassis" on page 4-1. 1 rear view mirror (fz1-n) 2 2 front brake light switch connector 2 disconnect. 3 front master cylinder bracket 1 4 front brake master cylinde...

  • Page 169: Handlebar

    Handlebar 4-44 15 handlebar 1 16 lower handlebar holder 2 for installation, reverse the removal procedure. Removing the handlebar order job/parts to remove q’ty remarks.

  • Page 170: Handlebar

    Handlebar 4-45 eas22860 removing the handlebar 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 handlebar and the handlebar grip, and gradually p...

  • Page 171: Handlebar

    Handlebar 4-46 4. Tighten: • lower handlebar holder nuts 5. Install: • clutch lever holder “1” • clutch cable note: align the slit in the clutch lever holder with the punch mark "a" in the handlebar. 6. Install: • left handlebar switch note: align the projections “a” on the left handlebar switch wit...

  • Page 172: Handlebar

    Handlebar 4-47 note: • align the projections "a" on the handlebar switch with the holes "b" in the handlebar. • threre should be 1–3 mm (0.04–0.12 in) of clearance “c” between the handlebar grip and the grip end. 10. Install: • front brake master cylinder assembly • front brake master cylinder holde...

  • Page 173: Front Fork

    Front fork 4-48 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks front wheel front brake calipers refer to "checking the tires" on page 3-32 and "checking the wheels" on page 3-34. 1 front fender 1 2 cap bolt 1 loosen. 3 upper bracket pinch bolt 1 loosen. 4 low...

  • Page 174: Front Fork

    Front fork 4-49 disassembling the front fork legs order job/parts to remove q’ty remarks 1 cap bolt 1 2 o-ring 1 3 damper adjusting rod 1 4 nut 1 5 washer 1 6 spacer 1 7 fork spring 1 8 dust seal 1 9 oil seal clip 1 10 oil seal 1 11 washer 1 12 damper rod assembly bolt 1 13 copper washer 1 14 damper...

  • Page 175: Front Fork

    Front fork 4-50 eas22970 removing the front fork legs the following procedure applies to both of the front fork legs. Note: each front fork leg is eqipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screan and left front fprk is equippe...

  • Page 176: Front Fork

    Front fork 4-51 3. Remove: • oil seal clip “1” (with a flat-head screwdriver) caution: eca14180 do not scratch the inner tube. 4. Remove: • damper rod assembly bolt • damper rod assembly caution: ec2d1080 for the damper rod assembly, the right side is used for the rebound operation and left side for...

  • Page 177: Front Fork

    Front fork 4-52 3. Check: • damper rod “1” damage/wear → replace. Obstruction → blow out all of the oil pas- sages with compressed air. • damper adjusting rod bends/damage → replace. Caution: eca14200 • the front fork leg has a built-in damper adjusting rod and a very sophisticated internal construc...

  • Page 178: Front Fork

    Front fork 4-53 4. Install: • dust seal “1” • oil seal clip “2” • oil seal “3” • washer “4” 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-based grease. • lubricate the outer surface of the inner tu...

  • Page 179: Front Fork

    Front fork 4-54 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) caution: eca14230 • be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. • when disassembling and assembling the front fork leg, do not allow any f...

  • Page 180: Front Fork

    Front fork 4-55 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rod puller and adapter. B. Install the nut. C. Install the fork spring and spacer. Note: install the spring with the smaller pitch “a” fac- ing up “a”. D. Press down in the spacer with the fork spring compressor “1” e. Pull up the rod pull...

  • Page 181: Front Fork

    Front fork 4-56 warning ew2d1003 • the fork spring is compressed. • always use a new cap bolt o-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. Note: each front fork leg is eqipped with a spring preload adju...

  • Page 182: Steering Head

    Steering head 4-57 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front wheel refer to "front wheel" on page 4-8. Front brake calipers refer to "front brake" on page 4-20. Front cowling (fz1-s) refer to "general chassis" on page 4-1. Headlight and meter asse...

  • Page 183: Steering Head

    Steering head 4-58 5 front brake hose joint bracket 1 6 horn 1 7 horn bracket 1 8 lock washer 1 9 upper ring nut 1 10 rubber washer 1 11 lower ring nut 1 12 lower bracket 1 13 lower bearing 1 14 lower bearing dust seal 1 15 lower bearing inner race 1 16 bearing cover 1 17 upper bearing inner race 1 ...

  • Page 184: Steering Head

    Steering head 4-59 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: • upper ring nut “1” • rubber washer • lower ring nut “2” • lower bracket note: hold the lower ring ...

  • Page 185: Steering Head

    Steering head 4-60 4. Check: • 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 ring nut “1” • rubber washer “2” • upper ring nut “3” • l...

  • Page 186: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-61 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Side cover (left and right) refer to "general chassis" on page 4-1. Brake fluid re...

  • Page 187: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-62 for installation, reverse the removal procedure. Removing the rear shock absorber assembly order job/parts to remove q’ty remarks.

  • Page 188: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-63 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 189: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-64 gas leaks/oil leaks → replace the rear shock absorber assembly. • spring damage/wear → replace the rear shock absorber assembly. • bushings damage/wear → replace. • dust seals damage/wear → replace. • bolts bends/damage/wear → replace. Eas23260 checking the connecti...

  • Page 190: Swingarm

    Swingarm 4-65 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to "rear wheel" on page 4- 14. Rear brake caliper refer to "rear brake" on page 4- 32. Rear shock absorber refer to "rear shock absorber assembly" on page 4-61. Drive sprocket refer to "engi...

  • Page 191: Swingarm

    Swingarm 4-66 8 drive chain 1 9 dust cover 2 10 drive chain guide 1 11 spacer 1 12 bearing 2 for installation, reverse the removal procedure. Removing the swingarm order job/parts to remove q’ty remarks.

  • Page 192: Swingarm

    Swingarm 4-67 eas23350 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. Remove: • relay arm-to-swingarm bolt “...

  • Page 193: Swingarm

    Swingarm 4-68 5. Check: • connecting arms “1” • relay arm “2” damage/wear → replace. 6. Check: • bearings “3” • oil seals “4” damage/pitting → replace. 7. Check: • collars “5” damage/scratches → replace. Eas23380 installing the swingarm 1. Lubricate: • bearings • spacers • dust covers • pivot shaft ...

  • Page 194: Chain Drive

    Chain drive 4-69 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket refer to "engine removal" on page 5-2. 1 drive chain guard 1 2 drive chain 1 for installation, reverse the removal procedure..

  • Page 195: Chain Drive

    Chain drive 4-70 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 196: Chain Drive

    Chain drive 4-71 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 197: Engine

    5 engine engine removal ...................................................................................... 5-2 installing the engine .................................................................... 5-8 camshafts....................................................................................

  • Page 198

    Checking the friction plates .................................................. 5-49 checking the clutch plates..................................................... 5-49 checking the clutch springs .................................................. 5-50 checking the clutch housing .....................

  • Page 199

    Checking the transmission ...................................................... 5-91 installing the transmission..................................................... 5-92.

  • Page 200: Engine Removal

    Engine removal 5-2 eas23710 engine removal removing the drive sprocket order job/parts to remove q’ty remarks 1 locknut 2 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 1 8 plate 1 for installation, reverse the removal procedure..

  • Page 201: Engine Removal

    Engine removal 5-3 removing the exhaust pipe order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. 1 exup pulley cover 1 2 exup servo motor cover 1 3 exup cables 2 4 exup servo motor 1 5 o 2 sensor 1 6 exhaust pipe assembly 1 7 exhaust pipe gasket 4 ...

  • Page 202: Engine Removal

    Engine removal 5-4 disassembling the exhaust valve pipe order job/parts to remove q’ty remarks 1 nut 1 2 pulley 1 3 spring 1 4 spring seat 1 for assembly, reverse the disassem- bly procedure..

