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- FZ8-NA
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Yamaha FZ8-NA Service Manual
Summary of FZ8-NA
Page 1
Service manual fz8na fz8sa 2011 1bd-28197-e0
Page 2
Eas20040 fz8na fz8sa service manual ©2010 by yamaha motor co., ltd. First edition, may 2010 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..
Page 3: Important
Eas20071 important 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 y...
Page 4: How To Use This Manual
Eas20091 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
Eas20101 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special tool...
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 eas39p1101 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 1. Engine trouble warning light 2. Intake air temperature sensor 3. Ecu (engine control unit) 4. Intake air pressure sensor 5. Throttle position sensor 6. Sub-throttle position sensor 7. Air filter case 8. Fuel tank 9. Fuel pump 10.Battery 11.Atmospheric pressure sensor 12.Relay unit (f...
Page 13: Features
Features 1-4 eas39p1102 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 kgf/cm², 46.1 psi). Accordingly, when the energizing signal from the ecu energizes the...
Page 14: Features
Features 1-5 eas39p1103 instrument functions multi-function meter unit warning ewa12422 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The multi-function me...
Page 15: Features
Features 1-6 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 tripmeter modes push the “select” button to switch the dis- play between the odometer mode “odo” and the tripmeter modes “trip a” and “trip b” in the followi...
Page 16: Features
Features 1-7 self-diagnosis device this model is equipped with a self-diagnosis device for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on and the display will indicate an error code. The self-diagnosis device also detects...
Page 17: Features
Features 1-8 eas4b56001 outline of the abs 1. The yamaha abs (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The abs features a compact and lightweight design to help maintain the basic maneuverability of the vehicle. 3. The h...
Page 18: Features
Features 1-9 abs the operation of the yamaha abs brakes is the same as conventional brakes on other vehicles, with a front brake lever for operating the front brake and a rear brake pedal for operating the rear brake. When wheel lock is detected during emergency braking, hydraulic control is perform...
Page 19: Features
Features 1-10 brake force and vehicle stability when the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and the road surface and brake force is generated. The limit of this brake force is determined by the friction force between the tire and the road surface an...
Page 20: Features
Features 1-11 wheel slip and hydraulic control the abs ecu calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the abs ecu calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed ...
Page 21: Features
Features 1-12 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 fron...
Page 22: Features
Features 1-13 electronic abs features the yamaha abs (anti-lock brake system) has been developed with the most advanced electronic technology. The abs control is processed with good response under various vehicle travel conditions. The abs also includes a highly developed self-diagnosis function. Th...
Page 23: Features
Features 1-14 eas4b56009 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 contains a hall ic. The wheel sensors are installed in the sensor housing for each wheel. ...
Page 24: Features
Features 1-15 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 25: Features
Features 1-16 2. When the abs is activated, the inlet solenoid valve “1” closes and the outlet solenoid valve “2” opens using the power supplied from the abs ecu signals. This reduces the hydraulic pres- sure. 3. When the abs ecu sends a signal to stop reducing the hydraulic pressure, the outlet sol...
Page 26: Features
Features 1-17 abs ecu the abs ecu is integrated with the hydraulic unit to achieve a compact and lightweight design. 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 ...
Page 27: Features
Features 1-18 abs control operation the abs control operation performed in the abs ecu is divided into the following two parts. • hydraulic control • self-diagnosis when a malfunction is detected in the abs, a fault code is stored in the memory of the abs ecu for easy problem identification and trou...
Page 28: Features
Features 1-19 eas4b56010 abs operation the abs hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following describes the system for the front wheel only. Normal braking (abs not activated) when the abs is not activated, the inlet solenoid valve is open and the outlet so...
Page 29: Features
Features 1-20 emergency braking (abs activated) 1. Depressurizing phase when the front wheel is about to lock, the outlet solenoid valve is opened by the “depressuriza- tion” signal transmitted from the abs ecu. When this occurs, the inlet solenoid valve com- presses the spring and closes the brake ...
Page 30: Features
Features 1-21 2. Pressurizing phase the outlet solenoid valve is closed by the “pressurization” signal transmitted from the abs ecu. At this time, the abs ecu controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, all...
Page 31: Features
Features 1-22 eas4b56011 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. Instances when the abs warning light comes on 1. The abs warning light comes on when the main switc...
Page 32: Features
Features 1-23 3. The abs warning light comes on while riding. If the abs warning light comes on while riding, a malfunction has been detected in the abs. The abs hydraulic control will not be performed. The abs will have recourse to manual braking if this occurs. 4. The abs warning light flashes whi...
Page 33: Features
Features 1-24.
Page 34: Features
Features 1-25 eas4b56012 abs warning light and operation abs warning light • when the main switch is turned to “on”, the abs warning light comes on for 2 seconds, then goes off. • the abs warning light comes on while the start switch is being pushed. • if the abs warning light comes on while riding,...
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 1-33. 3. When disasse...
Page 36: Important Information
Important information 1-27 eas20231 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer 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 a...
Page 37: Basic Service Information
Basic service information 1-28 eas30380 basic service information eas30390 quick fasteners rivet type 1. Remove: • quick fastener tip to remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • quick fastener tip to install the quick fastener, push its pi...
Page 38: Basic Service Information
Basic service information 1-29 eca16750 when disconnecting the battery leads from the battery, be sure to disconnect the nega- tive battery lead first, then the positive bat- tery lead. If a tool or similar item contacts the vehicle while only the negative battery lead is connected, a spark could be...
Page 39: Basic Service Information
Basic service information 1-30 eca16630 electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the contacts clean. Tip when resetting the ecu by turning the main switch to “off”, be sure to wait approximately 5 s...
Page 40: Basic Service Information
Basic service information 1-31 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector eca16780 • when disconnecting a coupler, release the coupler lock, hold both sections of the coupler securely, and then disco...
Page 41: Basic Service Information
Basic service information 1-32 5. Check: • continuity (with the pocket tester) tip • if there is no continuity, clean the terminals. • when checking the wire harness, perform steps (1) to (3). • as a quick remedy, use a contact revitalizer available at most part stores. Pocket tester 90890-03112 ana...
Page 42: Special Tools
Special tools 1-33 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 43: Special Tools
Special tools 1-34 oil filter wrench 90890-01426 yu-38411 3-25 rod holder 90890-01434 damper rod holder double ended ym-01434 4-71, 4-76 rod puller attachment (m10) 90890-01436 universal damping rod bleeding tool set ym-a8703 4-75, 4-76 rod puller 90890-01437 universal damping rod bleeding tool set ...
Page 44: Special Tools
Special tools 1-35 pivot shaft wrench 90890-01518 frame spanner socket ym-01518 5-9 compression gauge 90890-03081 engine compression tester yu-33223 5-1 vacuum gauge 90890-03094 vacuummate yu-44456 3-9 pocket tester 90890-03112 analog pocket tester yu-03112-c 1-32, 8-183, 8- 184, 8-185, 8- 189, 8-19...
Page 45: Special Tools
Special tools 1-36 digital circuit tester 90890-03174 model 88 multimeter with tachometer yu-a1927 5-43, 7-12, 8- 173, 8-195, 8- 196, 8-201, 8- 202 fuel pressure adapter 90890-03176 ym-03176 7-4 thickness gauge 90890-03180 feeler gauge set yu-26900-9 3-6, 5-21, 5-51 test harness- speed sensor (3p) 9...
Page 46: Special Tools
Special tools 1-37 valve spring compressor 90890-04019 ym-04019 5-25, 5-31 middle driven shaft bearing driver 90890-04058 middle drive bearing installer 40 & 50 mm ym-04058 6-13 mechanical seal installer 90890-04078 water pump seal installer ym-33221-a 6-13 universal clutch holder 90890-04086 ym-910...
Page 47: Special Tools
Special tools 1-38 valve guide reamer (ø4) 90890-04113 valve guide reamer (4.0 mm) ym-04113 5-27 extension 90890-04136 5-1 camshaft wrench 90890-04162 ym-04162 5-13, 5-17 ignition checker 90890-06754 oppama pet-4000 spark checker ym-34487 8-193 yamaha bond no.1215 (three bond no.1215®) 90890-85505 5...
Page 48: Special Tools
Special tools 1-39.
Page 49: Specifications
2 specifications general specifications ...................................................................... 2-1 engine specifications..........................................................................2-2 chassis specifications...................................................................
Page 50: General Specifications
General specifications 2-1 eas20280 general specifications model model fz8na 59p1 fz8sa 1bd1 dimensions overall length 2140 mm (84.3 in) overall width 770 mm (30.3 in) overall height fz8na 1065 mm (41.9 in) fz8sa 1225 mm (48.2 in) seat height 815 mm (32.1 in) wheelbase 1460 mm (57.5 in) ground clear...
Page 51: Engine Specifications
Engine specifications 2-2 eas20290 engine specifications engine engine type liquid cooled 4-stroke, dohc displacement 779 cm³ cylinder arrangement forward-inclined parallel 4-cylinder bore × stroke 68.0 × 53.6 mm (2.68 × 2.11 in) compression ratio 12.00 :1 standard compression pressure (at sea level...
Page 52: Engine Specifications
Engine specifications 2-3 radiator core width 222.6 mm (8.76 in) height 360.0 mm (14.17 in) depth 22.0 mm (0.87 in) water pump water pump type single suction centrifugal pump reduction ratio 65/43 × 25/32 (1.181) impeller shaft tilt limit 0.15 mm (0.006 in) spark plug(s) manufacturer/model ngk/cr9e ...
Page 53: Engine Specifications
Engine specifications 2-4 valve, valve seat, valve guide valve clearance (cold) intake 0.10–0.17 mm (0.0039–0.0067 in) exhaust 0.25–0.29 mm (0.0098–0.0114 in) valve dimensions valve head diameter a (intake) 25.90–26.10 mm (1.0197–1.0276 in) valve head diameter a (exhaust) 21.90–22.10 mm (0.8622–0.87...
Page 54: Engine Specifications
Engine specifications 2-5 free length (exhaust) 38.62 mm (1.52 in) limit 36.69 mm (1.44 in) installed length (intake) 33.00 mm (1.30 in) installed length (exhaust) 33.00 mm (1.30 in) spring rate k1 (intake) 24.99 n/mm (2.55 kgf/mm, 142.69 lb/in) spring rate k2 (intake) 37.28 n/mm (3.80 kgf/mm, 212.8...
Page 55: Engine Specifications
Engine specifications 2-6 end gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) limit 0.60 mm (0.0236 in) ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) limit 0.115 mm (0.0045 in) 2nd ring ring type taper dimensions (b × t) 0.80 × 2.50 mm (0.03 × 0.10 in) end gap (installed) 0.35–0.50 mm (0.013...
