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Yamaha FAZER FZ1-S Service Manual

Manual is about: 2008 Motorcycle

Summary of FAZER FZ1-S

  • Page 1

    Service manual fz1-n(x) fz1-s(x) fz1-sa fz1-na 2008 5d0-28197-e1.

  • Page 2

    Eas20040 fz1-n(x)/fz1-s(x)/fz1-sa/fz1-na service manual ©2008 by yamaha motor co., ltd. First edition, december 2007 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: 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 eas5d01032 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburet...

  • Page 12: Features

    Features 1-3 eas5d01013 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm 2 , 46.1 psi). Accordingly, when the energizing signal from the ecu energizes th...

  • Page 13: Features

    Features 1-4 eas5d01014 instrument functions multi-function meter unit warning ewa5d01011 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a speedometer (which shows the riding speed) • a t...

  • Page 14: Features

    Features 1-5 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. Odometer and tri...

  • Page 15: Features

    Features 1-6 caution: eca5d01023 do not operate the engine if it is over- heated. 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 ...

  • Page 16: Features

    Features 1-7 this function allows you to adjust the bright- ness of the lcd and the tachometer panel and needle to suit the outside lighting conditions. To set the brightness 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...

  • Page 17: Features

    Features 1-8 useful terms • wheel speed: the rotation speed of the front and rear wheels. • chassis speed: the speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • b...

  • Page 18: Features

    Features 1-9 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed v...

  • Page 19: Features

    Features 1-10 abs operation and vehicle control if the abs starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the abs has been designed to gener- ate a reaction-force pulsating action in the brak...

  • Page 20: Features

    Features 1-11 abs block diagram eas5d01002 abs component functions wheel sensors and wheel sensor rotors wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the abs ecu. Each wheel sensor is composed of a permanent magnet and a hall ic. The wheel sensors are i...

  • Page 21: Features

    Features 1-12 abs warning light the abs warning light “1” comes on to warn the rider if a malfunction in the abs occurs. When the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off, so that the rider can check if the abs warning light is disconnected and check...

  • Page 22: Features

    Features 1-13 • hydraulic control valve the hydraulic control valve is composed of a flow control valve and solenoid valve. When the abs is activated, the flow control valve regulates the flow of brake fluid to the brake and the solenoid valve decreases and increases the brake fluid pressure. 1. Whe...

  • Page 23: Features

    Features 1-14 • buffer chamber the buffer chamber accumulates the brake fluid that is depressurized while the abs is operating. Abs ecu (electronic control unit) the abs ecu “1” controls the abs and is installed inside the right cowling. To protect the abs ecu from water damage, it is protected by a...

  • Page 24: Features

    Features 1-15 as shown in the block following diagram, the abs ecu receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic un...

  • Page 25: Features

    Features 1-16 abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis these operations are performed once every 8/1000th of a second. When a failure is detected in the abs, a malfunction code is stored in ...

  • Page 26: Features

    Features 1-17 composition and operation the abs motor relay is activated by signals transmitted from the abs ecu and operates simulta- neously when the abs starts to reduce the hydraulic pressure of the brake fluid. If the solenoid relay is turned off, the abs motor relay is also deactivated and the...

  • Page 27: Features

    Features 1-18 1. Brake master cylinder 2. Brake light switch 3. Abs motor 4. Hydraulic pump 5. Buffer chamber 6. Flow control valve 7. Port a 8. Spool 9. Port b 10.Orifice 11.Port d 12.Solenoid valve 13.Port c 14.Brake caliper 15.Abs ecu 16.Abs warning light 17.Brake fluid pressure 18.Time 19.Repres...

  • Page 28: Features

    Features 1-19 emergency braking (abs activated) 1. Depressurized state when the front wheel is about to lockup, port d “11” of the solenoid valve is opened by the “depressurization” signal transmitted from the abs ecu. When this occurs, the spool of the flow control valve compresses the return sprin...

  • Page 29: Features

    Features 1-20 2. Pressurized state port d “11” is closed by the “pressurization” signal transmitted from the abs ecu. Before this occurs, the spool of the flow control valve has compressed the return spring and closed port b “9”. Brake fluid that has entered through port a “7” is further restricted ...

  • Page 30: Features

    Features 1-21 eas5d01004 abs self-diagnosis function abs warning light the abs warning light “1” comes on when a malfunction is detected by the abs self-diagnosis. It is located in the meter assembly. 1. Brake master cylinder 2. Brake light switch 3. Abs motor 4. Hydraulic pump 5. Buffer chamber 6. ...

  • Page 31: Features

    Features 1-22 instances when the abs warning light comes on 1. The abs warning light comes on when the main switch is turned to “on”. The abs warning light comes on for 2 seconds while the abs is performing a self-diagnosis, then goes off if there are no problems. 2. The abs warning light comes on w...

  • Page 32: Features

    Features 1-23 4. The abs warning light “1” flashes and a malfunction code “2” is indicated on the multi-function display when the test coupler adapter “3” is connected to the abs test coupler “4” for trouble- shooting the abs. The abs test coupler can be accessed by removing the left inner panel (fr...

  • Page 33: Features

    Features 1-24 • diagnosis indication the place where the abs diagnosis code is displayed is also used for the indication of the fi diag- nosis code, odometer, trip meter and fuel trip. As the priority level of indication, the diagnosis code for fi is the first and the diagnosis code for abs is the s...

  • Page 34: Features

    Features 1-25 abs function • a brake system in which the hydraulic control has been performed by the abs alerts a rider that the wheels had a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the abs is activated, the grip between the road surfa...

  • Page 35: Important Information

    Important information 1-26 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 1-29. 3. When disasse...

  • Page 36: Important Information

    Important information 1-27 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 37: Checking The Connections

    Checking the connections 1-28 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 38: Special Tools

    Special tools 1-29 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 39: Special Tools

    Special tools 1-30 oil filter wrench 90890-01426 yu-38411 3-13 rod holder 90890-01434 damper rod holder double ended ym-01434 4-64, 4-69 rod puller 90890-01437 universal damping rod bleeding tool set ym-a8703 4-67 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a87...

  • Page 40: Special Tools

    Special tools 1-31 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 valve spring compressor adapter ym-04114 5-23, 5-29 middle driven shaft...

  • Page 41: Special Tools

    Special tools 1-32 valve guide installer (ø4) 90890-04112 valve guide installer (4.0 mm) ym-04112 5-25 valve guide installer (ø4.5) 90890-04117 valve guide installer (4.5 mm) ym-04117 5-25 valve guide reamer (ø4) 90890-04113 valve guide reamer (4.0 mm) ym-04113 5-25 valve guide reamer (ø4.5) 90890-0...

  • Page 42: Special Tools

    Special tools 1-33 pivot shaft wrench adapter 90890-01476 5-7 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-28, 5-41, 8- 137, 8-138, 8- 139, 8-142, 8- 144, 8-145, 8- 146, 8-147, 8- 148, 8-149, 8- 150, 8-151, 8- 152, 8-153, 8- 154, 8-155, 8- 156, 8-157 pressure gauge 90890-03153 yu-0315...

  • Page 43: Special Tools

    Special tools 1-34 camshaft wrench 90890-04143 ym-04143 5-11, 5-16 test coupler adapter 90890-03149 1-23, 4-54, 4-55 tool name/tool no. Illustration reference pages.

  • Page 44: Special Tools

    Special tools 1-35.

  • Page 45: Specifications

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

  • Page 46: General Specifications

    General specifications 2-1 eas20280 general specifications model model 2d1b (eur, zaf) (fz1-n) 2d1c (fra, bel) (fz1-n) 2d1d (aus) (fz1-n(x)) 2d1e (eur, zaf) (fz1-n) 2d1f (fra, bel) (fz1-n) 2d1g (aus) (fz1-n(x)) 3c3h (eur, zaf) (fz1-s) 3c3j (fra, bel) (fz1-s) 3c3k (aus) (fz1-s(x)) 5d03 (eur, zaf) (fz...

  • Page 47: Engine Specifications

    Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 998.0 cm 3 (60.90 cu.In) cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) compression ratio 11.50 : 1 standard compression pres...

  • Page 48: Engine Specifications

    Engine specifications 2-3 depth 22.0 mm (0.87 in) water pump water pump type single suction centrifugal pump reduction ratio 65/43 × 25/32 (1.181) max impeller shaft tilt limit 0.15 mm (0.0059 in) spark plug (s) manufacturer/model ngk/cr9ek spark plug gap 0.6–0.7 mm (0.024–0.028 in) cylinder head vo...

  • Page 49: Engine Specifications

    Engine specifications 2-4 exhaust 0.21–0.25 mm (0.0083–0.0098 in) valve dimensions valve head diameter a (intake) 23.40–23.60 mm (0.9213–0.9291 in) valve head diameter a (exhaust) 24.90–25.10 mm (0.9803–0.9882 in) valve face width b (intake) 1.760–2.900 mm (0.0693–0.1142 in) valve face width b (exha...

  • Page 50: Engine Specifications

    Engine specifications 2-5 valve spring inner spring free length (intake) 40.47 mm (1.59 in) free length (exhaust) 40.53 mm (1.60 in) installed length (intake) 32.66 mm (1.29 in) installed length (exhaust) 33.88 mm (1.33 in) spring rate k1 (intake) 17.53 n/mm (100.10 lb/in) (1.79 kgf/mm) spring rate ...

  • Page 51: Engine Specifications

    Engine specifications 2-6 end gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) 2nd ring ring type taper dimensions (b × t) 0.80 × 2.75 mm (0.03 × 0.11 in) end gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) ring side clearance 0.020–0.055 mm (0.00...

  • Page 52: Engine Specifications

    Engine specifications 2-7 secondary reduction system chain drive secondary reduction ratio 45/17 (2.647) operation left foot operation gear ratio 1st 38/15 (2.533) 2nd 33/16 (2.063) 3rd 37/21 (1.762) 4th 35/23 (1.522) 5th 27/20 (1.350) 6th 29/24 (1.208) main axle runout limit 0.08 mm (0.0032 in) dri...