  • Page 203: Engine Removal

    Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. Throttle body assembly refer to "throttle bodies" on page 7-4. Engine oil drain. Refer to "changing the engi...

  • Page 204: Engine Removal

    Engine removal 5-6 6 crankshaft position sensor lead coupler 1 disconnect. 7 oil level switch connector 1 disconnect. 8 neutral switch connector 1 disconnect. 9 cylinder identification sensor coupler 1 disconnect. 10 speed sensor coupler 1 disconnect. For assembly, reverse the removal procedure. Dis...

  • Page 205: Engine Removal

    Engine removal 5-7 removing the engine order job/parts to remove q’ty remarks 1 right front engine mounting bolt 1 1 2 left front engine mounting bolt 1 3 upper self-locking nut 1 4 upper engine mounting bolt 1 5 lower self-locking nut 1 6 lower engine mounting bolt 1 7 engine mounting adjust bolt 2...

  • Page 206: Engine Removal

    Engine removal 5-8 eas23720 installing the engine 1. Install: • right front engine mounting bolt 2 “1” refer to "cylinder head" on page 5-19. 2. Tighten: • right front engine mounting bolt 2 3. Install: • engine mounting adjust bolts (temporarily tighten) 4. Install: • engine 5. Install: • lower eng...

  • Page 207: Engine Removal

    Engine removal 5-9 8. Tighten: • lower self-locking nut “1” • upper self-locking nut “2” note: first tighten the lower self-locking nut, and then tighten the upper self-locking nut. 9. Tighten: • left front engine mounting bolt ”1” • right front engine mounting bolt 1 ”2” upper self-locking nut 51 n...

  • Page 208: Camshafts

    Camshafts 5-10 eas23760 camshafts removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank refer to "fuel tank" on page 7-1. Throttle body assembly refer to "throttle bodies" on page 7-4. Radiator assembly refer to "radiator" on page 6-1. Air cut-off valve refer to "air indu...

  • Page 209: Camshafts

    Camshafts 5-11 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to "crankshaft position sensor" on page 5-38. 1 camshaft sprocket bolt 4 loosen. 2 timing chain tensioner 1 3 timing chain tensioner gasket 1 4 intake camshaft cap 3 5 dowel pin 6 refer to "removing...

  • Page 210: Camshafts

    Camshafts 5-12 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to "crankshaft position sen- sor" on page 5-38. 2. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1...

  • Page 211: Camshafts

    Camshafts 5-13 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 of specification → replace. 4. Me...

  • Page 212: Camshafts

    Camshafts 5-14 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • camshaft journal diameter “a” out of specification → replace the cam- shaft. Within specification → replace the cylinder head and the camshaft caps as a set. Eas23870 checking the timing chain and cam- shaft sprocket 1. Check: • timing chai...

  • Page 213: Camshafts

    Camshafts 5-15 note: squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring and timing chain tensioner rod. 2. Check: • timing chain tensioner housing • timing chain tensioner rod • timing chain tensioner spring damage/wear → replace. 3. Install: • timing chain te...

  • Page 214: Camshafts

    Camshafts 5-16 eas24000 installing the camshafts 1. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When position #1 is at tdc, align the “t” mark “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲...

  • Page 215: Camshafts

    Camshafts 5-17 • the camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. • do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. 6. Tighten: • camshaft sprocket bolts “1” caution: ec2d1002 b...

  • Page 216: Camshafts

    Camshafts 5-18 11. Measure: • valve clearance out of specification → adjust. Refer to "adjusting the valve clearance" on page 3-4. 12. Install: • pickup coil rotor cover "crankshaft position sensor" on page 5-38..

  • Page 217: Cylinder Head

    Cylinder head 5-19 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to "engine removal" on page 5-2. Intake camshaft refer to "camshafts" on page 5-10. Exhaust camshaft refer to "camshafts" on page 5-10. 1 cylinder head 1 2 cylinder head gasket 1 ...

  • Page 218: Cylinder Head

    Cylinder head 5-20 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to "removing the camshafts" on page 5-12. 2. Remove: • cylinder head nuts • cylinder head bolts note: • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a t...

  • Page 219: Cylinder Head

    Cylinder head 5-21 • gasket “1” • dowel pins 3. Install: • cylinder head note: pass the timing chain through the timing chain cavity. 4. Tighten: • cylinder head nuts “1” – “10” • cylinder head bolts “11” “12” note: • first, tighten the nuts “1” – “10” to approxi- mately 19 nm (1.9 m·kg, 14 ft·lb) w...

  • Page 220: Valves and Valve Springs

    Valves and valve springs 5-22 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to "cylinder head" on page 5-19. 1 intake valve lifter 12 2 intake valve pad 12 3 intake valve cotter 24 4 intake valve upper spring seat 1...

  • Page 221: Valves and Valve Springs

    Valves and valve springs 5-23 16 exhaust valve lower spring seat 8 17 exhaust valve 8 18 exhaust valve guide 8 for installation, reverse the removal procedure. Removing the valves and valve springs order job/parts to remove q’ty remarks.

  • Page 222: Valves and Valve Springs

    Valves and valve springs 5-24 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 223: Valves and Valve Springs

    Valves and valve springs 5-25 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 224: Valves and Valve Springs

    Valves and valve springs 5-26 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 225: Valves and Valve Springs

    Valves and valve springs 5-27 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 226: Valves and Valve Springs

    Valves and valve springs 5-28 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 227: Valves and Valve Springs

    Valves and valve springs 5-29 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. Eas24330 installing the valves the following procedure applies to all of the valves ...

  • Page 228: Valves and Valve Springs

    Valves and valve springs 5-30 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. Caution: eca13800 hitting the valve tip with excessive force could damage the valve. 6. Install: • valve pad “1” • valve lifter “2” note: • lubricate the valve lifter...

  • Page 229: Generator

    Generator 5-31 eas24480 generator removing the generator order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Engine oil drain. Refer to "changing the engine oil" on page 3-12. 1 stator coil assembly lead ...

  • Page 230: Generator

    Generator 5-32 11 bearing 1 12 stator coil assembly lead holder 1 13 idler gear 1 14 idler gear shaft 1 15 washer 1 16 bearing 1 for assembly, reverse the removal procedure. Removing the generator order job/parts to remove q’ty remarks.

  • Page 231: Generator

    Generator 5-33 eas24490 removing the generator 1. Remove: • plug • generator rotor cover “1” note: • while pushing generator rotor, remove the generator rotor cover. • loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern. • after all of the bolts are fully loosened, remove th...

  • Page 232: Generator

    Generator 5-34 note: • first tighten the m8 bolts and then tighten the m6 bolts. • tighten the generator rotor cover bolts in stages and in a crisscross pattern. Generator rotor cover bolt (m6) 12 nm (1.2 m·kg, 8.7 ft·lb) generator rotor cover bolt (m8) 22 nm (2.2 m·kg, 16 ft·lb).

  • Page 233: Starter Clutch

    Starter clutch 5-35 eas24550 starter clutch removing the starter clutch order job/parts to remove q’ty remarks 1 generator rotor 1 2 damper 3 3 driven gear 1 4 washer 1 5 starter clutch drive gear 1 6 collar 1 7 washer 1 8 spacer 1 9 o-ring 1 for assembly, reverse the removal procedure..

  • Page 234: Starter Clutch

    Starter clutch 5-36 eas24560 removing the starter clutch 1. Remove: • spacer “1” • o-ring “2” • washer “3” 2. Remove: • starter clutch drive gear “1” • collar “2” • washer “3” 3. Remove: • driven gear “1” • dampers “2” • generator rotor “3” et2d1009 checking the damper 1. Check: • dampers “1” damage...