Page 56: Engine Specifications
Engine specifications 2-7 clutch spring free length 52.50 mm (2.07 in) limit 49.88 mm (1.96 in) spring quantity 6 pcs transmission transmission type constant mesh 6-speed primary reduction system spur gear primary reduction ratio 65/43 (1.512) secondary reduction system chain drive secondary reducti...
Page 57: Engine Specifications
Engine specifications 2-8 air induction system reed valve bending limit 0.4 mm (0.016 in) solenoid resistance 18–22 Ω at 20 °c (68 °f) idling condition engine idling speed 1150–1250 r/min co% 4.0–5.0 % intake vacuum 30.0 kpa (225 mmhg, 8.9 inhg) water temperature 90.0–110.0 °c (194.00–230.00 °f) oil...
Page 58: Chassis Specifications
Chassis specifications 2-9 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 × 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 59: Chassis Specifications
Chassis specifications 2-10 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 diameter 30.20 mm (1.19 in) 27.00 mm (1.06 in) ...
Page 60: Chassis Specifications
Chassis specifications 2-11 spring rate k1 78.40 n/mm (7.99 kgf/mm, 447.66 lb/in) spring stroke k1 0.0–60.0 mm (0.00–2.36 in) optional spring available no enclosed gas/air pressure (std) 1200 kpa (12.0 kgf/cm², 170.7 psi) spring preload adjusting positions minimum 1 standard 5 maximum 9 drive chain ...
Page 61: Electrical Specifications
Electrical specifications 2-12 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system tci ignition timing (b.T.D.C.) 5.0 °/1200 r/min engine control unit model/manufacturer tbdfd1/denso ignition coil minimum ignition spark gap 6.0 mm (0.24 in) primary coil res...
Page 62: Electrical Specifications
Electrical specifications 2-13 electric starting system system type constant mesh starter motor power output 0.70 kw armature coil commutator resistance 0.0100–0.2000 Ω at 20 °c (68 °f) insulation resistance above 1 m Ω at 20 °c (68 °f) brush overall length 12.0 mm (0.47 in) limit 6.50 mm (0.26 in) ...
Page 63: Tightening Torques
Tightening torques 2-14 eas20320 tightening torques eas20331 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 64: 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·kgf, 9.4 ft·lbf) cylinder head nut m10 10 see tip. Cylinder head bolt m6 2 12 nm (1.2 m·kgf, 8.7 ft·lbf) cylinder head plug m18 3 42 nm (4.2 m·kgf, 30 ft·lbf) cams...
Page 65: Tightening Torques
Tightening torques 2-16 exhaust pipe and muffler bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) exhaust pipe and exhaust pipe bracket bolt m8 1 20 nm (2.0 m·kgf, 14 ft·lbf) muffler and muffler bracket bolt m10 1 48 nm (4.8 m·kgf, 35 ft·lbf) crankcase stud bolt m10 10 8 nm (0.8 m·kgf, 5.8 ft·lbf) crankcase b...
Page 66: Tightening Torques
Tightening torques 2-17 tip cylinder head nut 1. Tighten the nut to 25 nm (2.5 m·kgf, 18 ft·lbf). 2. Tighten the nut to 25 nm (2.5 m·kgf, 18 ft·lbf). 3. Tighten the nuts 1–7 and 10 to 80 ° and nuts 8 and 9 to 100°. Tip connecting rod cap bolt 1. Tighten the bolts to 20 nm (2.0 m·kgf, 14 ft·lbf) 2. T...
Page 67: Tightening Torques
Tightening torques 2-18.
Page 68: 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·kgf, 19 ft·lbf) steering stem nut m28 1 115 nm (11.5 m·kgf, 83 ft·lbf) upper handlebar holder bolt m8 4 24 nm (2.4 m·kgf, 17 ft·lbf) lower handlebar ...
Page 69: Tightening Torques
Tightening torques 2-20 right front engine mounting bolt 2 m10 1 50 nm (5.0 m·kgf, 36 ft·lbf) left front engine mounting bolt m10 1 45 nm (4.5 m·kgf, 33 ft·lbf) upper self-locking nut m10 1 51 nm (5.1 m·kgf, 37 ft·lbf) lower self-locking nut m10 1 51 nm (5.1 m·kgf, 37 ft·lbf) engine mounting adjust ...
Page 70: Tightening Torques
Tightening torques 2-21 battery box and rear frame bolt m6 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) rectifier/regulator bracket and rear frame bolt m6 4 7 nm (0.7 m·kgf, 5.1 ft·lbf) rectifier/regulator bolt m6 2 7 nm (0.7 m·kgf, 5.1 ft·lbf) assist grip and rear frame bolt (fz8sa) m8 4 19 nm (1.9 m·kgf, 14 ft·...
Page 71: Tightening Torques
Tightening torques 2-22 tip lower ring nut 1. Tighten the ring nut to approximately 52 nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut 18 nm (1.8 m·kgf, 13 ft·lbf). Rear wheel sensor bolt m6 1 7 nm (0.7 m·kgf, 5.1 ft·lbf) rear ...
Page 72: 2-23
Lubrication points and lubricant types 2-23 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings coolant hose insertion part water or silicone fluid bearings camshaft lobes and journals (intake and exhaust) valve stem seals (intake and exh...
Page 73: 2-24
Lubrication points and lubricant types 2-24 left crankcase cover (three mating surface) yamaha bond no.1215 (three bond no.1215®) crankcase cover (lead grommet) yamaha bond no.1215 (three bond no.1215®) lubrication point lubricant.
Page 74: 2-25
Lubrication points and lubricant types 2-25 eas20380 chassis lubrication point lubricant steering bearings, seal lip and bearing lip tube guide (throttle grip) inner surface and throttle cables brake lever pivot bolt and metal-to-metal moving parts clutch lever pivot bolt, metal-to-metal moving part...
Page 75: 2-26
Lubrication points and lubricant types 2-26.
Page 76: 2-27
Lubrication system chart and diagrams 2-27 eas20390 lubrication system chart and diagrams eas20400 engine oil lubrication chart.
Page 77: 2-28
Lubrication system chart and diagrams 2-28 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. Ac magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.Ac magneto axle 13.Crankshaft 14.Piston cooler 15.Timing chain tens...
Page 78: 2-29
Lubrication system chart and diagrams 2-29 eas20410 lubrication diagrams.
Page 79: 2-30
Lubrication system chart and diagrams 2-30 1. Oil delivery pipe 2. Oil level switch 3. Oil filter cartridge 4. Crankshaft.
Page 80: 2-31
Lubrication system chart and diagrams 2-31 2 3 4 5 6 7 8 1.
Page 81: 2-32
Lubrication system chart and diagrams 2-32 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump.
Page 82: 2-33
Lubrication system chart and diagrams 2-33.
Page 83: 2-34
Lubrication system chart and diagrams 2-34 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler.
Page 84: 2-35
Lubrication system chart and diagrams 2-35.
Page 85: 2-36
Lubrication system chart and diagrams 2-36 1. Main axle 2. Oil pipe 3. Drive axle.
Page 86: 2-37
Lubrication system chart and diagrams 2-37.
Page 87: 2-38
Lubrication system chart and diagrams 2-38 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Main gallery 5. Crankshaft.
Page 88: Cooling System Diagrams
Cooling system diagrams 2-39 eas20420 cooling system diagrams.
Page 89: Cooling System Diagrams
Cooling system diagrams 2-40 1. Thermostat 2. Water pump 3. Radiator 4. Radiator fan 5. Oil cooler.
Page 90: Cooling System Diagrams
Cooling system diagrams 2-41.
Page 91: Cooling System Diagrams
Cooling system diagrams 2-42 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat.
Page 92: Cable Routing
Cable routing 2-43 eas20430 cable routing handlebar (front view) fz8na.
Page 93: Cable Routing
Cable routing 2-44 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Lower headlight stay 7. Front wheel sensor lead 8. Throttle cable (return side) 9. Throttle cable (pull side) 10.Brake hose 11.Wire harness 12.Right handlebar switch lead 13.Throt...
Page 94: Cable Routing
Cable routing 2-45 handlebar (front view) fz8sa.
Page 95: Cable Routing
Cable routing 2-46 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Horn bracket 7. Front wheel sensor lead 8. Throttle cable (return side) 9. Throttle cable (pull side) 10.Brake hose 11.Right handlebar switch lead 12.Throttle cables a. Route the ...
Page 96: Cable Routing
Cable routing 2-47 handlebar (right side view).
Page 97: Cable Routing
Cable routing 2-48 1. Wire harness 2. Throttle cable 3. Front wheel sensor lead 4. Radiator inlet hose 5. Right radiator fan motor lead 6. Coolant reservoir hose 7. Right handlebar switch lead 8. Throttle cables 9. Throttle cable (return side) 10.Throttle cable (pull side) 11.Radiator stay 12.Clutch...
Page 98: Cable Routing
Cable routing 2-49 engine (right side view).
Page 99: Cable Routing
Cable routing 2-50 1. Cable guide 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Brake fluid reservoir hose 5. Rear wheel sensor lead 6. Ac magneto lead 7. Rectifier/regulator lead 8. Rear brake light switch lead 9. Frame 10.Rear brake light switch stay 11.Rear brake light switch a. Clamp the...
Page 100: Cable Routing
Cable routing 2-51 handlebar (left side view).
Page 101: Cable Routing
Cable routing 2-52 1. Immobilizer lead 2. Main switch lead 3. Left handlebar switch lead 4. Clutch cable 5. Clutch cable swaging metal 6. Left radiator fan motor lead 7. Water pump breather hose 8. Radiator stay 9. Horn 10.Right handlebar switch lead 11.Meter bracket 12.Brake hose 13.Throttle cables...
Page 102: Cable Routing
Cable routing 2-53 engine (left side view).
Page 103: Cable Routing
Cable routing 2-54 1. Water pump breather hose 2. Oil level switch lead 3. Sidestand switch lead 4. O 2 sensor lead 5. Coolant reservoir tank drain hose 6. Water pump inlet pipe 7. Ac magneto lead 8. Throttle body 9. Ignition coil sub-wire harness 10.Left radiator fan motor lead 11.Clutch cable 12.W...
Page 104: Cable Routing
Cable routing 2-55 rear frame (left side view).
Page 105: Cable Routing
Cable routing 2-56 1. Wire harness 2. Starter motor lead 3. Battery negative lead 4. Seat lock cable 5. Ground lead 6. Fuel tank drain hose 7. Fuel tank breather hose 8. Ac magneto lead 9. Rectifier/regulator lead 10.Rear brake light switch lead 11.Coolant reservoir tank drain hose a. Clamp the wire...
Page 106: Cable Routing
Cable routing 2-57 frame (top view).
Page 107: Cable Routing
Cable routing 2-58 1. Throttle cable 2. Right handlebar switch lead 3. Wire harness 4. Front wheel sensor lead 5. Throttle cable (pull side) 6. Throttle cable (return side) 7. Intake air temperature sensor lead 8. Coolant reservoir hose 9. Radiator inlet hose 10.Right handlebar switch lead coupler 1...