  • Page 53: 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 54: Chassis Specifications

    Chassis specifications 2-9 brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness (inner) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) brake pad lining thickness (outer) 4.5 mm (0.18 in) limit 0.5 mm (0.02 in) master cylinder inside diameter 16.00 mm (0.63 in) caliper cylinder inside ...

  • Page 55: Chassis Specifications

    Chassis specifications 2-10 spring stroke k1 0.0–60.0 mm (0.00–2.36 in) optional spring available no enclosed gas/air pressure (std) 1000 kpa (142.2 psi) (10.0 kgf/cm 2 ) drive chain type/manufacturer 50va8/daido link quantity 122 drive chain slack 25.0–35.0 mm (0.98–1.38 in) 15-link length limit 23...

  • Page 56: Electrical Specifications

    Electrical specifications 2-11 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 crankshaf...

  • Page 57: Electrical Specifications

    Electrical specifications 2-12 meter lighting led indicator light neutral indicator light led turn signal indicator light led oil level warning light led high beam indicator light led coolant temperature warning light led engine trouble warning light led abs warning light led immobilizer system indi...

  • Page 58: Electrical Specifications

    Electrical specifications 2-13 ignition fuse 15.0 a radiator fan fuse 10.0 a × 2 fuel injection system fuse 15.0 a abs motor fuse 30.0 a (fz1-sa), (fz1-na) abs control unit fuse 10.0 a (fz1-sa), (fz1-na) backup fuse 10.0 a reserve fuse 30.0 a (fz1-sa), (fz1-na) reserve fuse 25.0 a (fz1-s(x)), (fz1-s...

  • Page 59: Tightening Torques

    Tightening torques 2-14 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 60: Tightening Torques

    Tightening torques 2-15 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 61: Tightening Torques

    Tightening torques 2-16 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 (0.6 m·kg, 4.3 ft·lb) exhaust pipe and exhaust pipe bracket bolt m8 2 20 nm (2.0 m·kg, 14 ft·lb) exup servo motor cover bolt m5 ...

  • Page 62: Tightening Torques

    Tightening torques 2-17 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 r...

  • Page 63: Tightening Torques

    Tightening torques 2-18.

  • Page 64: Tightening Torques

    Tightening torques 2-19 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 65: Tightening Torques

    Tightening torques 2-20 drive chain guide bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) rear fender screw m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) 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) f...

  • Page 66: Tightening Torques

    Tightening torques 2-21 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). Throttle cable adjust nut m6 2 4 nm (0.4 m·kg, 2.9 ft·lb) clutch cable...

  • Page 67: 2-22

    Lubrication points and lubricant types 2-22 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 68: 2-23

    Lubrication points and lubricant types 2-23 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 69: 2-24

    Lubrication points and lubricant types 2-24.

  • Page 70: 2-25

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

  • Page 71: 2-26

    Lubrication system chart and diagrams 2-26 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. Ac magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.Piston cooler 13.Piston cooler 14.Chain tensioner 15.Intake camshaf...

  • Page 72: 2-27

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

  • Page 73: 2-28

    Lubrication system chart and diagrams 2-28 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch.

  • Page 74: 2-29

    Lubrication system chart and diagrams 2-29.

  • Page 75: 2-30

    Lubrication system chart and diagrams 2-30 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump.

  • Page 76: 2-31

    Lubrication system chart and diagrams 2-31.

  • Page 77: 2-32

    Lubrication system chart and diagrams 2-32 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler.

  • Page 78: 2-33

    Lubrication system chart and diagrams 2-33.

  • Page 79: 2-34

    Lubrication system chart and diagrams 2-34 1. Main axle 2. Oil delivery pipe 3. Drive axle.

  • Page 80: 2-35

    Lubrication system chart and diagrams 2-35.

  • Page 81: 2-36

    Lubrication system chart and diagrams 2-36 1. Cylinder head 2. Crankshaft.

  • Page 82: Cooling System Diagrams

    Cooling system diagrams 2-37 eas20420 cooling system diagrams.

  • Page 83: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Water pump 2. Radiator 3. Radiator fan.

  • Page 84: Cooling System Diagrams

    Cooling system diagrams 2-39.

  • Page 85: Cooling System Diagrams

    Cooling system diagrams 2-40 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat.

  • Page 86: Cable Routing

    Cable routing 2-41 eas20430 cable routing.

  • Page 87: Cable Routing

    Cable routing 2-42 fz1-n(x)/fz1-s(x)/fz1-sa/fz1-na 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 handleba...

  • Page 88: Cable Routing

    Cable routing 2-43 mm nn oo fz1-s(x) h m m n n o h o fz1-n(x) / fz1-s(x).

  • Page 89: Cable Routing

    Cable routing 2-44 fz1-n(x)/fz1-s(x) 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 mot...

  • Page 90: Cable Routing

    Cable routing 2-45.

  • Page 91: Cable Routing

    Cable routing 2-46 fz1-sa 1. Throttle cables 2. Radiator inlet hose 3. Brake fluid reservoir hose 4. Abs breather hose 5. Exup cable wire bending attachment 6. Exup cable 7. Fuel tank breather hose 8. Rear brake light switch lead 9. Rear wheel sensor lead 10.Radiator fan motor lead (right) 11.Coolan...

  • Page 92: Cable Routing

    Cable routing 2-47.

  • Page 93: Cable Routing

    Cable routing 2-48 fz1-na 1. Throttle cables 2. Radiator inlet hose 3. Brake fluid reservoir hose 4. Abs breather hose 5. Exup cable wire bending attachment 6. Exup cable 7. Fuel tank breather hose 8. Rear brake light switch lead 9. Rear wheel sensor lead 10.Radiator fan motor lead (right) 11.Coolan...

  • Page 94: Cable Routing

    Cable routing 2-49 kk ll pp(fz1-n(x)) ff ee g q p p c e e f f g k k q(fz1-n(x)) cc l c l fz1-n(x) / fz1-s(x).

  • Page 95: Cable Routing

    Cable routing 2-50 fz1-n(x)/fz1-s(x) 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.Wat...

  • Page 96: Cable Routing

    Cable routing 2-51.

  • Page 97: Cable Routing

    Cable routing 2-52 fz1-sa 1. Clutch cable 2. Clutch cable swaging metal 3. Water pump breather hose 4. Oil level switch lead 5. Sidestand switch lead 6. O 2 sensor lead 7. Coolant reservoir tank drain hose 8. Battery negative lead 9. Wire harness 10.Starter motor lead 11.Seat lock cable 12.Water pum...

  • Page 98: Cable Routing

    Cable routing 2-53.

  • Page 99: Cable Routing

    Cable routing 2-54 ac.Route the water pump breather hose finally in the guide after passing other hoses so that it can be positioned on the outside of the vehicle. Ad.Route the coolant reservoir tank drain hose so that it is positioned at the inner- most part in hoses and leads. Ae.The rear side of ...

  • Page 100: Cable Routing

    Cable routing 2-55.

  • Page 101: Cable Routing

    Cable routing 2-56 fz1-na 1. Clutch cable 2. Clutch cable swaging metal 3. Water pump breather hose 4. Oil level switch lead 5. Sidestand switch lead 6. O 2 sensor lead 7. Coolant reservoir tank drain hose 8. Battery negative lead 9. Wire harness 10.Starter motor lead 11.Seat lock cable 12.Water pum...

  • Page 102: Cable Routing

    Cable routing 2-57 rr tt uu dd jj aa bb ee ff r r f f e e b b a u u a d j j d t t fz1-n(x) / fz1-s(x).

  • Page 103: Cable Routing

    Cable routing 2-58 fz1-n(x)/fz1-s(x) 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 positio...

  • Page 104: Cable Routing

    Cable routing 2-59 rr tt uu dd jj aa bb ee ff r r f f e e b b a u u a d j j d t t fz1-n(x) / fz1-s(x).

  • Page 105: Cable Routing

    Cable routing 2-60 r. Pass the license plate light lead and turn signal light lead under the turn signal relay. S. 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. T. Pass the turn signal light lead (lef...

  • Page 106: Cable Routing

    Cable routing 2-61.

  • Page 107: Cable Routing

    Cable routing 2-62 fz1-sa 1. Throttle cables 2. Right handlebar switch lead 3. Throttle cable (pull side) 4. Throttle cable (return side) 5. Coolant reservoir tank hose 6. Radiator inlet hose 7. Air filter drain hose 8. Ac magneto lead 9. Direct ignition coil lead coupler 10.Engine ground lead 11.Ne...

  • Page 108: Cable Routing

    Cable routing 2-63.

  • Page 109: Cable Routing

    Cable routing 2-64 m. Route the fuse box lead under the radiator fan motor relay. N. Route the battery positive lead under the fuse box lead. O. Pass the license plate light lead and turn signal light lead under the turn signal relay. P. Pass the turn signal light lead (right) and license plate ligh...

  • Page 110: Cable Routing

    Cable routing 2-65 pp hh aa xx jj tt cc dd w yy bb rr h y a x d j j d w t t x a b b y h p r r p d j j d w t t y x x a b b y h h p r r p c c c c fz1-na.

  • Page 111: Cable Routing

    Cable routing 2-66 fz1-na 1. Throttle cables 2. Throttle cable (pull side) 3. Throttle cable (return side) 4. Wire harness 5. Right handlebar switch lead 6. Coolant reservoir tank hose 7. Radiator inlet hose 8. Air filter drain hose 9. Direct ignition coil lead coupler 10.Ac magneto lead 11.Immobili...

  • Page 112: Cable Routing

    Cable routing 2-67 pp hh aa xx jj tt cc dd w yy bb rr h y a x d j j d w t t x a b b y h p r r p d j j d w t t y x x a b b y h h p r r p c c c c fz1-na.

  • Page 113: Cable Routing

    Cable routing 2-68 o. Route the fuse box lead under the radiator fan motor relay. P. Route the battery positive lead under the fuse box lead. Q. Route the license plate light lead and turn signal light lead under the turn signal relay. R. Route the turn signal light lead (right) and license plate li...