  • Page 235: Starter Clutch

    Starter clutch 5-37 otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch drive gear clockwise “b”, it should turn freely, other- wise the starter clutch is faulty and must be replaced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas24600 installing the starter clutch 1....

  • Page 236: Crankshaft Position Sensor

    Crankshaft position sensor 5-38 eas24520 crankshaft position sensor removing the crankshaft position sensor order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Engine oil drain. Refer to "changing the eng...

  • Page 237: Crankshaft Position Sensor

    Crankshaft position sensor 5-39 eas24530 removing the crankshaft position sensor 1. Disconnect: • crankshaft position sensor lead coupler 2. Remove: • crankshaft position sensor • o-ring • pickup coil rotor cover “1” note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross patte...

  • Page 238: Electric Starter

    Electric starter 5-40 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Throttle body assembly refer to "throttle bodies" on page 7-4. 1 starter moto...

  • Page 239: Electric Starter

    Electric starter 5-41 disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 front cover 1 3 lock washer 1 4 washer 1 5 starter motor yoke 1 6 armature assembly 1 7 o-ring 2 8 starter motor lead 2 9 brush holder 1 10 rear cover 1 for assembly, reverse the disassem- bly p...

  • Page 240: Electric Starter

    Electric starter 5-42 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 241: Electric Starter

    Electric starter 5-43 7. Check: • gear teeth damage/wear → replace the gear. Eas24800 assembling the starter motor 1. Install: • brush seat “1” note: align the tab “a” on the brush seat with the tab “b” in the starter motor rear cover. 2. Install: • armature “1” 3. Install: • starter motor yoke “1” ...

  • Page 242: Clutch

    Clutch 5-44 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to "changing the engine oil" on page 3-12. 1 clutch cable 1 2 clutch cover 1 3 clutch cover gasket 1 4 dowel pin 2 5 oil filler cap 1 for installation, reverse the removal procedure..

  • Page 243: Clutch

    Clutch 5-45 removing the pull lever shaft order job/parts to remove q’ty remarks 1 circlip 2 2 pull lever 1 3 pull lever spring 1 4 pull lever shaft 1 5 oil seal 1 6 bearing 2 for installation, reverse the removal procedure..

  • Page 244: Clutch

    Clutch 5-46 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 1 6 clutch plate 1 7 7 friction plate 2 7 8 wire circlip 1 9 clutch plate 2 1 10 friction plate 3 1 11 clutch damper spring 1 12 clutch damper ...

  • Page 245: Clutch

    Clutch 5-47 for assembly, reverse the removal procedure. Removing the clutch order job/parts to remove q’ty remarks.

  • Page 246: Clutch

    Clutch 5-48 eas25080 removing the clutch 1. Remove: • clutch cover “1” • gasket note: loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts “1” • compression springs • pressure pl...

  • Page 247: Clutch

    Clutch 5-49 • thrust plate 8. Remove: • wire circlip “1” note: there is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “1” and disassemble the built-in damper unless there is serious clutch chattering. 9. Remove: • clutch plate 2 “1” • ...

  • Page 248: Clutch

    Clutch 5-50 eas25140 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: • clutch spring damage → replace the clutch springs as a set. 2. Measure: • clutch spring free length “a” out of specification → replace the clutch springs as a set. Eas25150 chec...

  • Page 249: Clutch

    Clutch 5-51 • pull lever shaft pinion gear teeth “1” • pull rod teeth “2” damage/wear → replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: • pull rod bearing damage/wear → replace. Eas25240 installing the clutch 1. Install: • clutch damper spring seat “1” • clutch damper sprin...

  • Page 250: Clutch

    Clutch 5-52 • lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle. • while holding the clutch boss assembly “1” with the clutch holding tool “3”, tighten the clutch boss nut. 6. Lubricate • friction plates • clutch plates (with ...

  • Page 251: Clutch

    Clutch 5-53 10. Install: • pull lever note: install the pull lever with the “o“ mark facing toward lower side. 11. Install: • clutch cover • clutch cover gasket note: • install the pull rod so that the teeth a face towards the rear of the vehicle. Then, install the clutch cover. • apply oil onto the...

  • Page 252: Shift Shaft

    Shift shaft 5-54 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to "clutch" on page 5-44. Shift arm and shift rod refer to "engine removal" on page 5-2. 1 circlip 1 2 washer 1 3 shift shaft 1 4 collar 1 5 shift shaft sprin...

  • Page 253: Shift Shaft

    Shift shaft 5-55 for installation, reverse the removal procedure. Removing the shift shaft and stopper lever order job/parts to remove q’ty remarks.

  • Page 254: Shift Shaft

    Shift shaft 5-56 et2d1011 removing the shift shaft 1. Remove: • clutch assembly refetr to "clutch" on page 5-44 2. Remove: • shift arm • shift rod refetr to "engine removal" on page 5- 2 3. Remove: • circlip “1” • washer “2” (left side of the engine) 4. Remove • shift shaft “1” • shift shaft spring ...

  • Page 255: Shift Shaft

    Shift shaft 5-57 • stopper lever spring “3” 2. Install: • washer • collar • shift shaft spring “1” • shift shaft “2” note: • mesh the stopper lever with the shift drum segment assembly. • lubricate the oil seal lips with lithium soap base grease. • install the end of the shift shaft spring onto the ...

  • Page 256: Oil Pump

    Oil pump 5-58 eas24920 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks engine oil drain. Refer to "changing the engine oil" on page 3-12. Exup cables refer to "engine removal" on page 5-2. O 2 sensor refer to "engine removal" on page 5-2. Muffler refer to "engine re...

  • Page 257: Oil Pump

    Oil pump 5-59 2 oil level switch 1 3 oil level switch lead holder 1 4 oil pan 1 5 oil pan gasket 1 6 dowel pin 2 7 drain pipe 1 8 oil strainer 1 9 oil pipe 1 10 oil delivery pipe 1 11 relief valve assembly 1 12 oil/water pump assembly drive chain guide 1 13 collar 1 14 oil/water pump assembly drive ...

  • Page 258: Oil Pump

    Oil pump 5-60 18 oil/water pump assembly 1 for assembly, reverse the removal procedure. Removing the oil pan and oil pump order job/parts to remove q’ty remarks.

  • Page 259: Oil Pump

    Oil pump 5-61 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil/water pump driven sprocket 1 2 collar 1 3 oil pump housing 1 4 bearing 1 5 pin 2 6 oil pump outer roter 1 7 oil pump inner roter 1 8 pin 1 for assembly, reverse the disassem- bly procedure..

  • Page 260: Oil Pump

    Oil pump 5-62 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. Et2d1012 checking the sprocket and ...

  • Page 261: Oil Pump

    Oil pump 5-63 eas24970 checking the relief valve 1. Check: • relief valve body “1” • relief valve “2” • spring “3” • o-ring “4” damage/wear → replace the defective part(s). Eas24980 checking the oil delivery pipes 1. Check: • oil delivery pipe “1” • oil pipe “2” damage → replace. Obstruction → wash ...

  • Page 262: Oil Pump

    Oil pump 5-64 note: when installing the inner rotor, align the pin “1” in the oil pump shaft with the groove in the inner rotor “2”. 3. Install: • oil/water pump driven sprocket “1” note: 5vy mark of the oil/water pump driven gear is installed at oil pump side. 4. Check: • oil pump operation refer t...

  • Page 263: Oil Pump

    Oil pump 5-65 4. Install: • oil delivery pipe “1” 5. Install: • relief valve “1” • o-ring • oil strainer “2” • o-ring • oil pipe “3” • o-ring • drain pipe “4” • o-ring eas25050 installing the oil pan 1. Install: • dowel pins • gasket • oil pan “1” • oil level switch “2” • engine oil drain bolt “3” w...