Page 108: Cable Routing
Cable routing 2-59 frame (top view).
Page 109: Cable Routing
Cable routing 2-60 1. Air filter case drain hose 2. Pickup coil lead 3. Right radiator fan motor lead 4. Immobilizer anti-theft alarm coupler 5. Rear wheel sensor lead coupler 6. Engine ground lead 7. Neutral switch lead 8. Rear brake light switch lead 9. Rectifier/regulator lead 10.Fuel tank breath...
Page 110: Cable Routing
Cable routing 2-61 frame (top view).
Page 111: Cable Routing
Cable routing 2-62 1. Atmospheric pressure sensor 2. Battery positive lead 3. Radiator fan motor relay 4. Fuse box 1 5. Lean angle sensor 6. Right turn signal light lead 7. License plate light lead 8. Turn signal/hazard relay 9. Seat lock cable 10.Headlight relay 11.Tail/brake light coupler 12.Abs t...
Page 112: Cable Routing
Cable routing 2-63 fuel tank (left and bottom view).
Page 113: Cable Routing
Cable routing 2-64 1. Frame 2. Fuel tank cover 3. Fuel tank breather hose 4. Fuel tank drain hose 5. Fuel tank 6. Fuel pump 7. Clip 8. Fuel hose 9. Fuel hose connector cover a. Install the fuel tank drain hose with the white paint marks facing to the left of the vehicle. B. For the knob of the clip,...
Page 114: Cable Routing
Cable routing 2-65 front brake (right side view).
Page 115: Cable Routing
Cable routing 2-66 1. Brake hose (hydraulic unit to front brake calipers) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Front wheel sensor lead 4. Front wheel sensor lead guide 5. Front wheel sensor lead holder 6. Brake pipe/joint assembly (front brake master cylinder to hydraulic...
Page 116: Cable Routing
Cable routing 2-67 front brake (left side).
Page 117: Cable Routing
Cable routing 2-68 1. Front fork 2. Horn 3. Under bracket 4. Brake hose holder a. Install the clamp so that the distance from the clamp upper surface to the end of the brake hose protector may be 0–10 mm (0– 0.39 in). The front wheel sensor lead must be positioned at the outer rear of the vehi- cle ...
Page 118: Cable Routing
Cable routing 2-69 rear brake.
Page 119: Cable Routing
Cable routing 2-70 1. Brake hose (hydraulic unit to rear brake caliper) 2. Rear wheel sensor lead 3. Rear wheel sensor 4. Clamp 5. Swingarm 6. Rear fender a. Install the clip knob so that it faces to the outside of the vehicle as shown in the illus- tration. B. Face the clamp opening to the outside ...
Page 120: Cable Routing
Cable routing 2-71 hydraulic unit (top view).
Page 121: Cable Routing
Cable routing 2-72 1. Brake pipe/joint assembly (front brake master cylinder to hydraulic unit) 2. Brake pipe/joint assembly (hydraulic unit to front brake calipers) 3. Rear frame 4. Damper 5. Upper hydraulic unit bracket 6. Grommet 7. Hydraulic unit 8. Lower hydraulic unit bracket 9. Under cover a....
Page 122: Cable Routing
Cable routing 2-73 hydraulic unit (front view).
Page 123: Cable Routing
Cable routing 2-74 1. Fuse box 2 2. Waterproof coupler 3. Brake hose (hydraulic unit to rear brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Rear wheel sensor lead 6. Rear brake hose holder 7. Rear brake hose guide 8. Lower hydraulic unit bracket 9. Hydraulic unit a. I...
Page 124: Cable Routing
Cable routing 2-75 hydraulic unit (left side view).
Page 125: Cable Routing
Cable routing 2-76 1. Brake pipe/joint assembly (front brake master cylinder to hydraulic unit) 2. Brake pipe/joint assembly (hydraulic unit to front brake calipers) 3. Brake fluid reservoir tank stay 4. Rear frame 5. Battery box 6. Upper hydraulic unit bracket 7. Damper 8. Quick fastener 9. Lower h...
Page 126: Cable Routing
Cable routing 2-77.
Page 127
3 periodic checks and adjustments periodic maintenance ......................................................................... 3-1 introduction .................................................................................... 3-1 periodic maintenance chart for the emission control system..........
Page 128
Checking the front brake light switch .............................3-29 adjusting the rear brake light switch ..............................3-29 checking and lubricating the cables ..................................3-29 adjusting the throttle cable free play ............................3-30 checking...
Page 130: 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 131: Periodic Maintenance
Periodic maintenance 3-2 eas39p1302 general maintenance and lubrication chart no. Item check or maintenance job odometer reading annual check 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) 1 air filter element • replace. √ 2 clutch • check operation. ...
Page 132: Periodic Maintenance
Periodic maintenance 3-3 tip • 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 133: Periodic Maintenance
Periodic maintenance 3-4 eas21030 checking the fuel line the following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: • rider seat refer to “general chassis” on page 4-1. • fuel tank refer to “fuel tank” on page 7-1. 2. Check: • fuel hose “1” • vacuum hose “2” • breather...
Page 134: Periodic Maintenance
Periodic maintenance 3-5 7. Install: • spark plugs • ignition coils tip before installing the spark plug, clean the spark plug and gasket surface. 8. Install: • radiator upper bolt • radiator lower bolt • radiator upper cover (fz8na) • radiator upper panel (fz8sa) refer to “radiator” on page 6-1. • ...
Page 135: Periodic Maintenance
Periodic maintenance 3-6 tip tdc on the compression stroke can be found when the camshaft lobes are turned away from each other. C. Measure the valve clearance with a thick- ness gauge “2”. Tip • if the valve clearance is incorrect, record the measured reading. • measure the valve clearance in the f...
Page 136: Periodic Maintenance
Periodic maintenance 3-7 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. Tip • cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • make a note of the position of each valve lifter “1” and v...
Page 137: Periodic Maintenance
Periodic maintenance 3-8 • lubricate the valve lifter (outer side) with engine oil. • install the valve lifter and the valve pad in the correct place. • the valve lifter must turn smoothly when rotated by hand. G. Install the exhaust and intake camshafts, timing chain and camshaft caps. Tip • refer ...
Page 138: Periodic Maintenance
Periodic maintenance 3-9 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • throttle cable free play refer to “adjusting the throttle cable free play” on page 3-30. Eas20571 synchronizing the throttle bodies tip before synchronizing the throttle bodies, check the following items: • valve clearance • spark ...
Page 139: Periodic Maintenance
Periodic maintenance 3-10 b. Check the vacuum pressure. If out of specification → adjust the throttle body synchronization. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ adjusting the throttle body synchronization 1. Adjust: • throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. With throttle body #3 “1...
Page 140: Periodic Maintenance
Periodic maintenance 3-11 3. Install: • throttle bodies refer to “throttle bodies” on page 7-5. Eas20600 adjusting the exhaust gas volume tip be sure to set the co density level to stan- dard, and then adjust the exhaust gas volume. 1. Turn the main switch to “off” and set the engine stop switch to ...
Page 141: Periodic Maintenance
Periodic maintenance 3-12 4. Install: • radiator lower bracket refer to “radiator” on page 6-1. Eas39p1306 checking the air induction system refer to “checking the air induction system” on page 7-18. Eas21070 checking the crankcase breather hose 1. Remove: • rider seat refer to “general chassis” on ...
Page 142: Periodic Maintenance
Periodic maintenance 3-13 tip • replace the air filter element every 40000 km (24000 mi) of operation. • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 4. Install: • air filter element • air filter case cover eca14401 never operate the engine without th...
Page 143: Periodic Maintenance
Periodic maintenance 3-14 c. Tighten the locknut “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas39p1307 checking the brake operation 1. Check: • brake operation brake not working properly → check the brake system. Refer to “front brake” on page 4-30 and “rear brake” on page 4-43. Tip drive on the dry road, ...
Page 144: Periodic Maintenance
Periodic maintenance 3-15 eas21160 adjusting the front disc brake 1. Adjust: • brake lever position (distance “a” from the throttle grip to the brake lever) tip • while pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • be sure to align t...
Page 145: Periodic Maintenance
Periodic maintenance 3-16 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • rear brake light switch refer to “adjusting the rear brake light switch” on page 3-29. Eas21260 checking the rear brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • rear brake pa...
Page 146: Periodic Maintenance
Periodic maintenance 3-17 f. Fully pull the brake lever or fully press down the brake pedal and hold it in posi- tion. G. Loosen the bleed screw. Tip loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. H. Tigh...
Page 147: Periodic Maintenance
Periodic maintenance 3-18 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • brake hose brake fluid leakage → replace the dam- aged hose. Refer to “rear brake” on page 4-43. Eas21670 checking the wheels the following procedure applies to both of the wheels. 1. Check: • w...
Page 148: Periodic Maintenance
Periodic maintenance 3-19 warning ewa14090 after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be g...
Page 149: Periodic Maintenance
Periodic maintenance 3-20 tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Move the rear wheel several times and find the tightest position of drive chain. 3. Check: • drive chain slack “a” out of specification → adjust. 4. Loosen: • wheel axle nut “1” 5. Adjust: • dr...
Page 150: Periodic Maintenance
Periodic maintenance 3-21 eas21510 checking and adjusting the steer- ing head 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check:...
Page 151: Periodic Maintenance
Periodic maintenance 3-22 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • upper bracket refer to “handlebar” on page 4-64. Eas39p1303 lubricating the brake lever lubricate the pivoting point and metal-to-metal moving parts of the lever. Eas39p1304 lubricating the clutch lever lubricate the pivoting poi...
Page 152: Periodic Maintenance
Periodic maintenance 3-23 eas21531 checking the front fork 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. Check: • inner tube damage/scratches → replace. • front fork leg oil leaks between inner tube and outer ...
Page 153: Periodic Maintenance
Periodic maintenance 3-24 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas39p1312 checking the connecting arm and relay arm refer to “checking the connecting arm and relay arm” on page 4-86. Eas20731 checking the engine oil level 1. Stand the vehicle on a level surface. Tip • place the vehicle on a suitable stand...
Page 154: Periodic Maintenance
Periodic maintenance 3-25 4. Drain: • engine oil (completely from the crankcase) 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...
Page 155: Periodic Maintenance
Periodic maintenance 3-26 eas20820 measuring the engine oil pressure 1. Check: • engine oil level below the minimum level mark “a” → add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. Eca13410 when the engine is cold, the en...
Page 156: Periodic Maintenance
Periodic maintenance 3-27 2. Check: • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → add the recommended coolant to the proper level. Eca13470 • adding water instead of coolant lowers the antifreeze content of t...