  • Page 114: Cable Routing

    Cable routing 2-69 ee e e f f ff aa a a fz1-s(x).

  • Page 115: Cable Routing

    Cable routing 2-70 fz1-s(x) 1. Clutch cable 2. Left handlebar switch lead 3. Immobilizer lead 4. Main switch lead 5. Protector 6. Throttle cables 7. Right handlebar switch lead 8. Throttle cable (pull side) 9. Throttle cable (return side) 10.Bracket 11.Wire harness 12.Turn signal light lead 13.Seat ...

  • Page 116: Cable Routing

    Cable routing 2-71.

  • Page 117: Cable Routing

    Cable routing 2-72 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 118: Cable Routing

    Cable routing 2-73.

  • Page 119

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

  • Page 120

    Lubricating the centerstand (fz1-s(x)/fz1-sa)...................3-35 lubricating the rear suspension ..........................................3-35 electrical system .............................................................................. 3-36 checking and charging the battery....................

  • Page 122: 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 123: 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 124: 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 125: 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 126: 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 5-9. • when removing the timing ...

  • Page 127: Engine

    Engine 3-6 example: if the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062 in) 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)...

  • Page 128: Engine

    Engine 3-7 2. Remove: • rider and passenger seat 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 ...

  • Page 129: Engine

    Engine 3-8 9. Measure: • engine idling speed out of specification → adjust. Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: • throttle cable free play refer to “adjusting the throttle cable free play” on page 3-9. 12. In...

  • Page 130: 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 131: Engine

    Engine 3-10 c. Tighten the locknut. Warning ewa5d01003 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 ...

  • Page 132: 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 133: 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 134: 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 135: Engine

    Engine 3-14 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: regarding the oil pressure as its own data may fluctuate depending on the oil temperature and vi...

  • Page 136: 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 137: 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 138: Engine

    Engine 3-17 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 passenger seat refer to “general chassi...

  • Page 139: 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 140: Engine

    Engine 3-19 2. Check: • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → add the recommended coolant to the proper level. Caution: eca13470 • adding water instead of coolant lowers the antifreeze content of the co...

  • Page 141: 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 142: Engine

    Engine 3-21 handling notes for coolant 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 ...

  • Page 143: 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 144: 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 145: 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 146: Chassis

    Chassis 3-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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, disconnected or replaced. • the brake fluid level is very low. • brake operation is fault...

  • Page 147: Chassis

    Chassis 3-26 warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ bleeding the abs brake warning ewa14010 bleed the abs whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid lev...

  • Page 148: Chassis

    Chassis 3-27 warning ewa14020 after bleeding the abs, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas5d01015 adjusting the shift pedal 1. Adjust: • shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. B. Turn the shift rod “2” in direction “a” or “b” to obta...

  • Page 149: Chassis

    Chassis 3-28 e. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas5d01017 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. Therefore, the drive chain should be servi...

  • Page 150: Chassis

    Chassis 3-29 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 4-71. E. Install the rubber washer “3”. F. Install the ...

  • Page 151: Chassis

    Chassis 3-30 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 152: Chassis

    Chassis 3-31 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ rebound damping (right side front fork) caution: eca5d01014 • 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 ...

  • Page 153: Chassis

    Chassis 3-32 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 154: Chassis

    Chassis 3-33 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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...

  • Page 155: Chassis

    Chassis 3-34 warning ewa13190 it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. Warning ewa14080 • do not use a tubeless tire on a wheel designed only for tube tires to avo...

  • Page 156: Chassis

    Chassis 3-35 • install the tire with the mark pointing in the direction of wheel rotation. • align the mark “2” with the valve installation point. Eas21670 checking the wheels the following procedure applies to both of the wheels. 1. Check: • wheel damage/out-of-round → replace. Warning ewa13260 nev...

  • Page 157: Electrical System

    Electrical system 3-36 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 8-131. Eas21770 checking the fuses refer to “electrical components” on page 8-131. Eas21780 replacing the headlight bulbs 1. Remove: • headlight side cover bolts “1” ...

  • Page 158: Electrical System

    Electrical system 3-37 6. Remove: • headlight bulb “1” 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:...

  • Page 159: Electrical System

    Electrical system 3-38 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Fz1-n(x)/fz1-na b. Fz1-s(x)/fz1-sa.

  • Page 160: Electrical System

    Electrical system 3-39.

  • Page 161: Chassis

    4 chassis general chassis ....................................................................................4-1 removing the cover....................................................................... 4-8 installing the cover ..................................................................... 4...

  • Page 162

    Installing the rear brake master cylinder......................4-48 abs (anti-lock brake system) ........................................................ 4-50 [d-5] maintenance of the hydraulic unit..............................4-52 hydraulic unit operation test ........................................

  • Page 164: 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 165: General Chassis

    General chassis 4-2 removing the headlight and meter assembly (fz1-n(x)), (fz1-na) 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...

  • Page 166: General Chassis

    General chassis 4-3 removing the front cowling (fz1-s(x)/fz1-sa) 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 ...

  • Page 167: General Chassis

    General chassis 4-4 removing the under cowling (fz1-na) order job/parts to remove q’ty remarks 1 under cowling 1 2 rectifier/regulator 1 3 right under cowling bracket 1 4 left under cowling bracket 1 for installation, reverse the removal proce- dure..

  • Page 168: General Chassis

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

  • Page 169: General Chassis

    General chassis 4-6 removing the rear fender (fz1-s(x)/fz1-sa) order job/parts to remove q’ty remarks rider and passenger seat refer to “general chassis” on page 4-1. 1 licence plate light lead coupler 1 disconnect. 2 turn signal light lead coupler 1 disconnect. 3 mud guard assembly 1 4 rear fender ...

  • Page 170: General Chassis

    General chassis 4-7 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 coupler 1 disconnect. 2 intake air temperature sensor 1 3 air filt...

  • Page 171: General Chassis

    General chassis 4-8 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 172: Front Wheel

    Front wheel 4-9 eas21870 front wheel removing the front wheel and brake discs (fz1-n(x)/fz1-s(x)) order job/parts to remove q’ty remarks 1 brake hose holder 2 2 front brake caliper 2 3 front wheel axle pinch bolt 1 4 front wheel axle 1 5 collar 2 6 dust cover 2 7 front wheel 1 8 front brake disc 2 f...

  • Page 173: Front Wheel

    Front wheel 4-10 removing the front wheel sensor and sensor rotor (fz1-sa), (fz1-na) order job/parts to remove q’ty remarks 1 brake hose holder 2 2 front brake caliper 2 3 front wheel sensor 1 4 front wheel axle pinch bolt 1 5 front wheel axle 1 6 collar 1 7 sensor housing 1 8 dust cover 2 9 front w...

  • Page 174: Front Wheel

    Front wheel 4-11 disassembling the front wheel order job/parts to remove q’ty remarks 1 oil seal 2 2 wheel bearing 2 3 spacer 1 for assembly, reverse the disassembly pro- cedure..

  • Page 175: Front Wheel

    Front wheel 4-12 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 176: Front Wheel

    Front wheel 4-13 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 177: Front Wheel

    Front wheel 4-14 note: the wheel sensor rotor of the vehicle is inserted under pressure by a special process and cannot be replaced as a single unit. To replace the sensor rotor, replace the wheel assembly. Installing the front wheel sensor 1. Install: • front wheel note: align the slot in the senso...

  • Page 178: Front Wheel

    Front wheel 4-15 c. Turn the front wheel 90 ° so that the “x 1 ” mark is positioned as shown. D. Release the front wheel. E. When the wheel stops, put an “x 2 ” mark at the bottom of the wheel. F. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. G. The sp...

  • Page 179: Front Wheel

    Front wheel 4-16 4. Lower the front wheel so that it is on the ground. 5. Tighten: • wheel axle • wheel axle pinch bolt caution: eca14140 before tightening the front wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly. 6. Install: • brake caliper w...

  • Page 180: Rear Wheel

    Rear wheel 4-17 eas22020 rear wheel removing the rear wheel (fz1-n(x)/fz1-s(x)) order job/parts to remove q’ty remarks 1 rear brake caliper 1 2 locknut 2 loosen. 3 adjusting bolt 2 loosen. 4 wheel axle nut 1 5 washer 1 6 rear wheel axle 1 7 adjusting block (left) 1 8 adjusting block (right) 1 9 rear...

  • Page 181: Rear Wheel

    Rear wheel 4-18 removing the rear wheel sensor and sensor rotor (fz1-sa), (fz1-na) order job/parts to remove q’ty remarks 1 rear wheel sensor protector 1 2 rear wheel sensor 1 3 rear wheel sensor lead stay 1 4 rear brake caliper 1 5 lock nut 2 loosen. 6 adjusting nut 2 loosen. 7 wheel axle nut 1 8 w...

  • Page 182: Rear Wheel

    Rear wheel 4-19 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 collar (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 183: Rear Wheel

    Rear wheel 4-20 disassembling the rear wheel order job/parts to remove q’ty remarks 1 collar 1 2 bearing 1 3 spacer 1 4 oil seal 1 5 circlip 1 6 bearing 1 for assembly, reverse the disassembly pro- cedure..

  • Page 184: Rear Wheel

    Rear wheel 4-21 eas22040 removing the rear wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • brake caliper “1” note: ...

  • Page 185: Rear Wheel

    Rear wheel 4-22 eas22120 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → replace the rear wheel sprocket. Bent teeth → replace the rear wheel sprocket. 2. Replace: • rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-lo...

  • Page 186: Rear Wheel

    Rear wheel 4-23 3. Remove: • rear wheel sensor protector • rear wheel sensor “4” 4. Remove: • rear wheel refer to “removing the rear wheel” on page 4-21. 5. Remove: • sensor rotor “5” checking the rear wheel sensor and sensor rotor 1. Check: • rear wheel sensor cracks/bends/distortion → replace. Iro...