  • Page 264: Crankcase

    Crankcase 5-66 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks air filter case refer to "general chassis" on page 4-1. Throttle body assembly refer to "throttle bodies" on page 7-4. Engine refer to "engine removal" on page 5-2. Cylinder head refer to "cylinder head...

  • Page 265: Crankcase

    Crankcase 5-67 oil pump refer to "oil pump" on page 5-58. Starter motor refer to "electric starter" on page 5-40. 1 timing chain 1 2 timing chain guide (intake side) 1 3 pin 2 4 timing chain guide (exhaust side) 1 5 left side cover 1 6 o-ring 1 7 lower crankcase 1 8 dowel pin 3 9 damper 1 for assemb...

  • Page 266: Crankcase

    Crankcase 5-68 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 267: Crankcase

    Crankcase 5-69 3. Install: • dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: • lower crankcase “1” (onto the upper crankcase “2”) caution: eca13980 before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when th...

  • Page 268: Crankshaft

    Crankshaft 5-70 eas25950 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to "crankcase" on page 5- 66. 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 connectin...

  • Page 269: Crankshaft

    Crankshaft 5-71 removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to "crankcase" on page 5- 66. Connecting rod and connecting rod caps refer to "removing the con- necting rods and pistons" on page 5-72. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 cran...

  • Page 270: Crankshaft

    Crankshaft 5-72 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: • idetify the position of each big end bearing so that it can be reinstalled in its original place...

  • Page 271: Crankshaft

    Crankshaft 5-73 note: identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Et2d1032 checking the cylinder and piston 1. Check: • piston wall • cylinder wall vertical scratches → replace the cylinder, and the piston and piston rings as a ...

  • Page 272: Crankshaft

    Crankshaft 5-74 2. Install: • piston ring (into the cylinder) note: level the piston ring into the cylinder with the piston crown. 5 mm (0.20 in) “a” 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 ...

  • Page 273: Crankshaft

    Crankshaft 5-75 4. Calculate: • piston-pin-to-position clearance out of specification → replace the position pin and piston as a set. Et2d1017 checking the big end bearings 1. Measure: • crankshaft-pin-to-big-end-bearing crear- ance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 274: Crankshaft

    Crankshaft 5-76 e. Tighten the connecting rod bolts. Note: install by carrying out the following procedures in order to assemble in the most suitable con- dition. Note: • first, tighten the bolts to 15 nm (1.5 m·kg, 11 ft·lb). • retighten the bolts to 29.4 nm (3.0 m·kg, 21 ft·lb). F. Replace the con...

  • Page 275: Crankshaft

    Crankshaft 5-77 p. After the installation, check that the section shown “a” is flush with each other by touch- ing the surface. • side machined face “a” warning ewa13120 • 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 276: Crankshaft

    Crankshaft 5-78 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 277: Crankshaft

    Crankshaft 5-79 8. Install: • big end bearings (onto the connecting rods and connecting rod caps) note: • align the projections “a” on the big end bear- ings with the notches “b” in the connecting rods and connecting rod caps. • be sure to reinstall each big end bearing in its original place. • make...

  • Page 278: Crankshaft

    Crankshaft 5-80 11. Install: • cylinder assembly “1” • connecting rod caps “2” note: • make sure that the “y” marks “a” on the con- necting rods face towards the left side of the crankshaft. • make sure that the characters on both the connecting rod and connecting rod cap are aligned. 12. Tighten: •...

  • Page 279: Crankshaft

    Crankshaft 5-81 • if they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step “9”. In this case, make sure to replace the con- necting rod bolt. Caution: eca14680 • do not use a torque wrench to tighten the bolt to the specified angle. • tighten th...

  • Page 280: Crankshaft

    Crankshaft 5-82 d. Put a piece of plastigauge® “2” on each crankshaft journal. Note: do not put the plastigauge® over the oil hole in the crankshaft journal. E. Install the crankshaft journal lower bear- ings “1” into the lower crankcase and assemble the crankcase halves. Note: • align the projectio...

  • Page 281: Crankshaft

    Crankshaft 5-83 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • crankshaft journal bearings (j1–j5) note: • the numbers “a” stamped into the crank- shaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “j1–j5” refer to th...

  • Page 282: Crankshaft

    Crankshaft 5-84 note: • align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • be sure to install each crankshaft journal upper bearing in its original place. 3. Install: • crankshaft 4. Install: • crankcase (lower) refer to "crankcase" on p...

  • Page 283: Transmission

    Transmission 5-85 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks crankcase lower separate. Refer to "crankcase" on page 5- 66. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 bearing 1 5 washer 1 6 shift fork guide bar ...

  • Page 284: Transmission

    Transmission 5-86 14 main axle assembly 1 15 oil pipe 1 16 o-ring 2 17 oil baffle plate 1 for installation, reverse the removal procedure. Removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks.

  • Page 285: Transmission

    Transmission 5-87 disassembling the main axle assenbly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion gear 1 5 collar 1 6 washer 1 7 circlip 1 8 3rd pinion gear 1 9 circlip 1 10 washer 1 11 5th pinion gear 1 12 collar ...

  • Page 286: Transmission

    Transmission 5-88 disassembling the drive axle assenbly 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 3rd wheel gear 1 8 collar 1 9 toothed lock washer 1 10 toothed lock washer retainer 1 11 4th wheel gear 1 12 collar 1 13...

  • Page 287: Transmission

    Transmission 5-89 21 oil seal 1 22 bearing 1 23 drive axle 1 for assembly, reverse the disassem- bly procedure. Disassembling the drive axle assenbly order job/parts to remove q’ty remarks.

  • Page 288: Transmission

    Transmission 5-90 eas26250 removing the transmission 1. Remove: • drive axle asseembly “1” • shift drum retainers “2” • shift fork guide bars • shift fork “l” and “r” • shift drum assembly • shift fork “c” 2. Remove: • bearing housing “1” • main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. In...

  • Page 289: Transmission

    Transmission 5-91 3. Check: • shift fork movement (along the shift fork guide bar) rough movement → replace the shift forks and shift fork guide bar as a set. Eas26270 checking the shift drum assembly 1. Check: • shift drum grooves “1” damage/scratches/wear → replace the shift drum assembly. • shift...

  • Page 290: Transmission

    Transmission 5-92 et2d1022 installing the transmission 1. Install: • bearing “1” note: make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. • oil pipe “2” 2. Install: • main axle assembly “1” • bearing housing “2” • shift fork “c” • shift d...

  • Page 291: Transmission

    Transmission 5-93 4. Check: • transmission rough movement → repair. Note: oil each gear, shaft, and bearing thoroughly..

  • Page 292: Cooling System

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

  • Page 293: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. Coolant drain. Refer to "changing the cool-...

  • Page 294: Radiator

    Radiator 6-2 10 water pump inlet pipe 1 11 o-ring 1 for installation, reverse the removal procedure. Removing the radiator order job/parts to remove q’ty remarks.

  • Page 295: 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 296: Oil Cooler

    Oil cooler 6-4 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks engine oil drain. Refer to "changing the engine oil" on page 3-12. 1 oil cooler inlet hose 1 2 oil cooler bolt 1 3 washer 1 4 oil cooler 1 5 o-ring 1 6 water pump outlet pipe 1 7 o-ring 1 8 water jacket...

  • Page 297: 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 298: Thermostat

    Thermostat 6-6 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. Coolant drain. Refer to "cha...

  • Page 299: Thermostat

    Thermostat 6-7 disassembling the thermostat assembly order job/parts to remove q’ty remarks 1 thermostat housing cover 1 2 thermostat 1 3 thermostat housing 1 4 o-ring 1 for assembly, reverse the disassem- bly procedure..