Page 157: Periodic Maintenance
Periodic maintenance 3-28 3. Remove: • coolant reservoir tank 4. Disconnect: • coolant reservoir hose 5. Drain: • coolant (from the coolant reservoir) 6. Remove: • radiator cap bolt “1” • radiator cap “2” warning ewa13030 a hot radiator is under pressure. Therefore, do not remove the radiator cap wh...
Page 158: Periodic Maintenance
Periodic maintenance 3-29 • use only distilled water. However, if dis- tilled water is not available, soft water may be used. • if coolant comes into contact with painted surfaces, immediately wash them with water. • do not mix different types of antifreeze. 13. Install: • radiator cap • radiator ca...
Page 159: Periodic Maintenance
Periodic maintenance 3-30 2. Check: • cable operation rough movement → lubricate. Tip hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. Eas20630 adjusting the throttle cable free play tip prior to adjusting the throttle cable fre...
Page 160: Periodic Maintenance
Periodic maintenance 3-31 2. Remove: • headlight bolt “1” 3. Remove: • headlight bolts “2” • headlight unit “3” 4. Remove: • headlight coupler “1” 5. Remove: • headlight bulb cover “1” 6. Remove: • headlight bulb holder “1” warning ewa13320 since the headlight bulb gets extremely hot, keep flammable...
Page 161: Periodic Maintenance
Periodic maintenance 3-32 12. Install: • headlight bolts 13. Install: • headlight side covers • headlight side cover bolts 14. Install: • headlight side panels • headlight side panel bolts 15. Install: • headlight top cover • headlight top cover bolts eas39p1305 replacing the headlight bulbs (fz8sa)...
Page 162: Periodic Maintenance
Periodic maintenance 3-33 eca13690 avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moist...
Page 163: Periodic Maintenance
Periodic maintenance 3-34 right headlight ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ direction “a” headlight beam moves to the left. Direction “b” headlight beam moves to the right..
Page 164: Periodic Maintenance
Periodic maintenance 3-35.
Page 165: Chassis
4 chassis general chassis.................................................................................... 4-1 removing the inner panel (fz8sa) ............................................. 4-9 installing the inner panel (fz8sa) ............................................ 4-9 removing the side p...
Page 166
Rear brake ............................................................................................4-43 introduction ..................................................................................4-49 checking the rear brake disc .................................................4-49 replacing...
Page 167
Swingarm ................................................................................................4-88 removing the swingarm .............................................................4-89 checking the swingarm .............................................................4-89 installing the...
Page 168: 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 tool kit 1 4 battery negative lead 1 5 battery positive lead 1 6 main fuse 1 7 battery band 1 8 battery 1 9 battery seat 1 for installation, reverse t...
Page 169: General Chassis
General chassis 4-2 removing the headlight and meter assembly (fz8na) order job/parts to remove q’ty remarks 1 headlight top cover 1 2 left headlight side panel 1 3 right headlight side panel 1 4 headlight assembly 1 5 headlight sub-wire harness coupler 1 disconnect. 6 left turn signal light lead co...
Page 170: General Chassis
General chassis 4-3 removing the front cowling assembly (fz8sa) order job/parts to remove q’ty remarks 1 right inner panel 1 2 left inner panel 1 3 headlight sub-wire harness coupler 2 disconnect. 4 left turn signal light lead connector 2 disconnect. 5 right turn signal light lead connector 2 discon...
Page 171: General Chassis
General chassis 4-4 disassembling the front cowling assembly (fz8sa) order job/parts to remove q’ty remarks 1 inner panel bracket 2 2 front cowling side panel 2 3 windshield 1 4 rear view mirror 2 5 auxiliary light lead coupler 2 disconnect. 6 ground lead 1 disconnect. 7 front cowling stay 1 8 meter...
Page 172: General Chassis
General chassis 4-5 removing the under cowling order job/parts to remove q’ty remarks 1 left bottom cowling 1 2 left bottom cowling bracket 1 3 right bottom cowling 1 4 rectifier/regulator coupler 1 disconnect. 5 rectifier/regulator 1 6 right bottom cowling bracket 1 7 rectifier/regulator bracket 1 ...
Page 173: General Chassis
General chassis 4-6 removing the rear cover (fz8na) order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. 1 left side cover 1 2 right side cover 1 3 tail/brake light lead coupler 1 disconnect. 4 upper tail cover 1 5 tail/brake light bracket 1 6 tail...
Page 174: General Chassis
General chassis 4-7 removing the rear cover (fz8sa) order job/parts to remove q’ty remarks passenger seat/rider seat refer to “general chassis” on page 4-1. 1 left side cover 1 2 right side cover 1 3 assist grip 2 4 tail/brake light lead coupler 1 disconnect. 5 upper tail cover 1 6 tail/brake light ...
Page 175: General Chassis
General chassis 4-8 removing the air filter case order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. 1 air filter case cover...
Page 176: General Chassis
General chassis 4-9 eas39p1404 removing the inner panel (fz8sa) 1. Remove: • inner panel “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. First remove the right inner panel, and then remove the left inner panel. B. Remove the quick fastener and the bolts. C. Slightly lift the rear of the inner panel and then d...
Page 177: General Chassis
General chassis 4-10 b. Install the quick fastener and bolt. C. Connect the turn signal light connectors. D. Fasten headlight sub-wire harness “1” and left turn signal light lead connector “2” at clamp “3” inside of the front cowling. Make sure to fasten the left turn signal lead con- nector at the ...
Page 178: General Chassis
General chassis 4-11 eas39p1410 installing the headlight assembly (fz8sa) 1. Install: • headlight assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporarily tighten the screw “1”. B. Tighten the screw “2”. C. Tighten the screw “1”. D. Tighten the screws “3” not specified can be in any order. ▲▲▲▲▲▲▲▲▲▲▲...
Page 179: Front Wheel
Front wheel 4-12 eas21870 front wheel removing the front wheel and brake discs order job/parts to remove q’ty remarks 1 brake hose holder 1 2 front brake caliper 2 3 front wheel sensor 1 4 wheel axle pinch bolt 1 loosen. 5 wheel axle 1 6 collar 2 7 front wheel sensor housing 1 8 front wheel 1 9 fron...
Page 180: Front Wheel
Front wheel 4-13 disassembling the front wheel order job/parts to remove q’ty remarks 1 front wheel sensor rotor 1 2 oil seal 2 3 wheel bearing 1 4 spacer 1 5 wheel bearing 1 for assembly, reverse the disassembly pro- cedure..
Page 181: Front Wheel
Front wheel 4-14 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. 2. Remove: • left brake caliper • right brake caliper • front wheel sensor tip do not apply the brake lever when re...
Page 182: Front Wheel
Front wheel 4-15 c. Remove the wheel bearings “3” with a gen- eral bearing puller. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas21960 assembling the front wheel 1. Install: • wheel bearings • oil seals ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the new wheel bearing (right side). Eca2s31011 do not contact the w...
Page 183: Front Wheel
Front wheel 4-16 • the abs wheel sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. Removing the front wheel sensor 1. Disconnect: • front wheel sensor coupler “1” 2. Remove: • clamps “1” • front wheel sensor lead holders “2” • brake caliper “3” • f...
Page 184: Front Wheel
Front wheel 4-17 c. If the deflection is above specification, replace the wheel sensor. Eca4b56023 replace the wheel sensor rotor bolts with new ones. D. If the deflection is still above specification, replace the wheel sensor rotor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ installing the front wheel sensor 1...
Page 185: Front Wheel
Front wheel 4-18 4. Connect: • front wheel sensor coupler “1” 5. Check: • front wheel sensor installation check if the wheel sensor housing is installed properly. Eas21970 adjusting the front wheel static balance tip • after replacing the tire, wheel or both, the front wheel static balance should be...
Page 186: Front Wheel
Front wheel 4-19 b. Turn the front wheel 90 ° so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • front wheel static b...
Page 187: Front Wheel
Front wheel 4-20 tip check that wheel axle end “a” is flush with front folk surface “b” and then tighten the wheel axle pinch bolt. If end “a” is not flush with sur- face “b”, align the ends manually or with a plastic hammer. 6. Install: • front brake caliper warning ewa13500 make sure the brake hos...
Page 188: Rear Wheel
Rear wheel 4-21 eas22020 rear wheel removing the rear wheel order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-43. 1 rear wheel sensor protector 1 2 rear wheel sensor 1 3 rear wheel sensor bracket 1 4 locknut 2 loosen. 5 adjusting bolt 2 loosen. 6 wheel axle nu...
Page 189: Rear Wheel
Rear wheel 4-22 removing the brake disc and rear wheel sprocket order job/parts to remove q’ty remarks 1 rear brake disc 1 2 collar 1 3 rear wheel sprocket 1 4 rear wheel drive hub 1 5 rear wheel drive hub damper 6 6 collar 1 7 oil seal 1 8 bearing 1 9 rear wheel 1 for installation, reverse the remo...
Page 190: Rear Wheel
Rear wheel 4-23 disassembling the rear wheel order job/parts to remove q’ty remarks 1 rear wheel sensor rotor 1 2 oil seal 1 3 wheel bearing 1 4 spacer 1 5 wheel bearing 1 for assembly, reverse the disassembly pro- cedure..
Page 191: Rear Wheel
Rear wheel 4-24 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. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear brake caliper “1” • r...
Page 192: Rear Wheel
Rear wheel 4-25 eas14b1003 checking and replacing the rear wheel sprocket 1. Check: • rear wheel sprocket more than 1/4 tooth “a” wear → replace the drive chain sprockets as a set. Bent teeth → replace the drive chain sprockets as a set. 2. Replace: • rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 193: Rear Wheel
Rear wheel 4-26 removing the rear wheel sensor 1. Disconnect: • rear wheel sensor coupler “1” 2. Remove: • clamps “1” • brake hose holders “2” 3. Remove: • rear wheel sensor • rear wheel refer to “removing the rear wheel” on page 4-24. Eca1cw1402 • be sure not to contact the sensor elec- trode to an...
Page 194: Rear Wheel
Rear wheel 4-27 eca14470 make sure there are no foreign materials in the wheel hub. Foreign materials cause damage to the inner sensor rotor and wheel sensor. 3. Measure: tip measure the distance “a” only if the wheel bearings, wheel sensor rotor, or both were replaced. • distance “a” (between the w...
Page 195: Rear Wheel
Rear wheel 4-28 eas22150 adjusting the rear wheel static balance tip • after replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: • rear wheel static balance refe...
Page 196: Rear Wheel
Rear wheel 4-29 5. Install: • rear brake caliper • rear brake caliper retaining bolts 6. Adjust: • drive chain slack refer to “adjusting the drive chain slack” on page 3-19. 7. Tighten: • wheel axle nut • rear brake caliper retaining bolts warning ewa13500 make sure the brake hose is routed prop- er...
Page 197: Front Brake
Front brake 4-30 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 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 blee...