  • Page 187: Rear Wheel

    Rear wheel 4-24 4. Check: • check the clearance “a” between the rear wheel sensor and sensor rotor. Out of specification → check the exist- ence of foreign matters in the wheel sen- sor attaching section, remove if any, and perform the installation. 5. Install: • rear wheel sensor lead stay • rear w...

  • Page 188: Rear Wheel

    Rear wheel 4-25 • wheel axle nut • brake caliper bolts warning ewa13500 make sure the brake hose is routed prop- erly. Wheel axle nut 150 nm (15 m·kg, 108 ft·lb) brake caliper bolt (front) 27 nm (2.7 m·kg, 20 ft·lb) brake caliper bolt (rear) 22 nm (2.2 m·kg, 16 ft·lb).

  • Page 189: Front Brake

    Front brake 4-26 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 proce- dure..

  • Page 190: Front Brake

    Front brake 4-27 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-25. 1 right rear view mirror (fz1-n(x)), (fz1-na) 1 2 brake master cylinder reservoir cap 1 3 brake master cylinder reservoir d...

  • Page 191: Front Brake

    Front brake 4-28 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 disassembly pro- cedure..

  • Page 192: Front Brake

    Front brake 4-29 removing the front brake calipers order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic 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 proce- dure..

  • Page 193: Front Brake

    Front brake 4-30 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 dust seal 4 7 brake caliper piston seal 4 8 bleed screw 1 for assembly, reverse the d...

  • Page 194: Front Brake

    Front brake 4-31 eas22220 introduction warning ewa14100 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • never disassemble brake components unless absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ent...

  • Page 195: Front Brake

    Front brake 4-32 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 196: Front Brake

    Front brake 4-33 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 197: Front Brake

    Front brake 4-34 • do not loosen the bolts “3”. 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/scra...

  • Page 198: Front Brake

    Front brake 4-35 caution: eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “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...

  • Page 199: Front Brake

    Front brake 4-36 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 200: Front Brake

    Front brake 4-37 warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to “cable routing” on page 2-41. 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 201: Rear Brake

    Rear brake 4-38 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 proce- dure..

  • Page 202: Rear Brake

    Rear brake 4-39 removing the rear brake master cylinder (fz1-n(x)/fz1-s(x)) order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-25. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphrag...

  • Page 203: Rear Brake

    Rear brake 4-40 removing the rear brake master cylinder (fz1-sa), (fz1-na) order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-25. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm...

  • Page 204: Rear Brake

    Rear brake 4-41 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 disassembly pro- cedure..

  • Page 205: Rear Brake

    Rear brake 4-42 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 brake caliper 1 for installation, reverse the removal proce- dure..

  • Page 206: Rear Brake

    Rear brake 4-43 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 dust seal 1 8 brake caliper piston seal 1 9 bleed screw 1 for assembly, r...

  • Page 207: Rear Brake

    Rear brake 4-44 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 208: Rear Brake

    Rear brake 4-45 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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...

  • Page 209: Rear Brake

    Rear brake 4-46 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 210: Rear Brake

    Rear brake 4-47 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 2-41. Caution: ec...

  • Page 211: Rear Brake

    Rear brake 4-48 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 212: Rear Brake

    Rear brake 4-49 2. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ewa5d01007 • 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 typ...

  • Page 213: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-50 eas22760 abs (anti-lock brake system) removing the hydraulic unit (fz1-sa), (fz1-na) order job/parts to remove q’ty remarks passenger seat refer to “general chassis” on page 4-1. Rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on pa...

  • Page 214: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-51 9 union bolt 1 10 copper washer 2 11 brake hose (hydraulic unit to rear brake caliper) 1 12 union bolt 1 13 copper washer 2 14 brake hose (rear brake master cylinder to hydraulic unit) 1 15 abs motor coupler 1 16 hydraulic unit solenoid coupler 1 17 brake hose holde...

  • Page 215: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-52 eas22770 [d-5] maintenance of the hydraulic unit caution: eca15060 do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fl...

  • Page 216: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-53 installing the hydraulic unit proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit bracket note: tighten the nuts in the proper sequence. 2. Install: • hydraulic unit note: do not allow any foreign materials...

  • Page 217: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-54 action that is generated in the brake lever and brake pedal when the abs is activated. • hydraulic unit operation test 2: this test checks the function of the abs after the sys- tem was disassembled, adjusted, or ser- viced. Hydraulic unit operation test 1 warning e...

  • Page 218: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-55 when the main switch is set to “on”, the abs warning light comes on for 2 seconds, goes off for 3 seconds, then starts flashing. When the abs warning light starts flashing, the brake lever “1” will return to its home position. The brake pedal “2” will then return to...

  • Page 219: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-56 6. Set the engine stop switch to “ ”. 7. Set the main switch to “on”. Note: after setting the main switch to “on”, wait (approximately 2 seconds) until the abs warn- ing light goes off. 8. Push the start switch for at least 4 seconds. Caution: eca14790 do not operat...

  • Page 220: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 4-57 • if the pulsating action is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hydraulic unit. 12. Set the main switch to “off”. 13. Remove the test coupler adaptor from the test coupler. 14. Set the main...

  • Page 221: Handlebar

    Handlebar 4-58 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks front cowling (fz1-s(x)/fz1-sa) refer to “general chassis” on page 4-1. 1 rear view mirror (fz1-n(x)), (fz1-na) 2 2 front brake light switch connector 2 disconnect. 3 front master cylinder bracket 1 4 fro...

  • Page 222: Handlebar

    Handlebar 4-59 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 223: Handlebar

    Handlebar 4-60 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 224: Handlebar

    Handlebar 4-61 note: • align the projections “a” on the handlebar switch with the holes “b” in the handlebar. • there should be 1–3 mm (0.04–0.12 in) of clearance “c” between the handlebar grip and the grip end. 10. Install: • front brake master cylinder assembly • front brake master cylinder holder...

  • Page 225: Front Fork

    Front fork 4-62 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 3-33 and “checking the wheels” on page 3-35. 1 front fender 1 2 cap bolt 1 loosen. 3 upper bracket pinch bolt 1 loosen. 4 low...

  • Page 226: Front Fork

    Front fork 4-63 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 227: Front Fork

    Front fork 4-64 eas22970 removing the front fork legs the following procedure applies to both of the front fork legs. Note: each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screen and left front fork is equipp...

  • Page 228: Front Fork

    Front fork 4-65 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: eca5d01026 for the damper rod assembly, the right side is used for the rebound operation and left side f...

  • Page 229: Front Fork

    Front fork 4-66 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 230: Front Fork

    Front fork 4-67 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 231: Front Fork

    Front fork 4-68 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 232: Front Fork

    Front fork 4-69 d. Press down in the spacer with the fork spring compressor “1” e. Pull up the rod puller and install the rod holder “2” between the damper adjusting rod locknut “3” and the spacer “4”. Note: use the side of the rod holder that is marked “b”. F. Remove the rod puller and the rod pull...

  • Page 233: Front Fork

    Front fork 4-70 1. Install: • front fork leg temporarily tighten the upper and lower bracket pinch bolts. Note: make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: • lower bracket pinch bolt “1” • cap bolt “2” • upper bracket pinch bolt “3” warning ewa13680 make ...

  • Page 234: Steering Head

    Steering head 4-71 eas23090 steering head removing the lower bracket order job/parts to remove q’ty remarks front wheel refer to “front wheel” on page 4-9. Front brake calipers refer to “front brake” on page 4-26. Front cowling (fz1-s(x)/fz1-sa) refer to “general chassis” on page 4-1. Headlight and ...

  • Page 235: Steering Head

    Steering head 4-72 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 18 upper bearing 1 19 bearing outer race 2 for installation, reverse the removal proce- dure. Removing the lower bracket order job/parts to remove q’ty re...

  • Page 236: Steering Head

    Steering head 4-73 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 237: Steering Head

    Steering head 4-74 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 238: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-75 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 239: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-76 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 240: Rear Shock Absorber Assembly

    Rear shock absorber assembly 4-77 • rear shock absorber 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...

  • Page 241: Swingarm

    Swingarm 4-78 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-17. Rear brake caliper refer to “rear brake” on page 4-38. Rear shock absorber refer to “rear shock absorber assembly” on page 4-75. Drive sprocket refer to “engine...

  • Page 242: Swingarm

    Swingarm 4-79 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 243: Swingarm

    Swingarm 4-80 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 244: Chain Drive

    Chain drive 4-81 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket refer to “engine removal” on page 5-1. 1 drive chain guard 1 2 drive chain 1 for installation, reverse the removal proce- dure..

  • Page 245: Chain Drive

    Chain drive 4-82 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 246: Chain Drive

    Chain drive 4-83 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 247: Engine

    5 engine engine removal ......................................................................................5-1 installing the engine .................................................................... 5-7 camshafts ....................................................................................

  • Page 248

    Checking the clutch plates.....................................................5-47 checking the clutch springs ..................................................5-48 checking the clutch housing ................................................. 5-48 checking the clutch boss ............................

  • Page 249

    Installing the transmission.....................................................5-88.

  • Page 250: Engine Removal

    Engine removal 5-1 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 proce- dure..

  • Page 251: Engine Removal

    Engine removal 5-2 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 252: Engine Removal

    Engine removal 5-3 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 disassembly pro- cedure..

  • Page 253: Engine Removal

    Engine removal 5-4 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 254: Engine Removal

    Engine removal 5-5 for assembly, reverse the removal proce- dure. Disconnecting the leads and hoses order job/parts to remove q’ty remarks.

  • Page 255: Engine Removal

    Engine removal 5-6 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 256: Engine Removal

    Engine removal 5-7 eas23720 installing the engine 1. Install: • right front engine mounting bolt 2 “1” refer to “cylinder head” on page 5- 18. 2. Tighten: • right front engine mounting bolt 2 3. Install: • engine mounting adjust bolts (temporarily tighten) 4. Install: • engine 5. Install: • lower en...