  • Page 300: Thermostat

    Thermostat 6-8 eas26450 checking the thermostat 1. Check: • thermostat 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 301: Thermostat

    Thermostat 6-9 below the specified pressure → replace the radiator cap. Refer to "checking the radiator" on page 6-3..

  • Page 302: Water Pump

    Water pump 6-10 eas26500 water pump removing the impeller shaft order job/parts to remove q’ty remarks oil/water pump assembly refer to "oil pump" on page 5-58. Oil pump roter refer to "oil pump" on page 5-58. 1 water pump cover 1 2 o-ring 1 3 pin 2 4 impeller shaft (along with the impeller) 1 5 wat...

  • Page 303: Water Pump

    Water pump 6-11 eas26520 disassembling the water pump 1. Remove: • water pump seal “1” • water pump housing “2” note: tap out the water pump seal from the inside of the water pump housing. 2. Remove: • oil seal “1” • bearing “2” • water pump housing “3” note: tap out the bearing and oil seal from th...

  • Page 304: Water Pump

    Water pump 6-12 2. Install: • water pump seal “1” caution: eca14080 never lubricate the water pump seal sur- face with oil or grease. Note: • install the water pump seal with the special tools. • before installing the water pump seal, apply yamaha bond no.1215 (three bond no.1215® ) “2” to the water...

  • Page 305: Water Pump

    Water pump 6-13.

  • Page 306: Fuel System

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

  • Page 307: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. 1 fuel hose 1 disconnect. 2 fuel sender coupler 1 disconnect. 3 fuel pump coupler 1 disconnect. 4 fuel tank drain hose 1 disconnect. 5 fuel ...

  • Page 308: 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 hose connector cover • fuel hose • fuel sender coupler • fuel pump coupler • fuel tank breather hose • fuel tank drain hose caution: ec2d1009 • be sure to disco...

  • Page 309: Fuel Tank

    Fuel tank 7-3 et2d1023 installing the fuel tank 1. Install: • fuel hose • fuel hose connector cover caution: eca14740 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 ins...

  • Page 310: Throttle Bodies

    Throttle bodies 7-4 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks rider and passenger seat refer to "general chassis" on page 4-1. Fuel tank refer to "fuel tank" on page 7-1. Air filter case refer to "general chassis" on page 4-1. 1 sub-wire harness cou...

  • Page 311: Throttle Bodies

    Throttle bodies 7-5 for installation, reverse the removal procedure. Removing the throttle bodies order job/parts to remove q’ty remarks.

  • Page 312: Throttle Bodies

    Throttle bodies 7-6 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor coupler 1 disconnect. 2 sub-throttle position sensor coupler 1 disconnect. 3 sub-throttle motor assembly coupler 1 disconnect. 4 intake air pressure sensor coupler 1 disconnect. 5 cylinder #1...

  • Page 313: Throttle Bodies

    Throttle bodies 7-7 19 washer 2 20 link 1 21 sub-throttle servo motor assembly 1 22 throttle position sensor 1 23 throttle body assembly 1 for installation, reverse the removal procedure. Removing the injectors order job/parts to remove q’ty remarks.

  • Page 314: Throttle Bodies

    Throttle bodies 7-8 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 315: Throttle Bodies

    Throttle bodies 7-9 1. Check: • throttle position sensor refer to "checking the throttle position sensor" on page 8-109. 2. Adjust: • throttle position sensor angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the throttle position sensor cou- pler to the wire harness. B. Connect the digital circuit te...

  • Page 316: Throttle Bodies

    Throttle bodies 7-10 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: • primary opening ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. After performing the full open angle of the sub-throttle position sensor, turn the nut of the worm shaft clockwise, measure the dimension of “b” section with a micrometer caliper or oth...

  • Page 317: Throttle Bodies

    Throttle bodies 7-11 out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check whether or not the sub-throttle valve is seized. 1 turn the nut of worm shaft of the sub-throt- tle servo motor by hand to check that the sub-throttle valve is moved smoothly by hand. 2 if it is not moved sm...

  • Page 318: Throttle Bodies

    Throttle bodies 7-12 it shorter when the coolant temperature is high.) • in case of turning the adjusting bolt two-third turn, the temperature varies about 10 °c (50 °f)..

  • Page 319: Air Induction System

    Air induction system 7-13 eas27040 air induction system removing the air cut-off valve assembly and hoses order job/parts to remove q’ty remarks 1 air cut-off valve coupler 1 disconnect. 2 air cut-off valve hose 1 1 disconnect. 3 air cut-off valve hose 2 1 disconnect. 4 air cut-off valve hose 3 1 di...

  • Page 320: Air Induction System

    Air induction system 7-14 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 321: Air Induction System

    Air induction system 7-15 out of specification → replace the reed valve. 4. Check: • air cut-off valve cracks/damage → replace. 5. Check • air induction system solenoid ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air induction system solenoid coupler from the wire harness. B. Connect the pocket tes...

  • Page 322: Electrical System

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

  • Page 323

    Electrical components................................................................... 8-89 checking the switches............................................................... 8-93 checking the bulbs and bulb sockets................................. 8-96 checking the fuses...........................

  • Page 325: Ignition System

    Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram.

  • Page 326: Ignition System

    Ignition system 8-2 1. Main switch 6. Fuse (main) 7. Battery 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 17.Crankshaft position sensor 21.Lean angle sensor 23.Ecu 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Ignition coil #4 28.Spark plug 5...

  • Page 327: Ignition System

    Ignition system 8-3 eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ng ↓ ng → ok ↓ ng → ok ↓ 1 check the f...

  • Page 328: 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 8-93. Replace the right handlebar switch. 9 check the neutral switch. Refer to "checking the switches" on page 8-93. Replace the neutral ...

  • Page 329: Electric Starting System

    Electric starting system 8-5 eas27160 electric starting system eas27170 circuit diagram.

  • Page 330: Electric Starting System

    Electric starting system 8-6 1. Main switch 6. Fuse (main) 7. Battery 9. Starter relay 10.Starter motor 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 56.Engine stop switch 57.Start switch 60.Clutch switch 78.Fuse (ignition).

  • Page 331: Electric Starting System

    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 332: Electric Starting System

    Electric starting system 8-8 a. When the transmission is in neu- tral b. When the sidestand is up and the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Starting circuit cut-off relay 7. Diode 8. Clutch switch 9. Sidestand swi...

  • Page 333: Electric Starting System

    Electric starting system 8-9 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuses. (main...

  • Page 334: Electric Starting System

    Electric starting system 8-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8 check the main switch. Refer to "checking the switches" on page 8-93. Replace the immobilizer kit. 9 check the engine stop switch. Refer to "checking the switches" on page 8-93. Replace the right ha...

  • Page 335: Charging System

    Charging system 8-11 eas27200 charging system eas27210 circuit diagram.

  • Page 336: Charging System

    Charging system 8-12 2. Rectifier/regulator 3. A.C.Magneto 6. Fuse (main) 7. Battery.

  • Page 337: Charging System

    Charging system 8-13 eas27230 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuse. (main) refer to "checking the fuses" on page 8-97. Replace the ...

  • Page 338: Charging System

    Charging system 8-14.

  • Page 339: Lighting System

    Lighting system 8-15 eas27240 lighting system eas27250 circuit diagram (fz1-n).

  • Page 340: Lighting System

    Lighting system 8-16 1. Main switch 6. Fuse (main) 7. Battery 23.Ecu 49.High beam indicator light 52.Meter light 61.Pass switch 62.Dimmer switch 72.Auxiliary light 73.Headlight 74.License plate light 75.Tail/brake light 76.Headlight relay (on/off) 77.Fuse (tail light)) 81.Fuse (headlight).