Page 198: Front Brake
Front brake 4-31 removing the front brake master cylinder order job/parts to remove q’ty remarks right rear view mirror fz8na refer to “handlebar” on page 4-64. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-16. 1 brake master cylinder reservoir cap 1 2 brake master cyli...
Page 199: Front Brake
Front brake 4-32 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 200: Front Brake
Front brake 4-33 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-16. 1 brake hose union bolt 1 2 brake hose gasket 2 3 brake hose ...
Page 201: Front Brake
Front brake 4-34 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 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 br...
Page 202: Front Brake
Front brake 4-35 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 203: Front Brake
Front brake 4-36 d. Measure the brake disc deflection. E. If out of specification, repeat the adjust- ment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. ...
Page 204: Front Brake
Front brake 4-37 tip the arrow mark “a” on the brake pad spring must point in the direction of disc rotation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: • brake pad pin • brake pad clips • front brake caliper 6. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake ...
Page 205: Front Brake
Front brake 4-38 warning ewa39p1401 • never try to pry out the brake caliper pis- tons. • do not loosen the bolts “4”. C. Remove the brake caliper piston dust seals and brake caliper piston seals. D. Repeat the previous steps to force out the right side pistons from the brake caliper. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 206: Front Brake
Front brake 4-39 warning ewa13530 proper brake hose routing is essential to insure safe vehicle operation. Refer to “cable routing” on page 2-43. 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. Remov...
Page 207: Front Brake
Front brake 4-40 eas22490 removing the front brake master cylinder tip before removing the front brake master cylin- der, drain the brake fluid from the entire brake system. 1. Disconnect: • brake light switch connectors (from the front brake light switch) 2. Remove: • brake hose union bolt “1” • br...
Page 208: Front Brake
Front brake 4-41 • align the end of the front brake master cylin- der holder with the punch mark “b” on the handlebar. • first, tighten the upper bolt, then the lower bolt. • there should be more than 11 mm (0.43 in) for clearance between the right handlebar switch and the front brake master cylinde...
Page 209: Front Brake
Front brake 4-42 6. Check: • brake lever operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” on page 3-16..
Page 210: Rear Brake
Rear brake 4-43 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 2 5 brake pad shim 2 6 brake pad insulator 2 7 brake pad spring 1 8 bleed screw 1 for installation, reverse the removal proce- d...
Page 211: Rear Brake
Rear brake 4-44 removing the rear brake master cylinder order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Right side cover...
Page 212: Rear Brake
Rear brake 4-45 removing the rear brake master cylinder order job/parts to remove q’ty remarks 11 rear brake light switch 1 12 rear brake master cylinder assembly 1 for installation, reverse the removal proce- dure..
Page 213: Rear Brake
Rear brake 4-46 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 brake master cylinder yoke 1 2 brake master cylinder kit 1 3 hose joint 1 4 bushing 1 5 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure..
Page 214: Rear Brake
Rear brake 4-47 removing the rear brake caliper order job/parts to remove q’ty remarks 1 brake hose union bolt 1 2 brake hose gasket 2 3 brake hose 1 4 rear brake caliper 1 for installation, reverse the removal proce- dure..
Page 215: Rear Brake
Rear brake 4-48 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 2 5 brake pad insulator 2 6 brake pad spring 1 7 brake caliper piston 1 8 brake caliper piston dust seal 1 9 brake caliper piston seal 1 10 blee...
Page 216: Rear Brake
Rear brake 4-49 eas22561 introduction warning ewa14101 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 217: Rear Brake
Rear brake 4-50 2. Install: • brake pad insulators • brake pad shims (onto the brake pads) • brake pad spring (into the rear brake caliper) • brake pads tip always install new brake pads, brake pad insu- lators, brake pad shims, and brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connec...
Page 218: Rear Brake
Rear brake 4-51 6. Check: • brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” on page 3-16. Eas22590 removing the rear brake caliper tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. ...
Page 219: Rear Brake
Rear brake 4-52 1. Check: • brake caliper piston “1” rust/scratches/wear → replace the brake caliper piston. • brake caliper cylinder “2” scratches/wear → replace the brake cal- iper assembly. • brake caliper body “3” cracks/damage → replace the brake caliper assembly. • brake fluid delivery passage...
Page 220: Rear Brake
Rear brake 4-53 2. Remove: • rear brake caliper 3. Install: • brake pad insulators • brake pad shims (onto the brake pads) • brake pad spring (into the rear brake caliper) • brake pads • rear brake caliper refer to “replacing the rear brake pads” on page 4-49. 4. Fill: • brake fluid reservoir (with ...
Page 221: Rear Brake
Rear brake 4-54 eas22720 checking the rear brake master cylinder 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/wear → r...
Page 222: Rear Brake
Rear brake 4-55 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chem...
Page 223: 4-56
Abs (anti-lock brake system) 4-56 eas22760 abs (anti-lock brake system) removing the hydraulic unit assembly order job/parts to remove q’ty remarks rider seat refer to “general chassis”. Side cover refer to “general chassis”. Fuel tank refer to “fuel tank”. Brake fluid drain. Refer to “bleeding the ...
Page 224: 4-57
Abs (anti-lock brake system) 4-57 removing the hydraulic unit assembly order job/parts to remove q’ty remarks 10 brake pipe/joint assembly (hydraulic unit to rear brake caliper) 1 disconnect. 11 brake pipe/joint assembly (front brake master cylinder to hydraulic unit) 1 disconnect. 12 brake pipe/joi...
Page 225: 4-58
Abs (anti-lock brake system) 4-58 eas4b56004 removing the hydraulic unit assem- bly eca4b56013 unless necessary, avoid removing and installing the brake pipes of the hydraulic unit assembly. Warning ewa13930 refill with the same type of brake fluid that is already in the system. Mixing fluids may re...
Page 226: 4-59
Abs (anti-lock brake system) 4-59 eas4b56006 checking the brake pipes the following procedure applies to all of the brake pipes. 1. Check: • brake pipe end (flare nut) damage → replace the hydraulic unit, brake pipes, and related parts as a set. Eas4b56007 installing the hydraulic unit assembly 1. I...
Page 227: 4-60
Abs (anti-lock brake system) 4-60 warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result...
Page 228: 4-61
Abs (anti-lock brake system) 4-61 6. Turn the main switch to “on” while operat- ing the brake lever and then brake pedal simultaneously. Tip do not push the start switch when turning the main switch to “on”, otherwise the operation test will not begin. 7. Check: • hydraulic unit operation when the m...
Page 229: 4-62
Abs (anti-lock brake system) 4-62 5. Connect the test coupler adapter “1” to the abs test coupler “2”. 6. Set the engine stop switch “1” to “ ”. 7. Turn the main switch to “on”. 8. Push the start switch “2” for at least 4 sec- onds. Eca14790 do not operate the brake lever or the brake pedal. 9. Afte...
Page 230: 4-63
Abs (anti-lock brake system) 4-63 12. After the pulsating action has stopped in the rear brake pedal, it is generated in the front brake lever 0.5 second later and con- tinues for approximately 1.5 seconds. Tip the reaction-force pulsating action consists of quick pulses. Eca4b56021 • check that the...
Page 231: Handlebar
Handlebar 4-64 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks inner panel fz8sa refer to “general chassis” on page 4-1. 1 rear view mirror 2 fz8na 2 front brake light switch connector 2 disconnect. 3 front master cylinder holder 1 4 front brake master cylinder assem...
Page 232: Handlebar
Handlebar 4-65 removing the handlebar order job/parts to remove q’ty remarks 15 upper handlebar holder 2 16 handlebar 1 17 lower handlebar holder 2 for installation, reverse the removal proce- dure..
Page 233: Handlebar
Handlebar 4-66 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” tip blow compressed air between the left handle- bar and the handlebar grip, and gradua...
Page 234: Handlebar
Handlebar 4-67 3. Tighten: • lower handlebar holder nuts 4. Install: • throttle grip “1” • throttle cables • throttle cable housings “2” • grip end tip • align the projection “a” on the throttle cable housing with the hole “b” in the handlebar. • there should be 1–3 mm (0.04–0.12 in) of clearance “c...
Page 235: Handlebar
Handlebar 4-68 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. B. Side the handlebar grip over the end of the left handlebar. C. Wipe off any excess rubber adhesive with a clean rag. Warning ewa13700 do not touch the handlebar grip until the...
Page 236: Front Fork
Front fork 4-69 eas22950 front fork removing the front fork legs order job/parts to remove q’ty remarks the following procedure applies both of the front fork legs. Front wheel refer to “front wheel” on page 4-12. 1 front fender 1 2 band 1 left side only. 3 upper bracket pinch bolt 1 loosen. 4 cap b...
Page 237: Front Fork
Front fork 4-70 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies both of the front fork legs. 1 cap bolt 1 2 o-ring 1 3 spacer 1 4 fork spring 1 5 locknut 1 6 outer tube 1 7 dust seal 1 8 oil seal clip 1 9 oil seal 1 10 washer 1 11 damper rod a...
Page 238: Front Fork
Front fork 4-71 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Tip place the vehicle on a suitable stand so tha...
Page 239: Front Fork
Front fork 4-72 eca39p1404 do not scratch the outer tube. 4. Remove: • damper rod assembly bolt • damper rod assembly tip while holding the damper rod with the damper rod holder “1”, loosen the damper rod assem- bly bolt. Eas23011 checking the front fork legs the following procedure applies to both ...
Page 240: Front Fork
Front fork 4-73 eas23031 assembling the front fork legs the following procedure applies to both of the front fork legs. Warning ewa39p1404 • note that the amount of the fork oil is dif- ferent in the left and right front fork legs. Make sure to fill each of the left and right front fork legs with th...
Page 241: Front Fork
Front fork 4-74 eca14b1007 make sure the numbered side of the oil seal faces bottom side. Tip • before installing the oil seal, lubricate its lips with lithium-soap-based grease. • lubricate the outer surface of the inner tube with fork oil. 5. Install: • outer tube (to the inner tube) 6. Install: •...
Page 242: Front Fork
Front fork 4-75 • when disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 10. Install: • rod puller “1” • rod puller attachment (m10) “2” (onto the damper rod “3”) 11. After filling the front fork leg, slowly stroke the damper rod “1” up and d...
Page 243: Front Fork
Front fork 4-76 c. Install the locknut all the way onto the damper rod assembly. D. Install the spacer. E. Install the rod puller, rod puller attachment, and fork spring compressor. F. Press down on the spacer with the fork spring compressor “1”. G. Pull up the rod puller and install the rod holder ...
Page 244: Front Fork
Front fork 4-77 eas23050 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: • front fork leg temporarily tighten the upper and lower bracket pinch bolts. Tip make sure the outer tube is flush with the top of the upper bracket. 2. Tighten: • low...