  • Page 257: Engine Removal

    Engine removal 5-8 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 258: Camshafts

    Camshafts 5-9 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 induc...

  • Page 259: Camshafts

    Camshafts 5-10 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to “crankshaft position sen- sor” on page 5-37. 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 “removi...

  • Page 260: Camshafts

    Camshafts 5-11 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to “crankshaft position sensor” on page 5-37. 2. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When piston #1 i...

  • Page 261: Camshafts

    Camshafts 5-12 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 262: Camshafts

    Camshafts 5-13 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • camshaft journal diameter “a” out of specification → replace the cam- shaft. Within specification → replace the cylin- der head and the camshaft caps as a set. Eas23870 checking the timing chain and cam- shaft sprocket 1. Check: • timing ch...

  • Page 263: Camshafts

    Camshafts 5-14 • timing chain tensioner spring “3” 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 → re...

  • Page 264: Camshafts

    Camshafts 5-15 eas24000 installing the camshafts 1. Align: • “t” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. B. When position #1 is at tdc, align the “t” mark “a” with the crankcase mating surface “b”. ▲▲▲▲▲▲▲▲...

  • Page 265: Camshafts

    Camshafts 5-16 • 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: eca5d01010...

  • Page 266: Camshafts

    Camshafts 5-17 11. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clearance” on page 3-4. 12. Install: • pickup coil rotor cover “crankshaft position sensor” on page 5-37..

  • Page 267: Cylinder Head

    Cylinder head 5-18 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Intake camshaft refer to “camshafts” on page 5-9. Exhaust camshaft refer to “camshafts” on page 5-9. 1 cylinder head 1 2 cylinder head gasket 1 3 ...

  • Page 268: Cylinder Head

    Cylinder head 5-19 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to “removing the cam- shafts” on page 5-11. 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...

  • Page 269: Cylinder Head

    Cylinder head 5-20 2. Install: • 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,...

  • Page 270: Valves and Valve Springs

    Valves and valve springs 5-21 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-18. 1 intake valve lifter 12 2 intake valve pad 12 3 intake valve cotter 24 4 intake valve upper spring seat 1...

  • Page 271: Valves and Valve Springs

    Valves and valve springs 5-22 for installation, reverse the removal proce- dure. Removing the valves and valve springs order job/parts to remove q’ty remarks.

  • Page 272: Valves and Valve Springs

    Valves and valve springs 5-23 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 273: Valves and Valve Springs

    Valves and valve springs 5-24 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 274: Valves and Valve Springs

    Valves and valve springs 5-25 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 275: Valves and Valve Springs

    Valves and valve springs 5-26 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 276: Valves and Valve Springs

    Valves and valve springs 5-27 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 277: Valves and Valve Springs

    Valves and valve springs 5-28 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 278: Valves and Valve Springs

    Valves and valve springs 5-29 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 279: Generator

    Generator 5-30 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 280: Generator

    Generator 5-31 15 washer 1 16 bearing 1 for assembly, reverse the removal proce- dure. Removing the generator order job/parts to remove q’ty remarks.

  • Page 281: Generator

    Generator 5-32 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 282: Generator

    Generator 5-33 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 283: Starter Clutch

    Starter clutch 5-34 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 proce- dure..

  • Page 284: Starter Clutch

    Starter clutch 5-35 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” eas5d01018 checking the damper 1. Check: • dampers “1” dama...

  • Page 285: Starter Clutch

    Starter clutch 5-36 b. When turning the starter clutch drive gear counterclockwise “a”, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. C. When turning the starter clutch drive gear clockwise “b”, it should turn freely,...

  • Page 286: Crankshaft Position Sensor

    Crankshaft position sensor 5-37 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 287: Crankshaft Position Sensor

    Crankshaft position sensor 5-38 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 288: Electric Starter

    Electric starter 5-39 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 289: Electric Starter

    Electric starter 5-40 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 disassembly pro...

  • Page 290: Electric Starter

    Electric starter 5-41 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 291: Electric Starter

    Electric starter 5-42 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 292: Clutch

    Clutch 5-43 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 proce- dure...

  • Page 293: Clutch

    Clutch 5-44 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 proce- dure..

  • Page 294: Clutch

    Clutch 5-45 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 295: Clutch

    Clutch 5-46 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 296: Clutch

    Clutch 5-47 • 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 297: Clutch

    Clutch 5-48 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 298: Clutch

    Clutch 5-49 eas25220 checking the pull lever shaft and pull rod 1. Check: • pull lever shaft pinion gear teeth “1” • pull rod teeth “2” damage/wear → replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: • pull rod bearing damage/wear → replace. Eas25240 installing the clutch 1. ...

  • Page 299: Clutch

    Clutch 5-50 • 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 300: Clutch

    Clutch 5-51 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 301: Shift Shaft

    Shift shaft 5-52 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch assembly refer to “clutch” on page 5-43. Shift arm and shift rod refer to “engine removal” on page 5-1. 1 circlip 1 2 washer 1 3 shift shaft 1 4 collar 1 5 shift shaft sprin...

  • Page 302: Shift Shaft

    Shift shaft 5-53 eas5d01019 removing the shift shaft 1. Remove: • clutch assembly refer to “clutch” on page 5-43 2. Remove: • shift arm • shift rod refer to “engine removal” on page 5- 1 3. Remove: • circlip “1” • washer “2” (left side of the engine) 4. Remove • shift shaft “1” • shift shaft spring ...

  • Page 303: Shift Shaft

    Shift shaft 5-54 • 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 304: Oil Pump

    Oil pump 5-55 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 5-1. O 2 sensor refer to “engine removal” on page 5-1. Muffler refer to “engine re...

  • Page 305: Oil Pump

    Oil pump 5-56 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 sprocket 1 15 washer 1 16 oil/water pump assembly drive chain 1 17 dowel pin 1 18 oil/water pump assembly 1 for assembly, reverse the removal pr...

  • Page 306: Oil Pump

    Oil pump 5-57 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 rotor 1 7 oil pump inner rotor 1 8 pin 1 for assembly, reverse the disassembly pro- cedure..

  • Page 307: Oil Pump

    Oil pump 5-58 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. Eas25620 checking the sprocket and ...

  • Page 308: Oil Pump

    Oil pump 5-59 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 309: Oil Pump

    Oil pump 5-60 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 310: Oil Pump

    Oil pump 5-61 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 311: Crankcase

    Crankcase 5-62 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. Throttle body assembly refer to “throttle bodies” on page 7-4. Engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head...

  • Page 312: Crankcase

    Crankcase 5-63 7 lower crankcase 1 8 dowel pin 3 9 damper 1 for assembly, reverse the removal proce- dure. Separating the crankcase order job/parts to remove q’ty remarks.

  • Page 313: Crankcase

    Crankcase 5-64 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 314: Crankcase

    Crankcase 5-65 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 315: Crankshaft

    Crankshaft 5-66 eas25950 crankshaft removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-62. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 piston pin 4 6 piston 4 7 connecting...

  • Page 316: Crankshaft

    Crankshaft 5-67 removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-62. Connecting rod and connecting rod caps refer to “removing the connecting rods and pistons” on page 5-68. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 cranksh...

  • Page 317: Crankshaft

    Crankshaft 5-68 eas26030 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap “1” • big end bearings note: • identify the position of each big end bearing so that it can be reinstalled in its original plac...

  • Page 318: Crankshaft

    Crankshaft 5-69 note: identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Eas24390 checking the cylinder and piston 1. Check: • piston wall • cylinder wall vertical scratches → replace the cylin- der, and the piston and piston rings as ...

  • Page 319: Crankshaft

    Crankshaft 5-70 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 320: Crankshaft

    Crankshaft 5-71 4. Calculate: • piston-pin-to-position clearance out of specification → replace the posi- tion pin and piston as a set. Eas5d01021 checking the big end bearings 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance out of specification → replace the big end bearings. ▼▼▼▼▼▼▼▼▼▼...

  • Page 321: Crankshaft

    Crankshaft 5-72 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 322: Crankshaft

    Crankshaft 5-73 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 ewa5d01010 • when the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with ...

  • Page 323: Crankshaft

    Crankshaft 5-74 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 324: Crankshaft

    Crankshaft 5-75 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 325: Crankshaft

    Crankshaft 5-76 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 326: Crankshaft

    Crankshaft 5-77 • 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 327: Crankshaft

    Crankshaft 5-78 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 328: Crankshaft

    Crankshaft 5-79 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 329: Crankshaft

    Crankshaft 5-80 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 330: Transmission

    Transmission 5-81 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 5-62. 1 drive axle assembly 1 2 circlip 1 3 oil seal 1 4 bearing 1 5 washer 1 6 shift fork guide bar r...

  • Page 331: Transmission

    Transmission 5-82 for installation, reverse the removal proce- dure. Removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks.

  • Page 332: Transmission

    Transmission 5-83 disassembling the main axle assembly 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 333: Transmission

    Transmission 5-84 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 1st wheel gear 1 3 collar 1 4 5th wheel gear 1 5 circlip 1 6 washer 1 7 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 334: Transmission

    Transmission 5-85 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks.

  • Page 335: Transmission

    Transmission 5-86 eas26250 removing the transmission 1. Remove: • drive axle assembly “1” • shift drum retainers “2” • shift fork guide bars • shift fork “l” and “r” • shift drum assembly • shift fork “c” 2. Remove: • bearing housing “1” • main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Ins...

  • Page 336: Transmission

    Transmission 5-87 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 337: Transmission

    Transmission 5-88 eas26350 installing the transmission 1. Install: • bearing “1” note: make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. • oil pipe “2” 2. Install: • main axle assembly “1” • bearing housing “2” • shift fork “c” • shift d...

  • Page 338: Transmission

    Transmission 5-89 4. Check: • transmission rough movement → repair. Note: oil each gear, shaft, and bearing thoroughly..

  • Page 339: Cooling System

    6 cooling system radiator .................................................................................................... 6-1 checking the radiator..................................................................6-2 installing the radiator .........................................................