  • Page 341: Lighting System

    Lighting system 8-17 et2d1026 circuit diagram (fz1-s).

  • Page 342: Lighting System

    Lighting system 8-18 1. Main switch 6. Fuse (main) 7. Battery 23.Ecu 49.High beam indicator light 52.Meter light 61.Pass switch 62.Dimmer switch 72.Auxiliary light 73.Headlight 74.License plate light 75.Tail/brake light 76.Headlight relay (on/off) 77.Headlight relay (dimmer) 78.Fuse (tail light) 82....

  • Page 343: Lighting System

    Lighting system 8-19 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ok ↓ ...

  • Page 344: Lighting System

    Lighting system 8-20 ng → ok ↓ ng → ok ↓ ng → ok ↓ 8 check the headlight relay (on/off). Refer to "checking the relays" on page 8-100. Replace the headlight relay. 9 check the headlight relay (dimmer) (fz1-s). Refer to "checking the relays" on page 8-100. Replace the headlight relay. 10 check the en...

  • Page 345: Signaling System

    Signaling system 8-21 eas27270 signaling system eas27280 circuit diagram.

  • Page 346: Signaling System

    Signaling system 8-22 1. Main switch 6. Fuse (main) 7. Battery 11.Relay unit 14.Neutral switch 16.Fuel pump 19.Speed sensor 23.Ecu 42.Fuel level warning light 43.Oil level warning light 44.Neutral indicator light 45.Tacho meter 46.Multi function meter 48.Coolant temperature indicator light 50.Turn s...

  • Page 347: Signaling System

    Signaling system 8-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ...

  • Page 348: Signaling System

    Signaling system 8-24 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 system’s wiring. Refer to "circuit diagram" on page 8-21. Properly...

  • Page 349: Signaling System

    Signaling system 8-25 ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. 3 check the hazard switch. Refer to "checking the switches" on page 8...

  • Page 350: Signaling System

    Signaling system 8-26 ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 1 check the fuel sender. Refer to "checking the fuel sender" on page 8-107. Replace the fuel pump assembly. 2 check the entire signaling system’s wiring. Refer to "circuit diagram" on page 8-21. Properly ...

  • Page 351: Cooling System

    Cooling system 8-27 eas27300 cooling system eas27310 circuit diagram.

  • Page 352: Cooling System

    Cooling system 8-28 1. Main switch 6. Fuse (main) 7. Battery 23.Ecu 38.Coolant temperature sensor 78.Fuse (ignition) 82.Radiator fan motor relay 83.Fuse (radiator fan motor left) 84.Fuse (radiator fan motor right) 85.Radiator fan motor (left) 86.Radiator fan motor (right).

  • Page 353: Cooling System

    Cooling system 8-29 eas27320 troubleshooting note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuses. (main, ignition and radiator fan motor) refer t...

  • Page 354: Cooling System

    Cooling system 8-30

  • Page 355: Fuel Injection System

    Fuel injection system 8-31 eas27330 fuel injection system eas27340 circuit diagram.

  • Page 356: Fuel Injection System

    Fuel injection system 8-32 1. Main switch 4. Fuse (backup) 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Sidestand switch 16.Fuel pump 17.Crankshaft position sensor 18.Cylinder identification sensor 19.Speed...

  • Page 357: Fuel Injection System

    Fuel injection system 8-33 eas27370 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ...

  • Page 358: Fuel Injection System

    Fuel injection system 8-34 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8 check the main switch. Refer to "checking the switches" on page 8-93. Replace the immobilizer kit. 9 check the engine stop switch. Refer to "checking the switches" on page 8-93. Rep...

  • Page 359: Fuel Injection System

    Fuel injection system 8-35 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 17 checking the aomospheric pres- sure sensor. Refer to "checking the atmo- spheric pressure sensor" on page 8-111. Replace the atomospheric pressure sensor. 18 check the injector. Refer to "checking the...

  • Page 360: Fuel Injection System

    Fuel injection system 8-36 ng → ok ↓ 24 check the entire ignition system’s wiring. Refer to "circuit diagram" on page 8-1. Properly connect or repair the ignition system’s wiring replace the ecu..

  • Page 361: Fuel Injection System

    Fuel injection system 8-37 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 362: Fuel Injection System

    Fuel injection system 8-38 et2d1027 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for th...

  • Page 363: Fuel Injection System

    Fuel injection system 8-39 21 coolant temperature sensor (open or short circuit) coolant temperature sensor: open or short circuit detected. Able able 22 intake air temperature sensor (open or short circuit) intake air temperature sensor: open or short circuit detected. Able able 23 atmospheric pres...

  • Page 364: Fuel Injection System

    Fuel injection system 8-40 communication error with the meter 39 injector (open circuit) injector: open circuit detected. Able (depend- ing on the num- ber of faulty cylin- ders) able (depend- ing on the num- ber of faulty cylin- ders) 41 lean angle sensor (open or short-circuit) lean angle sensor: ...

  • Page 365: Fuel Injection System

    Fuel injection system 8-41 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 faulty system with the faul...

  • Page 366: Fuel Injection System

    Fuel injection system 8-42 if a malfunction is detected in the sensors or actuators, repair or replace all faulty parts. If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine. Eas27420 diagnostic mode setting the diagnostic mode 1. Turn the main switc...

  • Page 367: Fuel Injection System

    Fuel injection system 8-43 the data representing the operating conditions of the sensor appears on the odometer/tripme- ter/fuel reserve tripmeter lcd. • actuator operation set the engine stop switch to “ ” to operate the actuator. Note: if the engine stop switch is set to “ ”, set it to “ ”, and th...

  • Page 368: Fuel Injection System

    Fuel injection system 8-44 20 when the main switch is turned to “on”, the atmo- spheric pressure sensor voltage and intake air pres- sure sensor voltage differ greatly. • atmospheric pressure sensor hose is clogged. • intake air pressure sensor hose is clogged, kinked, or pinched. • malfunction of t...

  • Page 369: Fuel Injection System

    Fuel injection system 8-45 36 open circuit detected in the primary lead of the cylinder- #4 ignition coil. • open or short circuit in wire harness. • malfunction in ignition coil. • malfunction in a component of ignition cut- off circuit system. • malfunction in ecu. 33 39 open circuit detected in a...

  • Page 370: Fuel Injection System

    Fuel injection system 8-46 sensor operation table er-2 no signals are received from the ecu within the specified duration. • improper connection in wire harness. • malfunction in meter. • malfunction in ecu. — er-3 data from the ecu cannot be received correctly. • improper connection in wire harness...

  • Page 371: Fuel Injection System

    Fuel injection system 8-47 09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ” and then compare with the actually measured battery voltage. (if the bat- tery voltage is lower, recharge the battery.) 20 sidestand switch set on/off the sidestand switch (with t...

  • Page 372: Fuel Injection System

    Fuel injection system 8-48 actuator operation table 63 malfunction code reinstate • no mulfunction code 00 — • malfunction code exists fault code 24 • (if more than one code number is detected, the dis- play changes every two seconds to show all the detected code numbers. When all code numbers are s...

  • Page 373: Fuel Injection System

    Fuel injection system 8-49 38 injector #3 actuates the injector #3 five times at one-second inter- vals. Illuminates the engine trou- ble warning light. Check the operating sound of the injector #3 five times. 39 injector #4 actuates the injector #4 five times at one-second inter- vals. Illuminates ...

  • Page 374: Fuel Injection System

    Fuel injection system 8-50 eas27460 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 375: Fuel Injection System

    Fuel injection system 8-51 fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — orde r item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft posi- tion sensor check for l...