Page 245: Steering Head
Steering head 4-78 eas23090 steering head removing the lower bracket (fz8na) 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. Meter assembly refer to “general chassis” on page 4-1. Handlebar refer to “handlebar...
Page 246: Steering Head
Steering head 4-79 removing the lower bracket (fz8na) order job/parts to remove q’ty remarks 10 lock washer 1 11 upper ring nut 1 12 rubber washer 1 13 lower ring nut 1 14 lower bracket 1 15 bearing cover 1 16 lower bearing dust seal 1 17 upper bearing 1 18 lower bearing 1 for installation, reverse ...
Page 247: Steering Head
Steering head 4-80 removing the lower bracket (fz8sa) order job/parts to remove q’ty remarks inner panel/side panel/front cowling side panel 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. Handlebar refer to ...
Page 248: Steering Head
Steering head 4-81 removing the lower bracket (fz8sa) order job/parts to remove q’ty remarks 10 lock washer 1 11 upper ring nut 1 12 rubber washer 1 13 lower ring nut 1 14 lower bracket 1 15 bearing cover 1 16 lower bearing dust seal 1 17 upper bearing 1 18 lower bearing 1 for installation, reverse ...
Page 249: Steering Head
Steering head 4-82 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 • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...
Page 250: Steering Head
Steering head 4-83 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 2. Install: • lower ring nut “1” • rubber washer “2” • upper r...
Page 251: 4-84
Rear shock absorber assembly 4-84 eas23160 rear shock absorber assembly removing the rear shock absorber assembly order job/parts to remove q’ty remarks left side cover refer to “general chassis” on page 4-1. Right side cover refer to “general chassis” on page 4-1. Brake fluid reservoir bolt refer t...
Page 252: 4-85
Rear shock absorber assembly 4-85 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 253: 4-86
Rear shock absorber assembly 4-86 eas23261 checking the connecting arm and relay arm 1. Check: • connecting arm “1” • relay arms “2” damage/wear → replace. 2. Check: • bearings • oil seals damage/pitting → replace. 3. Check: • collars damage/scratches → replace. Eas23311 installing the rear shock ab...
Page 254: 4-87
Rear shock absorber assembly 4-87 4. Tighten: • rear shock absorber assembly upper nut • rear shock absorber assembly lower nut • frame and connecting arm nut • relay arm and swingarm nut • relay arm and connecting arm nut 3. Frame 4. Swingarm a. Left side b. Right side rear shock absorber assembly ...
Page 255: Swingarm
Swingarm 4-88 eas23330 swingarm removing the swingarm order job/parts to remove q’ty remarks rear brake caliper refer to “rear brake” on page 4-43. Rear wheel refer to “rear wheel” on page 4-21. Relay arm refer to “rear shock absorber assembly” on page 4-84. Chain refer to “chain drive” on page 4-91...
Page 256: Swingarm
Swingarm 4-89 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. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • relay arm and swingarm bolt “1...
Page 257: Swingarm
Swingarm 4-90 4. Check: • dust covers “1” • spacer “2” • oil seals “3” damage/wear → replace. • collar “4” damage/scratches → replace. • bearings “5” damage/pitting → replace. Eas23380 installing the swingarm 1. Lubricate: • spacer • dust covers • pivot shaft • oil seals • collar 2. Install: • beari...
Page 258: Chain Drive
Chain drive 4-91 eas23400 chain drive removing the drive chain order job/parts to remove q’ty remarks drive sprocket refer to “engine removal” on page 5-3. 1 drive chain 1 for installation, reverse the removal proce- dure..
Page 259: Chain Drive
Chain drive 4-92 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. Tip place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • drive chain tip cut the ...
Page 260: Chain Drive
Chain drive 4-93 eca39p1403 • this vehicle has a drive chain with small rubber o-rings “1” between the drive chain side plates. Never use high-pres- sure water or air, steam, gasoline, certain solvents (e.G., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dir...
Page 261: Chain Drive
Chain drive 4-94 eas39p1403 installing the drive chain 1. Install: • drive chain tip install the drive chain joint with the drive chain cut & rivet tool. (use goods on the market) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. When press fitting the connecting plate “1”, make sure the space “a” between the end o...
Page 262: Chain Drive
Chain drive 4-95.
Page 263: Engine
5 engine engine inspection.................................................................................. 5-1 measuring the compression pressure ................................. 5-1 engine removal ...................................................................................... 5-3 installi...
Page 264
Electric starter.................................................................................5-41 checking the starter motor ...................................................5-43 assembling the starter motor ...............................................5-44 installing the starter motor.........
Page 265
Crankshaft ...........................................................................................5-80 removing the crankshaft assembly .....................................5-81 checking the oil nozzles ..........................................................5-81 checking the crankshaft .........
Page 266: Engine Inspection
Engine inspection 5-1 eas14b1052 engine inspection eas20710 measuring the compression pres- sure the following procedure applies to all of the cylinders. Tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to ...
Page 267: Engine Inspection
Engine inspection 5-2 6. Install: • spark plug 7. Install: • ignition coils spark plug 13 nm (1.3 m·kgf, 9.4 ft·lbf).
Page 268: Engine Removal
Engine removal 5-3 eas23711 engine removal removing the drive sprocket order job/parts to remove q’ty remarks drive chain loosen. Refer to “adjusting the drive chain slack” on page 3-19. 1 locknut 2 2 shift rod 1 3 shift arm 1 4 joint 1 5 drive sprocket cover 1 6 plate 1 7 drive sprocket nut 1 8 was...
Page 269: Engine Removal
Engine removal 5-4 removing the muffler and exhaust pipe order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Drive sprocket cover refer to “engine removal” on page 5-3. 1 o 2 sensor coupler 1 disconnect. 2 o 2 sensor 1...
Page 270: Engine Removal
Engine removal 5-5 disconnecting the leads and hoses order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page 7-5. Thermostat assembly refer to “thermostat” on page 6-7. Oil cooler refer to “oil cooler” on page 6-5. Air cut...
Page 271: Engine Removal
Engine removal 5-6 disconnecting the leads and hoses order job/parts to remove q’ty remarks 7 stator coil assembly lead coupler 1 disconnect. 8 crankshaft position sensor lead coupler 1 disconnect. 9 oil level switch lead coupler 1 disconnect. 10 neutral switch connector 1 disconnect. For installati...
Page 272: Engine Removal
Engine removal 5-7 removing the engine order job/parts to remove q’ty remarks 1 right front engine mounting bolt 1 1 2 left front engine mounting bolt 1 3 upper engine mounting bolt/nut 1/1 4 lower engine mounting bolt/nut 1/1 5 engine mounting adjust bolt 2 loosen. 6 engine 1 for installation, reve...
Page 273: Engine Removal
Engine removal 5-8 eas23720 installing the engine 1. Install: • right front engine mounting bolt 2 “1” refer to “cylinder head” on page 5- 20. 2. Tighten: • right front engine mounting bolt 2 3. Install: • engine mounting adjust bolts (temporarily tighten) 4. Install: • engine 5. Install: • lower en...
Page 274: Engine Removal
Engine removal 5-9 8. Install: • lower engine mounting nut “1” • upper engine mounting nut “2” tip first tighten the lower engine mounting nut, and then tighten the upper engine mounting nut. 9. Tighten: • left front engine mounting bolt “1” • right front engine mounting bolt 1 “2” tip first tighten...
Page 275: Engine Removal
Engine removal 5-10 tip align punch mark “a” of the shift arm “1” with alignment mark “b” of the crankcase. Eas39p1501 installing the drive sprocket 1. Install: • drive sprocket • washer • drive sprocket nut “1” tip • while applying the rear brake, tighten the drive sprocket nut. • stake the drive s...
Page 276: Camshafts
Camshafts 5-11 eas23760 camshafts * silicone fluid removing the cylinder head cover order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page 7-5. Air cut-off valve refer to “air induction system” on page 7-15. 1 cylinder id...
Page 277: Camshafts
Camshafts 5-12 removing the camshafts order job/parts to remove q’ty remarks pickup rotor cover refer to “crankshaft position sen- sor” on page 5-39. Clutch cable (engine side) disconnect. Refer to “clutch” on page 5-45. 1 timing chain tensioner 1 2 timing chain tensioner gasket 1 3 intake camshaft ...
Page 278: Camshafts
Camshafts 5-13 eas23810 removing the camshafts 1. Remove: • pickup rotor cover refer to “crankshaft position sensor” on page 5-39. 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 279: Camshafts
Camshafts 5-14 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 280: Camshafts
Camshafts 5-15 c. Install the dowel pins and camshaft caps. Tip • tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clear- ance with the plastigauge®. D. Remove the cam...
Page 281: Camshafts
Camshafts 5-16 eas23960 checking the timing chain ten- sioner 1. Remove: • timing chain tensioner housing “1” • timing chain tensioner rod “2” • timing chain tensioner spring “3” • timing chain tensioner spring seat “4” tip squeeze the timing chain tensioner clip “5”, and then remove the timing chai...
Page 282: Camshafts
Camshafts 5-17 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 piston #1 is at tdc, align the “t” mark “a” with the crankcase...
Page 283: Camshafts
Camshafts 5-18 “el”: exhaust left side camshaft cap mark “er”: exhaust right side camshaft cap mark • make sure the arrow mark “a” on each cam- shaft points towards the right side of the engine. 5. Tighten: • camshaft cap bolts tip tighten the camshaft cap bolts in stages and in a crisscross pattern...
Page 284: Camshafts
Camshafts 5-19 10. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clearance” on page 3-5. 11. Install: • pickup rotor cover refer to “crankshaft position sensor” on page 5-39. 12. Install: • timing chain guide (top side) • cylinder head cover gasket • cylinde...
Page 285: Cylinder Head
Cylinder head 5-20 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Intake camshaft refer to “camshafts” on page 5-11. Exhaust camshaft refer to “camshafts” on page 5-11. 1 coolant pipe 1 2 fast idle plunger inlet ...
Page 286: Cylinder Head
Cylinder head 5-21 eas24120 removing the cylinder head 1. Remove: • intake camshaft • exhaust camshaft refer to “removing the cam- shafts” on page 5-13. 2. Remove: • cylinder head nuts • cylinder head bolts tip • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a t...
Page 287: Cylinder Head
Cylinder head 5-22 2. Install: • cylinder head gasket “1” • dowel pins 3. Install: • cylinder head • washers • cylinder head nuts • cylinder head bolts tip • pass the timing chain through the timing chain cavity. • lubricate the cylinder head nut thread and mating surface with engine oil. 4. Tighten...
Page 288: Valves And Valve Springs
Valves and valve springs 5-23 eas24270 valves and valve springs * silicone fluid removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-20. 1 intake valve lifter 8 2 intake valve pad 8 3 intake valve cotter 16 4 intake valve spri...