  • Page 340: 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 coola...

  • Page 341: Radiator

    Radiator 6-2 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 342: Oil Cooler

    Oil cooler 6-3 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 343: Oil Cooler

    Oil cooler 6-4 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 344: Thermostat

    Thermostat 6-5 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 345: Thermostat

    Thermostat 6-6 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 disassembly pro- cedure..

  • Page 346: Thermostat

    Thermostat 6-7 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. ...

  • Page 347: Thermostat

    Thermostat 6-8 3. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-2..

  • Page 348: Water Pump

    Water pump 6-9 eas26500 water pump removing the impeller shaft order job/parts to remove q’ty remarks oil/water pump assembly refer to “oil pump” on page 5-55. Oil pump rotor refer to “oil pump” on page 5-55. 1 water pump cover 1 2 o-ring 1 3 pin 2 4 impeller shaft (along with the impeller) 1 5 wate...

  • Page 349: Water Pump

    Water pump 6-10 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 350: Water Pump

    Water pump 6-11 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 351: Fuel System

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

  • Page 352: 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 353: 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: eca5d01017 • be sure to dis...

  • Page 354: Fuel Tank

    Fuel tank 7-3 eas5d01024 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 i...

  • Page 355: 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 356: Throttle Bodies

    Throttle bodies 7-5 removing the injectors order job/parts to remove q’ty remarks 1 throttle position sensor coupler 1 disconnect. 2 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 357: Throttle Bodies

    Throttle bodies 7-6 22 throttle position sensor 1 23 throttle body assembly 1 for installation, reverse the removal proce- dure. Removing the injectors order job/parts to remove q’ty remarks.

  • Page 358: Throttle Bodies

    Throttle bodies 7-7 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 359: Throttle Bodies

    Throttle bodies 7-8 1. Check: • throttle position sensor refer to “checking the throttle position sensor” on page 8-153. 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 360: Throttle Bodies

    Throttle bodies 7-9 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 othe...

  • Page 361: Throttle Bodies

    Throttle bodies 7-10 eas2d1011 checking the sub-throttle servo motor 1. Check: • sub-throttle servo motor operation 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- throttle servo motor ...

  • Page 362: Throttle Bodies

    Throttle bodies 7-11 note: • setup tolerance of the longitudinal axis should be ± 0.2 mm (± 0.008 in). • after adjusting the thermo wax, check that the first idling is released at the coolant tem- perature around 60 ° c (140 ° f) by idling. • if the first idling is not released around 60 ° c (140 ° ...

  • Page 363: Air Induction System

    Air induction system 7-12 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 364: Air Induction System

    Air induction system 7-13 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 365: Air Induction System

    Air induction system 7-14 c. Measure the air induction system solenoid resistance. D. Out of specification → replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas27070 installing the air induction system 1. Install: • plate • reed valve assembly • reed valve cap 2. Install: • air cut-off valve • air cut-off v...

  • Page 366: Air Induction System

    Air induction system 7-15.

  • Page 367: Electrical System

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

  • Page 368

    Abs (anti-lock brake system) ........................................................ 8-89 circuit diagram (fz1-sa)..............................................................8-89 circuit diagram (fz1-na)..............................................................8-91 abs components chart..........

  • Page 369

    Checking the intake air pressure sensor .......................8-156 checking the intake air temperature sensor ................8-156.

  • Page 370: Ignition System

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

  • Page 371: Ignition System

    Ignition system 8-2 1. Main switch 6. Main fuse 7. Battery 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 17.Crankshaft position sensor 21.Lean angle sensor 23.Ecu (engine control unit) 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Ignition coi...

  • Page 372: 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 th...

  • Page 373: 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 8-135. Replace the right handlebar switch. 9. Check the neutral switch. Refer to “checking the switches” on page 8-135. Replace the neut...

  • Page 374: Electric Starting System

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

  • Page 375: Electric Starting System

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

  • Page 376: Electric Starting System

    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 377: 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 378: 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. (...

  • Page 379: 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 8-135. Replace the immobilizer kit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-135. Replace the righ...

  • Page 380: Charging System

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

  • Page 381: Charging System

    Charging system 8-12 2. Rectifier/regulator 3. Ac magneto 6. Main fuse 7. Battery.

  • Page 382: 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 8-139. Replace t...

  • Page 383: Charging System

    Charging system 8-14.

  • Page 384: Lighting System

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

  • Page 385: Lighting System

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

  • Page 386: Lighting System

    Lighting system 8-17 eas5d01027 circuit diagram (fz1-s(x)).

  • Page 387: Lighting System

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

  • Page 388: 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 389: 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 8-142. Replace the headlight relay. 9. Check the headlight relay (dimmer) (fz1-s(w)/fz1-sa). Refer to “checking the relays” on page 8-142. Replace the headlight relay. 10....

  • Page 390: Signaling System

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

  • Page 391: Signaling System

    Signaling system 8-22 1. Main switch 6. Main fuse 7. Battery 11.Relay unit 14.Neutral switch 16.Fuel pump 19.Speed sensor 23.Ecu (engine control unit) 42.Fuel level warning light 43.Oil level warning light 44.Neutral indicator light 45.Tachometer 46.Multi-function meter 48.Coolant temperature indica...

  • Page 392: 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 393: 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. Properl...

  • Page 394: 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 ↓ 3. Check the hazard switch. Refer to “checking the switches” on page 8-135. Replace the left handlebar switch. 4. Check the tu...

  • Page 395: Signaling System

    Signaling system 8-26 ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 2. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-21. Properly connect or repair the signal- ing system’s wiring....

  • Page 396: Cooling System

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

  • Page 397: Cooling System

    Cooling system 8-28 1. Main switch 6. Main fuse 7. Battery 23.Ecu (engine control unit) 38.Coolant temperature sensor 78.Ignition fuse 82.Radiator fan motor relay 83.Left radiator fan motor fuse 84.Right radiator fan motor fuse 85.Left radiator fan motor 86.Right radiator fan motor.

  • Page 398: 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) ref...

  • Page 399: Cooling System

    Cooling system 8-30

  • Page 400: Fuel Injection System

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

  • Page 401: Fuel Injection System

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

  • Page 402: 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 → ...

  • Page 403: 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 8-135. Replace the immobilizer kit. 9. Check the engine stop switch. Refer to “checking the switches” on page 8-135....

  • Page 404: 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 atmospheric pres- sure sensor. Refer to “checking the atmo- spheric pressure sensor” on page 8-155. Replace the atmospheric pressure sensor. 18.Check the injector. Refer to “checking the ...

  • Page 405: 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 406: 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 407: Fuel Injection System

    Fuel injection system 8-38 eas27362 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for th...

  • Page 408: 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 409: 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 410: 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 411: 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 412: Fuel Injection System

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

  • Page 413: 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 414: 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 415: 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 416: 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 417: Fuel Injection System

    Fuel injection system 8-48 actuator operation table 63 malfunction code reinstate • no malfunction 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 418: 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 419: 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 420: Fuel Injection System

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

  • Page 421: 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 order item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor coupler...

  • Page 422: 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. • c...

  • Page 423: 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 424: 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 425: Fuel Injection System

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

  • Page 426: 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 senso...

  • Page 427: 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 428: Fuel Injection System

    Fuel injection system 8-59 fault code no. 30 symptom no normal signal is received from the lean angle sensor. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the vehicle upright. Turni...

  • Page 429: Fuel Injection System

    Fuel injection system 8-60 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 430: Fuel Injection System

    Fuel injection system 8-61 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 431: Fuel Injection System

    Fuel injection system 8-62 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 432: Fuel Injection System

    Fuel injection system 8-63 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 433: Fuel Injection System

    Fuel injection system 8-64 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 co...

  • Page 434: Fuel Injection System

    Fuel injection system 8-65 fault code no. 42 symptom a. No normal signals are received from the speed sensor. 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 reinstate- ment...

  • Page 435: Fuel Injection System

    Fuel injection system 8-66 fault code no. 42 symptom a. No normal signals are received from the speed sensor. 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 m...

  • Page 436: Fuel Injection System

    Fuel injection system 8-67 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 437: Fuel Injection System

    Fuel injection system 8-68 fault code no. 44 symptom an error is detected while reading or writing on eeprom (co adjustment value). Diagnostic code no. 60 eeprom fault cylinder no. Order item/components and probable cause check or maintenance job reinstatement method 1 malfunction in ecu • set the f...

  • Page 438: Fuel Injection System

    Fuel injection system 8-69 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 439: Fuel Injection System

    Fuel injection system 8-70 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 pos...

  • Page 440: Fuel Injection System

    Fuel injection system 8-71 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 couple...

  • Page 441: Fuel Injection System

    Fuel injection system 8-72 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 442: Fuel Injection System

    Fuel injection system 8-73 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 443: Fuel Injection System

    Fuel injection system 8-74.

  • Page 444: Fuel Pump System

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

  • Page 445: Fuel Pump System

    Fuel pump system 8-76 1. Main switch 6. Main fuse 7. Battery 8. Fuel injection system fuse 13.Fuel pump relay 16.Fuel pump 23.Ecu (engine control unit) 46.Multi-function meter 56.Engine stop switch 78.Ignition fuse.

  • Page 446: 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,...

  • Page 447: Fuel Pump System

    Fuel pump system 8-78.

  • Page 448: Immobilizer System

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

  • Page 449: Immobilizer System

    Immobilizer system 8-80 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 23.Ecu (engine control unit) 41.Immobilizer indicator 46.Multi-function meter 78.Ignition fuse.

  • Page 450: 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 451: 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 452: Immobilizer System

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

  • Page 453: Immobilizer System

    Immobilizer system 8-84 voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the lost standard key. To re-regis...

  • Page 454: 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 ↓ 1. Check the fuses. (main, ignition and backup) refer to “checking the fuses” on page 8-139. Replace the fuse(s). 2. Check the...