  • Page 376: Fuel Injection System

    Fuel injection system 8-52 fault code no. 13 symptom intake air pressure sensor:open or short circuit detected. Diagnostic code no. 03 intake air pressure sensor orde r item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor coupler...

  • Page 377: Fuel Injection System

    Fuel injection system 8-53 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 reinstatement method 1 installed condition of throttle position sensor. • ch...

  • Page 378: Fuel Injection System

    Fuel injection system 8-54 fault code no. 16 symptom stuck throttle position sensor detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. • check the installe...

  • Page 379: Fuel Injection System

    Fuel injection system 8-55 fault code no. 18 symptom exup servo motor is stuck. Diagnostic code no. 53 exup servo motor order item/components and probable cause check or maintenance job reinstatement method 1 connections • exup servo motor coupler • main wire harness ecu coupler • check the couplers...

  • Page 380: Fuel Injection System

    Fuel injection system 8-56 fault code no. 20 symptom when the main switch is turned to “on”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Diagnostic code no. 02 03 atmospheric pressure sensor intake air pressure sensor orde r item/components and prob...

  • Page 381: Fuel Injection System

    Fuel injection system 8-57 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 reinstatement method 1 connections • intake air temperature sensor...

  • Page 382: Fuel Injection System

    Fuel injection system 8-58 fault code no. 23 symptom atmospheric pressure sensor:open or short circuit detected. Diagnostic code no. 02 atmospheric pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • atmospheric pressure sensor cou- ...

  • Page 383: Fuel Injection System

    Fuel injection system 8-59 fault code no. 24 symptom no normal signal is received from the o 2 sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed state of o 2 sensor. Check for looseness or pinching. Start and warm up th...

  • Page 384: Fuel Injection System

    Fuel injection system 8-60 fault code no. 33 symptom open circuit detected in the primary lead of the cylinder- #1 ignition coil. Diagnostic code no. 30 cylinder-#1 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#1 igniti...

  • Page 385: Fuel Injection System

    Fuel injection system 8-61 fault code no. 34 symptom open circuit detected in the primary lead of the cylinder- #2 ignition coil diagnostic code no. 31 cylinder-#2 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#2 ignitio...

  • Page 386: Fuel Injection System

    Fuel injection system 8-62 fault code no. 35 symptom open circuit detected in the primary lead of the cylinder- #3 ignition coil diagnostic code no. 32 cylinder-#3 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#3 ignitio...

  • Page 387: Fuel Injection System

    Fuel injection system 8-63 fault code no. 36 symptom open circuit detected in the primary lead of the cylinder- #4 ignition coil diagnostic code no. 33 cylinder-#4 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder-#4 ignitio...

  • Page 388: Fuel Injection System

    Fuel injection system 8-64 fault code no. 39 symptom open circuit detected in a injector. Diagnostic code no. 36 37 38 39 injector #1 injector #2 injector #3 injector #4 order item/components and probable cause check or maintenance job reinstatement method 1 connections • injector coupler • main wir...

  • Page 389: Fuel Injection System

    Fuel injection system 8-65 fault code no. 41 symptom lean angle sensor:open or short circuit detected. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • main wire harness ecu cou...

  • Page 390: Fuel Injection System

    Fuel injection system 8-66 fault code no. 42 symptom a. No normal signals are received from the speed sen- sor. B. Open 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 maintenance job reinstatement...

  • Page 391: Fuel Injection System

    Fuel injection system 8-67 b-1 installed state of neutral switch. • check for looseness or pinch- ing. Starting the engine, and activating the speed sensor by operating the vehicle at 20 to 30 km/h. B-2 connections • neutral switch coupler • main wire harness ecu coupler • check the couplers for any...

  • Page 392: Fuel Injection System

    Fuel injection system 8-68 fault code no. 43 symptom power supply to the injectors and fuel pump is not nor- mal. Diagnostic code no. 09 fuel system voltage (battery voltage) order item/components and probable cause check or maintenance job reinstatement method 1 connections • relay unit coupler (fu...

  • Page 393: Fuel Injection System

    Fuel injection system 8-69 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. Orde r item/components and probable cause check or maintenance job reinstatement method 1 malfunction in ecu • set the ...

  • Page 394: Fuel Injection System

    Fuel injection system 8-70 fault code no. 46 symptom power supply to the fuel injection system relay is not nor- mal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections. • main wire harness ecu coupler • check the coupler for ...

  • Page 395: Fuel Injection System

    Fuel injection system 8-71 fault code no. 47 symptom sub-throttle position sensor:open or short circuit detected. Diagnostic monitor- ing code no. 56 sub-throttle servo motor order item/components and probable cause check or maintenance job reinstatement method 1 installed state of sub-throttle posi...

  • Page 396: Fuel Injection System

    Fuel injection system 8-72 fault code no. 48 symptom sub-throttle servo motor:stuck. Diagnostic code no. 56 sub-throttle servo motor order item/components and probable cause check or maintenance job reinstatement method 1 connections • sub-throttle servo motor coupler • main wire harness ecu coupler...

  • Page 397: Fuel Injection System

    Fuel injection system 8-73 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 reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly coupler • sub-w...

  • Page 398: Fuel Injection System

    Fuel injection system 8-74 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 reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly coupl...

  • Page 399: Fuel Pump System

    Fuel pump system 8-75 eas27550 fuel pump system eas27560 circuit diagram.

  • Page 400: Fuel Pump System

    Fuel pump system 8-76 1. Main switch 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 13.Fuel pump relay 16.Fuel pump 23.Ecu 46.Multi function meter 56.Engine stop switch 78.Fuse (ignition).

  • Page 401: Fuel Pump System

    Fuel pump system 8-77 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1 rider and passenger seat 2 fuel tank 3 air filter case ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1 check the fuses. (main, ign...

  • Page 402: Fuel Pump System

    Fuel pump system 8-78.

  • Page 403: Immobilizer System

    Immobilizer system 8-79 eas27640 immobilizer system eas27650 circuit diagram.

  • Page 404: Immobilizer System

    Immobilizer system 8-80 1. Main switch 4. Fuse (backup) 5. Immobilizer unit 6. Fuse (main) 7. Battery 23.Ecu 41.Immobilizer indicator 46.Multi function meter 78.Fuse (ignition).

  • Page 405: Immobilizer System

    Immobilizer system 8-81 eas27670 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following. • a code re-registering key (with a red bow) • two standard keys (with a black bow) that...

  • Page 406: Immobilizer System

    Immobilizer system 8-82 * accessory locks mean the seat lock, fuel tank cap or the helmet holder. 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 sw...

  • Page 407: Immobilizer System

    Immobilizer system 8-83 standby mode standard key registration: standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ecu are replaced. Note: do not start the engine with a standa...

  • Page 408: Immobilizer System

    Immobilizer system 8-84 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 409: Immobilizer System

    Immobilizer system 8-85 eas27700 troubleshooting when the main switch is turn “on”, the indicator light does not come on or flashing. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ eas27720 self-diagnosis fault code indication when the system failure occurred, the error code number is indicated in the immo...

  • Page 410: Immobilizer System

    Immobilizer system 8-86 immobilizer system indicator light error 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. 52 immobilizer unit codes do not match between the key and immobilizer unit. 1 disturbed by other transponder. Fai...

  • Page 411: Immobilizer System

    Immobilizer system 8-87 a. Light on b. Light off.

  • Page 412: Immobilizer System

    Immobilizer system 8-88.

  • Page 413: Electrical Components

    Electrical components 8-89 eas27970 electrical components.

  • Page 414: Electrical Components

    Electrical components 8-90 1. Main switch (immobilizer unit) 2. Front brake light switch 3. Starter relay 4. Battery 5. Fuse box 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Radiator fan motor 11.Horn 12.Ignition coil.