Page 289: Valves And Valve Springs
Valves and valve springs 5-24 * silicone fluid removing the valves and valve springs order job/parts to remove q’ty remarks 10 exhaust valve lifter 8 11 exhaust valve pad 8 12 exhaust valve cotter 16 13 exhaust valve spring retainer 8 14 exhaust valve spring 8 15 exhaust valve 8 16 exhaust valve ste...
Page 290: Valves And Valve Springs
Valves and valve springs 5-25 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip 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 lif...
Page 291: Valves And Valve Springs
Valves and valve springs 5-26 tip identify the position of each part very carefully so that it can be reinstalled in its original place. 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 cleara...
Page 292: Valves And Valve Springs
Valves and valve springs 5-27 c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve- guide clearance. Tip after replacing the valve guide, reface the valve seat. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Eliminate: • carbon deposit...
Page 293: Valves And Valve Springs
Valves and valve springs 5-28 eas24300 checking the valve seats the following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat pitting/wear → replace the cylinder head. 3. Measure: • valve seat width “...
Page 294: Valves And Valve Springs
Valves and valve springs 5-29 e. Apply a fine lapping compound to the valve face and repeat the above steps. F. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. G. Apply mechanic’s blueing dye (dykem) “b” onto the valve face. H. Inst...
Page 295: Valves And Valve Springs
Valves and valve springs 5-30 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24320 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lifters and cylinder head....
Page 296: Valves And Valve Springs
Valves and valve springs 5-31 4. Install: • valve cotters “1” tip install the valve cotters by compressing the valve spring with the valve spring compressor “2” and the valve spring compressor attach- ment “3”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft...
Page 297: Generator
Generator 5-32 eas24480 generator removing the generator order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Left side cover 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” ...
Page 298: Generator
Generator 5-33 removing the generator order job/parts to remove q’ty remarks 11 bearing housing 1 12 collar 1 13 bearing 1 14 starter clutch idler gear 1 15 idler gear shaft 1 16 bearing 1 for installation, reverse the removal proce- dure..
Page 299: Generator
Generator 5-34 eas24490 removing the generator 1. Remove: • plug • generator rotor cover “1” tip • 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 them...
Page 300: Generator
Generator 5-35 4. Install: • generator rotor cover gasket • generator rotor cover “1” tip • 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 (m8) 22 nm (2.2 m·kgf, 16 ft·lbf) generato...
Page 301: Starter Clutch
Starter clutch 5-36 eas24550 starter clutch removing the starter clutch order job/parts to remove q’ty remarks 1 spacer 1 2 o-ring 1 3 washer 1 4 starter clutch drive gear 1 5 collar 1 6 washer 1 7 driven gear 1 8 damper 3 9 starter clutch assembly plate 1 10 starter clutch assembly 1 11 generator r...
Page 302: Starter Clutch
Starter clutch 5-37 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” 4. Remove: • starter clutch assembly plate “1” • starter clutch assembly “2” eas5...
Page 303: Starter Clutch
Starter clutch 5-38 3. Check: • starter clutch gear’s contacting surfaces damage/pitting/wear → replace the starter clutch gear. 4. Check: • starter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch drive gear “1” onto the starter clutch and hold the driven gear. B. When ...
Page 304: Crankshaft Position Sensor
Crankshaft position sensor 5-39 eas24520 crankshaft position sensor removing the crankshaft position sensor order job/parts to remove q’ty remarks rider 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 pa...
Page 305: Crankshaft Position Sensor
Crankshaft position sensor 5-40 eas24530 removing the crankshaft position sensor 1. Disconnect: • crankshaft position sensor lead coupler 2. Remove: • crankshaft position sensor • o-rings • pickup rotor cover “1” tip loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. Af...
Page 306: Electric Starter
Electric starter 5-41 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Throttle bodies refer to “throttle bodies” on page 7-5. Right throttle body joint refer to ...
Page 307: Electric Starter
Electric starter 5-42 * when replacing any of the front cover, starter motor yoke, armature assembly, and rear cover, replace the starter motor assembly. Disassembling the starter motor order job/parts to remove q’ty remarks 1 o-ring 1 2 front cover 1 3 starter motor yoke 1 4 armature assembly 1 5 g...
Page 308: Electric Starter
Electric starter 5-43 eas24791 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Tip the mica of t...
Page 309: Electric Starter
Electric starter 5-44 6. Check: • gear teeth damage/wear → replace the starter motor. 7. Check: • bearing • oil seal damage/wear → replace the starter motor. Eas24800 assembling the starter motor 1. Install: • brush holder set 2. Install: • rear cover “1” • starter motor yoke “2” • front cover “3” t...
Page 310: Clutch
Clutch 5-45 eas25061 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-24. 1 clutch cable 1 disconnect. 2 clutch cover 1 3 clutch cover gasket 1 4 dowel pin 2 5 oil filler cap 1 for installation, reverse the removal...
Page 311: Clutch
Clutch 5-46 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 312: Clutch
Clutch 5-47 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 green paint mark. 6 clutch plate 1 6 7 friction plate 2 6 purple paint mark. 8 clutch boss nut 1 9 washer 1 10 clutch boss 1 11 wire circlip ...
Page 313: Clutch
Clutch 5-48 removing the clutch order job/parts to remove q’ty remarks 16 thrust plate 1 17 clutch housing 1 18 bearing 1 for installation, reverse the removal proce- dure..
Page 314: Clutch
Clutch 5-49 eas30712 removing the clutch 1. Remove: • clutch cover “1” • gasket tip 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 plat...
Page 315: Clutch
Clutch 5-50 7. Remove: • clutch boss nut • washer • clutch boss assembly • thrust plate 8. Remove: • wire circlip “1” tip 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 se...
Page 316: Clutch
Clutch 5-51 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge “1”) out of specification → replace the clutch plates as a set. Eas25140 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: • clutch spring damage → replace the c...
Page 317: Clutch
Clutch 5-52 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 as a set. 2. Check: • pull rod bearing damage/wear → replace. Eas25240 installing the clutch 1. Install: • c...
Page 318: Clutch
Clutch 5-53 • stake the clutch boss nut at a cutout “a” in the main axle. • while holding the clutch boss assembly “1” with the universal clutch holder “3”, tighten the clutch boss nut. 6. Install: • friction plate 2 • clutch plate 1 “1” tip assemble friction plate 2 to the clutch boss assembly so t...
Page 319: Clutch
Clutch 5-54 9. Install: • dowel pins • clutch cover gasket • clutch cover “1” tip • apply engine oil onto the bearing. • apply locking agent (loctite®) to the threads of only the clutch cover bolts “a” shown in the illustration. • tighten the clutch cover bolts in stages and in a crisscross pattern....
Page 320: Shift Shaft
Shift shaft 5-55 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 5-45. Shift arm and shift rod refer to “engine removal” on page 5-3. 1 circlip 1 2 washer 1 3 shift shaft 1 4 washer 1 5 shift shaft sprin...
Page 321: Shift Shaft
Shift shaft 5-56 eas25420 checking the shift shaft 1. Check: • shift shaft “1” bends/damage/wear → replace. • shift shaft spring “2” • collar “3” damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever “1” bends/damage → replace. Roller turns roughly → replace the stop- ...
Page 322: Oil Pump
Oil pump 5-57 eas24921 oil pump removing the oil pan and oil pump order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 7-1. Drive sprocket cover refer to “engine removal” on page 5-3. Engine oil drain. Refer to “changing the engine oil” on page 3-24. O 2 sensor refer to “eng...
Page 323: Oil Pump
Oil pump 5-58 removing the oil pan and oil pump order job/parts to remove q’ty remarks 6 dowel pin 2 7 drain pipe 1 8 oil strainer 1 9 oil pipe 1 10 oil delivery pipe 1 11 relief valve assembly 1 12 oil/water pump assembly drive chain guide 1 13 collar 1 14 oil/water pump assembly drive sprocket 1 1...
Page 324: Oil Pump
Oil pump 5-59 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 rotor assembly 1 7 pin 1 for assembly, reverse the disassembly pro- cedure..
Page 325: Oil Pump
Oil pump 5-60 eas24930 removing the oil pan 1. Remove: • oil level switch “1” • oil pan “2” • oil pan gasket • dowel pins tip 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 ch...
Page 326: Oil Pump
Oil pump 5-61 3. Check: • oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas24971 checking the relief valve 1. Check: • relief valve body “1” • relief valve “2” • spring “3” • o-ring “4” damage/wear → replace the relief valve assembly. Eas24980 checkin...
Page 327: Oil Pump
Oil pump 5-62 eas25010 assembling the oil pump 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) 2. Install: • pin “1” • inner rotor “2” • outer rotor “3” • oil pump housing “4” • oil pump housing bolt tip when installing the inner rotor, align the pin “1” i...
Page 328: Oil Pump
Oil pump 5-63 tip install the oil/water pump assembly drive chain “1” onto the oil/water pump assembly drive sprocket “2”. 3. Install: • oil/water pump assembly drive chain guide “1” tip “up” mark of the oil/water pump assembly drive chain guide is upward. 4. Install: • oil delivery pipe “1” 5. Inst...
Page 329: Oil Pump
Oil pump 5-64 • oil level switch “2” • engine oil drain bolt “3” warning ewa12820 always use new copper washers. Tip • tighten the oil pan bolts in stages and in a crisscross pattern. • lubricate the oil level switch o-ring with lith- ium-soap-based grease. Oil level switch bolt 10 nm (1.0 m·kgf, 7....
Page 330: Crankcase
Crankcase 5-65 eas25540 crankcase * yamaha bond no.1215 (three bond no.1215®) separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-3. Cylinder head refer to “cylinder head” on page 5-20. Shift shaft assembly refer to “shift shaft” on page 5-55. C...
Page 331: Crankcase
Crankcase 5-66 * yamaha bond no.1215 (three bond no.1215®) separating the crankcase order job/parts to remove q’ty remarks 4 crankcase breather hose 1 5 ventilation chamber cover 1 6 ventilation chamber cover gasket 1 7 left side cover 1 8 o-ring 1 9 lower crankcase 1 10 dowel pin 3 for installation...
Page 332: Crankcase
Crankcase 5-67 eas25550 disassembling the crankcase 1. Place the engine upside down. 2. Remove: • crankcase bolts tip • 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 numerical ...
Page 333: Crankcase
Crankcase 5-68 3. Install: • dowel pins 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: • lower crankcase “1” (onto the upper crankcase “2”) eca13980 before tightening the crankcase bolts, make sure the transmission gears shift cor- rectly when the shift ...
Page 334: Connecting Rods and Pistons
Connecting rods and pistons 5-69 eas39p1503 connecting rods and pistons removing the connecting rods and pistons order job/parts to remove q’ty remarks lower crankcase refer to “crankcase” on page 5-65. 1 connecting rod cap 4 2 big end lower bearing 4 3 big end upper bearing 4 4 piston pin clip 8 5 ...