  • Page 455: Immobilizer System

    Immobilizer system 8-86 eas27720 self-diagnosis fault code indication when the system failure occurred, the error code number is indicated in the immobilizer system indi- cator light blinks at the same time. The pattern of blinking also shows the error code. Error code detection symptoms trouble mea...

  • Page 456: Immobilizer System

    Immobilizer system 8-87 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. 55 immobilizer unit key code registra- tion error. Same standard key was attempted to continu- ously two times regis...

  • Page 457: Immobilizer System

    Immobilizer system 8-88.

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

    Abs (anti-lock brake system) 8-89 eas28790 abs (anti-lock brake system) eas27730 circuit diagram (fz1-sa).

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

    Abs (anti-lock brake system) 8-90 fz1-sa 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 12.Starting circuit cut-off relay 14.Neutral switch 46.Multi-function meter 53.Abs warning light 56.Front brake light switch 57.Engine stop switch 58.Start switch 59.Rear brake light swi...

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

    Abs (anti-lock brake system) 8-91 eas22c1001 circuit diagram (fz1-na) off on g/y l/w r/w r/b b br ch b ch b dg b dg b l p/w b/l l/r b l/r b b b/g b/y b br/r br br/r r/w r/b o r/b gy/r r/b o/g b b b l/r /lr c b b c ch ch c dg dg c b/y b/y c b/g b/gc b/l br/w a g/w g/w a y y a l l a b/l b/l a p/w p/w ...

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

    Abs (anti-lock brake system) 8-92 fz1-na 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 12.Starting circuit cut-off relay 14.Neutral switch 46.Multi-function meter 53.Abs warning light 56.Front brake light switch 57.Engine stop switch 58.Start switch 59.Rear brake light swi...

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

    Abs (anti-lock brake system) 8-93 eas27740 abs components chart fz1-sa.

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

    Abs (anti-lock brake system) 8-94 fz1-sa 1. Abs warning light 2. Abs test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. Abs ecu 9. Abs motor relay 10.Fuse box.

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

    Abs (anti-lock brake system) 8-95 fz1-na.

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

    Abs (anti-lock brake system) 8-96 fz1-na 1. Abs warning light 2. Abs test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. Abs ecu 9. Abs motor relay 10.Fuse box.

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

    Abs (anti-lock brake system) 8-97 eas27750 abs connector location chart fz1-sa.

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

    Abs (anti-lock brake system) 8-98 fz1-sa 1. Abs ecu coupler 2. Front wheel sensor coupler 3. Rear wheel sensor coupler 4. Hydraulic unit coupler 5. Abs motor relay 6. Abs test coupler 7. Multi-function coupler.

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

    Abs (anti-lock brake system) 8-99 fz1-na.

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

    Abs (anti-lock brake system) 8-100 fz1-na 1. Front wheel sensor coupler 2. Rear wheel sensor coupler 3. Hydraulic unit coupler 4. Abs ecu coupler 5. Abs motor relay 6. Abs test coupler 7. Multi-function coupler.

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

    Abs (anti-lock brake system) 8-101 eas27760 abs ecu and abs motor relay removing the abs ecu and abs motor relay (fz1-sa) order job/parts to remove q’ty remarks right front cowling inner panel refer to “general chassis” on page 4-1. Under cover refer to “abs (anti-lock brake sys- tem)” on page 4-50....

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

    Abs (anti-lock brake system) 8-102 removing the abs ecu and abs motor relay (fz1-na) order job/parts to remove q’ty remarks right front cowling inner panel refer to “general chassis” on page 4-1. Under cover refer to “abs (anti-lock brake sys- tem)” on page 4-50. 1 rear fender lower cover 1 2 abs mo...

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

    Abs (anti-lock brake system) 8-103 eas27770 [d-1] maintenance of the abs ecu removing the abs ecu 1. Remove: • abs ecu “1” note: when removing the abs ecu, take care not to damage the abs ecu or abs ecu couplers. 2. Remove: • abs ecu coupler “1” • abs ecu coupler “2” note: • do not pull the abs ecu ...

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

    Abs (anti-lock brake system) 8-104 eas27780 [d-2] maintenance of the abs motor relay removing the abs motor relay 1. Remove: • abs motor relay coupler note: do not pull the abs motor relay leads to remove the abs motor relay coupler. Always press on the lock to disconnect the abs motor relay coupler...

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

    Abs (anti-lock brake system) 8-105 eas27790 abs troubleshooting outline this section describes the troubleshooting about abs in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ecu) has the self diagnostic...

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

    Abs (anti-lock brake system) 8-106 differences between the normal handling and services on a vehicle • care should be taken not to damage components by shocks and pulling too much since the abs components are precisely adjusted. • abs ecu, hu, wheel sensors and abs motor relay cannot be disassembled...

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

    Abs (anti-lock brake system) 8-107 eas27810 basic process for troubleshooting.

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

    Abs (anti-lock brake system) 8-108 note: do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. Warning ewa14050 always execute the “final check” when the components related to abs are checked and ser- viced. Eas27830 [a] abs malf...

  • Page 478: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-109 eas4s81020 [b-3] the abs warning light flashes note: check the battery voltage before proceeding. Check the test coupler located in the left inner panel (front cowling). Is the t/c terminal ground? 1. Yes → disconnect the grounding lead from the t/c terminal and in...

  • Page 479: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-110 1. Indicate the malfunction code (example: malfunction code 11) 2. Abs warning light flashes every 0.5 second for more than 6 seconds. → [c-4, c-5] if the abs warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in ...

  • Page 480: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-111 as an example, “10 digits/1 digit pattern” of tester reading is shown below. 1. Abs test coupler 2. Lock plate 3. Protective cap 4. Grounding 5. T/c terminal 6. T/f terminal 7. Abs warning light terminal (white/red) 8. Test coupler adapter 9. Light green 10.Black 1...

  • Page 481: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-112 eas4s81021 [c] determining the cause and location of the malfunction eas4s81022 [c-1] only the abs warning light does not come on when the main switch is set to “on” 1. Confirmation using the test coupler adaptor connect the test coupler adapter to the test coupler...

  • Page 482: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-113 eas4s81024 [c-3] abs warning light flashes 1. When the warning light flashes “on” for 0.25 seconds and “off” for 0.75 seconds, check the stop switch or 3-4), 5). 2. When the warning light flashes “on” for 0.75 seconds and “off” for 0.25 seconds, the starter motor m...

  • Page 483: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-114 eas27880 [c-5] diagnosis by the malfunction code malfunction codes are used to determine the malfunctions that have occurred. (refer to “[b-4] mal- function check by the abs self-diagnosis (past malfunction)” and “[b-5] mal- function check by the abs self-diagnosis...

  • Page 484: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-115 24 stop light failure (brake system circuit has failure.) • adjust the brake light switch. • brake light switch • bulb has burned out. • check the wire harness for the brake light system circuit. Malfunction code 24 25 at the beginning of running, there is no pulse...

  • Page 485: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-116 35 disconnection is detected between the abs ecu and solenoid sys- tem. Downstream side of the solenoid relay • abs harness circuit (from abs ecu to the solenoid) • solenoid coupler • battery terminal is disconnected. Malfunction code 35 41 front wheel will not rec...

  • Page 486: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-117 * malfunction code 11 is indicated if the rear wheel rotates for more than 20 seconds with the front wheel stopped. Note: malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor) is displayed if a defective con- nection to either the front or rear sensor ...

  • Page 487: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-118 • abs ecu coupler terminal is disconnected. → [d-1] 2. Abs warning light goes on for 2 seconds then goes off. 1. With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is not a malfunction. 2. Signal is not generated at the re...

  • Page 488: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-119 1. Check the wheel sensor signal measure the wheel sensor signal output voltage. Refer to “checking the wheel sensor” on page 8-149. 2. Check the appearance. 3. Check the wire harness. 1. Disconnection of the abs ecu coupler terminal 2. Remove the abs ecu coupler a...

  • Page 489: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-120 *continuity between: “a”–“b”, “a”–“c”, “d”–“g”, “e”–“f” • check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal. 4. Battery • battery terminal is disconnected malfunction code 22 (starter motor monitor malfunction) 1. Discon...

  • Page 490: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-121 *continuity between: “a”–“b” malfunction code 25 (at the beginning of running, there is no pulse from the front wheel sen- sor.) • rear wheel was rotated with the vehicle on the stand. • rear wheel was wheel-spin. • wheel tried. • defective installation of the whee...

  • Page 491: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-122 4. When the items 1 to 3 are normal, replace the abs ecu. Malfunction code 32 (circuit malfunction of abs ecu is detected. Upstream side of the sole- noid relay.) note: check following the steps in sequence. 1. Short-circuit between the battery positive terminal an...

  • Page 492: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-123 • check for continuity between the positive battery terminal and the battery end of the abs motor fuse terminal (terminal “b” shown in the above illustration). • remove the abs ecu and the abs motor relay from the wire harness (abs), and then check for continuity b...

  • Page 493: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-124 2. Brake master cylinder and brake caliper • check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever is operated and that the pressure decreases when the lever is released. 3. Brake fluid • visually check the brake flu...

  • Page 494: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-125 malfunction code 42 (rear wheel not recover from the locking tendency even though the sig- nal is continuously transmitted from the abs ecu to release the hydraulic state [when the battery voltage is normal].) check the following: 1. Rotation of the rear wheel • ch...

  • Page 495: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-126 6. Hydraulic unit if the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be sure to connect the brake hose lines and couplers correctly and securely. Check the hydraulic unit operation. (refer to “[d-6] final check” on page 8...

  • Page 496: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-127 refer to “malfunction code 42”. 6. Hydraulic unit refer to “malfunction code 42”. 7. Battery voltage measure the battery voltage. Malfunction code 61 (front), 62 (rear) (sensor power supply is low) 1. Battery voltage low charge, check or replace the battery. 2. Bat...

  • Page 497: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-128 eas5d01005 [d-6-4] deleting the malfunction code 1. Connect the test coupler adapter “1” to the test coupler “2”. Refer to “[b-5] malfunction check by the abs self diagnosis (present malfunction)” 2. Turn the main switch on. • the multi-function display indicates p...