  • Page 415: Electrical Components

    Electrical components 8-91.

  • Page 416: Electrical Components

    Electrical components 8-92 1. Coolant temperature sensor 2. Intake air temperature sensor 3. Intake air pressure sensor 4. Fuel pump 5. Ecu 6. Lean angle sensor 7. Starting circuit cut-off relay 8. Headlight relay (on/off) 9. Radiator fan motor relay 10.Turn signal relay 11.Recifier/regulator 12.Thr...

  • Page 417: Electrical Components

    Electrical components 8-93 eas27980 checking the switches.

  • Page 418: Electrical Components

    Electrical components 8-94 1. Main switch 2. Horn switch 3. Dimmer switch 4. Pass switch 5. Turn signal switch 6. Hazard switch 7. Clutch switch 8. Sidestand switch 9. Engine stop switch 10.Front brake light switch 11.Start switch 12.Oil level switch 13.Neutral switch 14.Rear brake light switch 15.F...

  • Page 419: Electrical Components

    Electrical components 8-95 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 “1”. Always insert the probe...

  • Page 420: Electrical Components

    Electrical components 8-96 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. N...

  • Page 421: Electrical Components

    Electrical components 8-97 the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in the bulb section; however, note the followi...

  • Page 422: Electrical Components

    Electrical components 8-98 • keep batteries away from fire, sparks or open flames (e.G., welding equipment, lighted cigarettes). • do not smoke when charging or han- dling batteries. • keep batteries and electrolyte out of reach of children. • avoid bodily contact with electrolyte as it can cause se...

  • Page 423: Electrical Components

    Electrical components 8-99 into the battery quickly and can cause battery overheating and battery plate damage. • if it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. • when charging a battery, be sure to remove it from the vehicle. (...

  • Page 424: Electrical Components

    Electrical components 8-100 note: if the current is lower than the standard charg- ing current written on the battery, this type of battery charger cannot charge the mf battery. A variable voltage charger is recommended. D. Charge the battery until the battery’s charg- ing voltage is 15 v. Note: set...

  • Page 425: Electrical Components

    Electrical components 8-101 relay unit (fuel pump relay) fz1-n fz1-s headlight relay (on/off) (fz1-n) headlight relay (on/off) (fz1-s) headlight relay (dimmer) (fz1-s) radiator fan motor relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity/no continu...

  • Page 426: Electrical Components

    Electrical components 8-102 et2d1030 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. Con...

  • Page 427: Electrical Components

    Electrical components 8-103 note: the pocket tester and the analog pocket tester readings are shown in the following table. Fz1-n fz1-s ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω×1) to the relay unit terminal as shown. ...

  • Page 428: Electrical Components

    Electrical components 8-104 c. Measure the primary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • secondary coil resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the ignition coil leads from the wire harness. B. Connect the pocket tester ( Ω × 1k) ...

  • Page 429: Electrical Components

    Electrical components 8-105 a. Connect the pocket tester ( Ω × 100) to the crankshaft position sensor coupler as shown. B. Measure the crankshaft position sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28130 checking the lean angle sensor 1. Remove: • lean angle sensor 2. Check: • lean angle s...

  • Page 430: Electrical Components

    Electrical components 8-106 out of specification → replace the startor coil. Eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the startor coil. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect th...

  • Page 431: Electrical Components

    Electrical components 8-107 c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • horn sound faulty sound → adjust or replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a battery (12 v) to the horn. B. Turn the adjusting screw in direction “a” or “b” until the specified horn sou...

  • Page 432: Electrical Components

    Electrical components 8-108 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 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 433: Electrical Components

    Electrical components 8-109 d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. E. Check the coolant temperature sensor for continuity at the temperatures indicated in the table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28300 checking the throttle position ...

  • Page 434: Electrical Components

    Electrical components 8-110 note: when installing the throttle position sensor, adjust its angle properly. Refer to "adjust- ing the throttle position sensor" on page 7-8. Eas2d1010 checking the sub-throttle position sensor 1. Remove: • sub-throttle position sensor (from the throttle body) 2. Check:...

  • Page 435: Electrical Components

    Electrical components 8-111 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the air induction system solenoid coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the air induction system solenoid terminal as shown. C. Measure the air induction system solenoid resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 436: Electrical Components

    Electrical components 8-112 b. Set the main switch to “on”. C. Rotate the crankshaft. D. Measure the voltage (dc 20 v) of white/ black and black/blue. With each full rota- tion of the crankshaft, the voltage reading should cycle from 0.8 v to 4.8 v to 0.8 v to 4.8 v. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e...

  • Page 437: Electrical Components

    Electrical components 8-113.

  • Page 438: Troubleshooting

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

  • Page 439: 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 440: 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 441: 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 442: Troubleshooting

    Troubleshooting 9-4 • 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 wheel runout 8. Frame • bent frame • damaged steering head pipe • impro...

  • Page 443: Wiring Diagram

    Eas28740 wiring diagram fz1-n (v) 2006 1. Main switch 2. Rectifier/regulator 3. A.C.Magneto 4. Fuse (backup) 5. Immobilizer unit 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 9. Starter relay 10. Starter motor 11. Relay unit 12. Starting circuit cut-off relay 13. Fuel pump relay 14. Neutral swi...

  • Page 444

    Fz1-s (v) 2006 1. Main switch 2. Rectifier/regulator 3. A.C.Magneto 4. Fuse (backup) 5. Immobilizer unit 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 9. Starter relay 10. Starter motor 11. Relay unit 12. Starting circuit cut-off relay 13. Fuel pump relay 14. Neutral switch 15. Sidestand switch...

  • Page 445

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

  • Page 446: Fz1-N (V) 2006

    Fz1-n (v) 2006 wiring diagram fz1-n (v) 2006 schema de cablage fz1-n (v) 2006 schaltplan fz1-n (v) 2006 schema elettrico diagrama de conexiones de fz1-n (v) 2006.

  • Page 447: Fz1-S (V) 2006

    Fz1-s (v) 2006 wiring diagram fz1-s (v) 2006 schema de cablage fz1-s (v) 2006 schaltplan fz1-s (v) 2006 schema elettrico diagrama de conexiones de fz1-s (v) 2006.

  • Page 448: Fz1-N (V) 2006

    Dg b dg b a b c off run free push dg ch on off p wire harness sub-wire harness 2 wire harness sub-wire harness 1 wire harness headlight sub-wire harness off on off on l n r off on hi lo 5 4 1 2 3 75 76 77 78 79 80 81 83 84 82 74 56 57 85 6 7 8 9 10 52 53 54 55 73 72 70 70 71 58 59 60 61 65 11 12 13 ...

  • Page 449: Fz1-S (V) 2006

    B c d a b b y hi lo off on off on on off p r n l on off wire harness sub-wire harness 2 wire harness headlight sub-wire harness 2 wire harness headlight sub-wire harness 1 wire harness sub-wire harness 1 b off run free push b b b 5 4 1 2 3 76 77 78 79 80 81 82 84 85 83 74 75 56 57 86 6 7 8 9 10 52 5...

  • Page 450: Fz1-N (V) 2006

    Fz1-n (v) 2006 wiring diagram fz1-n (v) 2006 schema de cablage fz1-n (v) 2006 schaltplan fz1-n (v) 2006 schema elettrico diagrama de conexiones de fz1-n (v) 2006.

  • Page 451: Fz1-S (V) 2006

    B c d a b b y hi lo off on off on on off p r n l on off wire harness sub-wire harness 2 wire harness headlight sub-wire harness 2 wire harness headlight sub-wire harness 1 wire harness sub-wire harness 1 b off run free push b b b fz1-s (v) 2006 wiring diagram fz1-s (v) 2006 schema de cablage fz1-s (...