  • Page 498: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-129 7. Turn the main switch off. 8. Disconnect the test coupler adapter from the test coupler, and install the protective cap with the test coupler adapter. Deleting the malfunction code is now finished. Note: do not forget to install the protective cap. Caution: eca5d...

  • Page 499: Abs (Anti-Lock Brake System)

    Abs (anti-lock brake system) 8-130 6. Check: • ecu-to-start-switch-lead continuity connect the pocket tester ( Ω × 1) to the ecu coupler and start switch coupler. Tester positive probe → blue/white “1” (start switch) tester negative probe → green/white “2” (ecu) no continuity → replace or repair the...

  • Page 500: Electrical Components

    Electrical components 8-131 eas27970 electrical components.

  • Page 501: Electrical Components

    Electrical components 8-132 1. Main switch (immobilizer unit) 2. Front brake light switch 3. Battery 4. Fuse box 5. Starter relay 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Ignition coil 11.Radiator fan motor 12.Horn.

  • Page 502: Electrical Components

    Electrical components 8-133.

  • Page 503: Electrical Components

    Electrical components 8-134 1. Abs ecu (fz1-sa), (fz1-na) 2. Ecu (engine control unit) 3. Intake air temperature sensor 4. Fuel pump 5. Headlight relay (on/off) 6. Radiator fan motor relay 7. Lean angle sensor 8. Starting circuit cut-off relay 9. Turn signal relay 10.Rear wheel sensor (fz1-sa), (fz1...

  • Page 504: Electrical Components

    Electrical components 8-135 eas27980 checking the switches.

  • Page 505: Electrical Components

    Electrical components 8-136 1. Main switch 2. Horn switch 3. Dimmer switch (fz1-n(x)/fz1-na) 4. Dimmer switch (fz1-s(x)/fz1-sa) 5. Pass switch (fz1-n(x)/fz1-na) 6. Pass switch (fz1-s(x)/fz1-sa) 7. Turn signal switch 8. Hazard switch 9. Clutch switch 10.Sidestand switch 11.Engine stop switch 12.Front...

  • Page 506: Electrical Components

    Electrical components 8-137 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 prob...

  • Page 507: Electrical Components

    Electrical components 8-138 eas27990 checking the bulbs and bulb sock- ets check each bulb and bulb socket for damage or wear, proper connections, and also for conti- nuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected → properly connect. ...

  • Page 508: Electrical Components

    Electrical components 8-139 checking the condition of the bulb sockets 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...

  • Page 509: Electrical Components

    Electrical components 8-140 warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly...

  • Page 510: Electrical Components

    Electrical components 8-141 • no charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 v. B. Check the charge of the battery, as shown in the charts and the following example. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Charge: • battery (refer to the appropriate charging method illustr...

  • Page 511: Electrical Components

    Electrical components 8-142 g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ charging method using a constant voltage charger a. Measure the open-circuit voltage prior to charging. Not...

  • Page 512: Electrical Components

    Electrical components 8-143 relay unit (starting circuit cut-off relay) fz1-n(x)/fz1-s(x)/fz1-na fz1-sa relay unit (fuel pump relay) fz1-n(x)/fz1-s(x)/fz1-na fz1-sa headlight relay (on/off) (fz1-n(x))/fz1-na headlight relay (on/off) fz1-s(x)/fz1-sa) relay operation continuity/no continuity (between ...

  • Page 513: Electrical Components

    Electrical components 8-144 headlight relay (dimmer) fz1-s(x)/fz1-sa) radiator fan motor relay eas5d01008 checking the abs motor relay 1. Check: • abs motor relay for continuity connect the pocket tester ( Ω × 1) to the terminals of abs motor relay. Check for continuity between terminals “1” and “2”...

  • Page 514: Electrical Components

    Electrical components 8-145 eas5d01009 checking the solenoid valves and motor caution: eca4s81023 when check the hydraulic unit solenoid relay and abs motor, do not remove the brake hoses. 1. Check: • solenoid valve resistance (front) out of specification → replace the hydraulic unit. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 515: Electrical Components

    Electrical components 8-146 eas5d01028 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/ hazard relay coupler is faulty and must be repaired. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Co...

  • Page 516: Electrical Components

    Electrical components 8-147 fz1-n(x)/fz1-s(x)/fz1-na fz1-sa ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω× 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (di...

  • Page 517: Electrical Components

    Electrical components 8-148 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 518: Electrical Components

    Electrical components 8-149 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 ...

  • Page 519: Electrical Components

    Electrical components 8-150 eas5d01030 checking the starter motor opera- tion 1. Check: • starter motor operation does not operate → perform the electric starting system troubleshooting, starting with step5. Refer to “troubleshooting” on page 8-9. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the positi...

  • Page 520: Electrical Components

    Electrical components 8-151 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. B. Connect the pocket tester (ac 20 v) to the rectifier/regulator coupler as shown. C. Start the engine and let it run at approxi- mately 5000 r/min. D. Measure the charging v...

  • Page 521: Electrical Components

    Electrical components 8-152 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 10) to the fuel sender terminal as shown. B. Measure the fuel sender resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28240 checking the speed sensor 1. Check: • speed sensor output voltage out of specificatio...

  • Page 522: Electrical Components

    Electrical components 8-153 2. Check: • coolant temperature sensor resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the coolant temperature sensor “1” as shown. B. Immerse the coolant temperature sensor in a container filled with coo...

  • Page 523: Electrical Components

    Electrical components 8-154 d. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. The resistance does not change or it changes abruptly → replace the throttle position sensor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • throttle posi...

  • Page 524: Electrical Components

    Electrical components 8-155 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • sub-throttle position sensor note: when installing the throttle position sensor, adjust its angle properly. Refer to “checking the sub-throttle position sensor” on page 8-154. Eas28370 checking the air induction system solenoid...

  • Page 525: Electrical Components

    Electrical components 8-156 eas28390 checking the cylinder identifica- tion sensor 1. Check: • cylinder identification sensor output volt- age out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v) to the cylinder identification sensor coupler (wire har...

  • Page 526: Electrical Components

    Electrical components 8-157 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. B. Measure the intake air temperature sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • intake air temperature sensor pocket tester...

  • Page 527: Troubleshooting

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

  • Page 528: 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 529: 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 530: Troubleshooting

    Troubleshooting 9-3 • 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 • thermostat • thermostat stays closed • oil ...

  • Page 531: Troubleshooting

    Troubleshooting 9-4 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 • improperly installed bearing race eas28710 faulty lighting or signaling sys- tem headlight ...

  • Page 532: Troubleshooting

    Troubleshooting 9-5 • defective starter motor monitor • other defective abs warning light flashes every 0.5 sec- onds • voltage drop (less than 10 v) • battery • rectifier/regulator • ac magneto • strong radio waves or static electricity • test coupler adapter is connected to test coupler abs warnin...

  • Page 533: Troubleshooting

    Troubleshooting 9-6.

  • Page 534: Wiring Diagram

    Eas28740 wiring diagram fz1-n(x) 2008 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 8. Fuel injection system fuse 9. Starter relay 10. Starter motor 11. Relay unit 12. Starting circuit cut-off relay 13. Fuel pump relay 14. Neutral swit...

  • Page 535

    Fz1-s(x) 2008 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 8. Fuel injection system fuse 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 536

    Fz1-sa 2008 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 8. Fuel injection system fuse 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 16...

  • Page 537

    Fz1-na 2008 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 8. Fuel injection system fuse 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 16...

  • Page 538

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

  • Page 539: Fz1-N(X) 2008

    Fz1-n(x) 2008 wiring diagram fz1-n(x) 2008 schema de cablage fz1-n(x) 2008 schaltplan fz1-n(x) 2008 schema elettrico diagrama de conexiones de fz1-n(x) 2008.

  • Page 540: Fz1-S(X) 2008

    Fz1-s(x) 2008 wiring diagram fz1-s(x) 2008 schema de cablage fz1-s(x) 2008 schaltplan fz1-s(x) 2008 schema elettrico diagrama de conexiones de fz1-s(x) 2008.

  • Page 541: Fz1-Sa 2008

    Fz1-sa 2008 wiring diagram fz1-sa 2008 schema de cablage fz1-sa 2008 schaltplan fz1-sa 2008 schema elettrico diagrama de conexiones de fz1-sa 2008.

  • Page 542: Fz1-Na 2008

    Off on g/y l/w r/w r/b b br ch b ch b dg b dg b l p/w b/l l/r b l/r b b b/g b/y b br/r br br/r r/w r/b o r/b gy/r r/b o/g b b b l/r /lr c b b c ch ch c dg dg c b/y b /y c b/g b/g c b/l br/w a g/w g/w a y y a l l a b/l b/l a p/w p/w a g/y g/y a y/w y/w a y/r y/r a r/l r/l a o/b o/b a l/b l/b a g/b g/...

  • Page 543: Fz1-N(X) 2008

    Fz1-n(x) 2008 wiring diagram fz1-n(x) 2008 schema de cablage fz1-n(x) 2008 schaltplan fz1-n(x) 2008 schema elettrico diagrama de conexiones de fz1-n(x) 2008.

  • Page 544: Fz1-S(X) 2008

    Fz1-s(x) 2008 wiring diagram fz1-s(x) 2008 schema de cablage fz1-s(x) 2008 schaltplan fz1-s(x) 2008 schema elettrico diagrama de conexiones de fz1-s(x) 2008.

  • Page 545: Fz1-Sa 2008

    Fz1-sa 2008 wiring diagram fz1-sa 2008 schema de cablage fz1-sa 2008 schaltplan fz1-sa 2008 schema elettrico diagrama de conexiones de fz1-sa 2008.

  • Page 546: Fz1-Na 2008

    Fz1-na 2008 wiring diagram fz1-na 2008 schema de cablage fz1-na 2008 schaltplan fz1-na 2008 schema elettrico diagrama de conexiones de fz1-na 2008.