Page 335: Connecting Rods and Pistons
Connecting rods and pistons 5-70 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” • connecting rod • big end bearings tip • identify the position of each big end bearing so that it can be ...
Page 336: Connecting Rods and Pistons
Connecting rods and pistons 5-71 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “c” with the cylinder bore gauge. Tip measure cylinder bore “c” by taking side-to- side and front-to-back measurements of the cylinder. Then, find the average of the me...
Page 337: Connecting Rods and Pistons
Connecting rods and pistons 5-72 2. Install: • piston ring (into the cylinder) tip level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer’s end gap cannot be measured. If the oi...
Page 338: Connecting Rods and Pistons
Connecting rods and pistons 5-73 3. Measure: • piston pin bore inside diameter “b” out of specification → replace the pis- ton. 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Eas39p1504 checking the connecting rods 1. Measur...
Page 339: Connecting Rods and Pistons
Connecting rods and pistons 5-74 d. Assemble the connecting rod halves. Eca39p1501 tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. Tip • clean the connecting rod bolts and lubricate the bolt threads and seats with molybdenum disulfide oil....
Page 340: Connecting Rods and Pistons
Connecting rods and pistons 5-75 h. Put a mark “1” on the corner of the con- necting rod bolt “2” and the connecting rod cap “3”. I. Tighten the connecting rod bolts further to reach the specified angle 145 °–155°. Warning ewa13400 if the connecting rod bolt is tightened more than the specified angl...
Page 341: Connecting Rods and Pistons
Connecting rods and pistons 5-76 eas26190 installing the connecting rod and piston the following procedure applies to all of the connecting rods and pistons. 1. Install: • big end bearings • connecting rod cap (onto the connecting rod) tip • be sure to reinstall each big end bearing in its original ...
Page 342: Connecting Rods and Pistons
Connecting rods and pistons 5-77 e. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • oil ring expander “1” • lower oil ring...
Page 343: Connecting Rods and Pistons
Connecting rods and pistons 5-78 7. Lubricate: • crankshaft pins • connecting rod big end bearing inner sur- face (with the recommended lubricant) 8. Check: • cylinder stud bolts 9. Install: • piston assemblies “1” (into the cylinder) tip while compressing the piston rings with one hand, install the...
Page 344: Connecting Rods and Pistons
Connecting rods and pistons 5-79 warning ewa13400 if the connecting rod bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Instead, replace the connecting rod bolt with a new one and perform the procedure again. Eca13950 do not use a torque wrench to tight...
Page 345: Crankshaft
Crankshaft 5-80 eas25950 crankshaft removing the crankshaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-65. Connecting rod refer to “removing the connecting rods and pistons” on page 5-70. 1 crankshaft 1 2 crankshaft journal lower bearing 5 3 crankshaft ...
Page 346: Crankshaft
Crankshaft 5-81 eas25980 removing the crankshaft assembly 1. Remove: • crankshaft assembly • crankshaft journal bearings tip identify the position of each crankshaft journal bearings so that it can be reinstalled in its orig- inal place. Eas14b1025 checking the oil nozzles the following procedure ap...
Page 347: Crankshaft
Crankshaft 5-82 tip 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. Tip • align the projections “a” of the crankshaft journal lower bearings with the notches “b...
Page 348: Crankshaft
Crankshaft 5-83 eas26200 installing the crankshaft 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) • crankshaft tip • align the projections “a” on the crankshaft journal bearings “1” with the notches “b” in the...
Page 349: Transmission
Transmission 5-84 eas26241 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 5-65. 1 drive axle assembly 1 2 oil seal 1 3 bearing 1 4 washer 1 5 shift fork guide bar retainer 2 6 ...
Page 350: Transmission
Transmission 5-85 removing the transmission, shift drum assembly, and shift forks order job/parts to remove q’ty remarks 14 oil pipe 1 15 oil baffle plate 1 16 bearing 2 for installation, reverse the removal proce- dure..
Page 351: Transmission
Transmission 5-86 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd pinion gear 1 tip when installing secondary pinion gear “1”, install the gear with groove “a” facing to the toothed lock washer. 2 toothed lock washer 1 3 toothed lock washer retainer 1 4 6th pinion g...
Page 352: Transmission
Transmission 5-87 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 353: Transmission
Transmission 5-88 disassembling the drive axle assembly order job/parts to remove q’ty remarks 20 collar 1 21 bearing 1 22 circlip 1 23 drive axle 1 for assembly, reverse the disassembly pro- cedure..
Page 354: Transmission
Transmission 5-89 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 355: Transmission
Transmission 5-90 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 groove damage/scratches/wear → replace the shift drum assembly. • shift drum...
Page 356: Transmission
Transmission 5-91 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect → reassemble the transmis- sion axle assemblies. 5. Check: • transmission gear movement rough movement → replace the defec- tive part(s). 6. Check: • circlips bends/damage/looseness →...
Page 357: Transmission
Transmission 5-92 tip • the embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “r”, “c”, “l”. • carefully position the shift forks so that they are installed correctly into the transmission gears. • install shift fork “c” into the gro...
Page 358: Transmission
Transmission 5-93.
Page 359: Cooling System
6 cooling system radiator .................................................................................................... 6-1 checking the radiator.................................................................. 6-3 installing the radiator ........................................................
Page 360: Radiator
Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air filter case ref...
Page 361: Radiator
Radiator 6-2 removing the radiator order job/parts to remove q’ty remarks 8 radiator upper panel 1 fz8sa 9 radiator fan motor coupler 2 disconnect. 10 radiator 1 11 radiator fan motor 2 12 water pump breather hose 2 1 disconnect. 13 water pump inlet pipe 1 for installation, reverse the removal proce...
Page 362: Radiator
Radiator 6-3 eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radiator. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage → ...
Page 363: Radiator
Radiator 6-4 b. Apply 122.7 kpa (1.23 kgf/cm², 17.8 psi) of pressure. C. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3..
Page 364: Oil Cooler
Oil cooler 6-5 eas26410 oil cooler removing the oil cooler order job/parts to remove q’ty remarks coolant drain. Refer to “changing the coolant” on page 3-27. Engine oil drain. Refer to “changing the engine oil” on page 3-24. 1 water jacket joint inlet hose 1 2 oil cooler inlet hose 1 3 oil cooler u...
Page 365: Oil Cooler
Oil cooler 6-6 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 366: Thermostat
Thermostat 6-7 eas26440 thermostat removing the thermostat assembly order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1. Air ...
Page 367: Thermostat
Thermostat 6-8 disassembling the thermostat assembly order job/parts to remove q’ty remarks 1 thermostat housing cover 1 2 thermostat 1 3 thermostat housing 1 for assembly, reverse the disassembly pro- cedure..
Page 368: Thermostat
Thermostat 6-9 eas26450 checking the thermostat 1. Check: • thermostat does not open at 71–85 °c (159.8–185.0 °f) → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in the water. D. Wh...
Page 369: Thermostat
Thermostat 6-10 eas26480 installing the thermostat assem- bly 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” on page 3-27. 2. Check: • cooling system leaks → repair or replace any faulty part. Refer to “installing the radiator” on p...
Page 370: Water Pump
Water pump 6-11 eas26500 water pump disassembling the water pump order job/parts to remove q’ty remarks oil/water pump assembly refer to “oil pump” on page 5-57. Oil pump rotor refer to “oil pump” on page 5-57. 1 water pump cover 1 2 pin 2 3 impeller shaft (along with the impeller) 1 4 water pump se...
Page 371: Water Pump
Water pump 6-12 eas26520 disassembling the water pump 1. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the water pump housing “2”. 2. Remove: • oil seal “1” • bearing “2” tip remove the oil seal and bearing from the out- side of the water pump housing “3”. 3. Remove...
Page 372: Water Pump
Water pump 6-13 2. Install: • water pump seal “1” eca14080 never lubricate the water pump seal sur- face with oil or grease. Tip install the water pump seal with the special tools. 3. Install: • rubber damper holder “1” • rubber damper “2” tip before installing the rubber damper, apply tap water or ...
Page 373: Fuel System
7 fuel system fuel tank .................................................................................................. 7-1 removing the fuel tank cover .................................................. 7-2 removing the fuel tank ................................................................ 7...
Page 374: Fuel Tank
Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. 1 fuel tank cover 1 2 fuel hose connector cover 1 3 fuel hos...
Page 375: Fuel Tank
Fuel tank 7-2 eas39p1713 removing the fuel tank cover 1. Remove: • fuel tank cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bolts. B. Disengage the projections from both ends of the fuel tank, slightly expanding both ends of the fuel tank cover. C. Slide the right side of the fuel tank cover...
Page 376: Fuel Tank
Fuel tank 7-3 eas26690 checking the fuel pump operation 1. Check: • fuel pump operation refer to “checking the fuel pres- sure” on page 7-4. Eas39p1703 installing the fuel pump 1. Install: • fuel pump gasket • fuel pump • fuel pump bracket • fuel pump bolts tip • do not damage the installation surfa...
Page 377: Fuel Tank
Fuel tank 7-4 eas39p1709 checking the fuel pressure 1. Check: • fuel pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rider seat and fuel tank cover. Refer to “general chassis” on page 4- 1 and “fuel tank” on page 7-1. B. Remove the fuel tank bolt and holdup the fuel tank. C. Disconnect the fue...
Page 378: Throttle Bodies
Throttle bodies 7-5 eas26970 throttle bodies removing the throttle bodies order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 7-1...
Page 379: Throttle Bodies
Throttle bodies 7-6 removing the throttle bodies order job/parts to remove q’ty remarks 10 coolant temperature sensor coupler 1 disconnect. 11 throttle bodies 1 12 throttle body joint 2 for installation, reverse the removal proce- dure..
Page 380: Throttle Bodies
Throttle bodies 7-7 removing the injectors order job/parts to remove q’ty remarks 1 fuel injection system sub-wire harness 1 2 hose joint 5 3 negative pressure hose (thin) 11 4 negative pressure hose (thick) 4 5 intake air pressure sensor 1 6 throttle position sensor 1 7 sub-throttle position sensor...
Page 381: Throttle Bodies
Throttle bodies 7-8 eas39p1710 removing the fuel hose (throttle body side) 1. Remove: • fuel tank refer to “removing the fuel tank” on page 7-2. 2. Remove: • fuel hose (throttle body side) eca14b1003 be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. Tip •...
Page 382: Throttle Bodies
Throttle bodies 7-9 1. Check: • injector pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the injector pressure adapter “1” to the fuel rail joint “2”, and then connect an air compressor “3” to the adapter. B. Connect the pressure gauge “4” to the injector pressure adapter “1”. C. Close the valve ...
Page 383: Throttle Bodies
Throttle bodies 7-10 2. Clean: • throttle bodies eca39p1703 observe the following precautions; other- wise, the throttle bodies may not operate properly. • do not open the throttle valves quickly. • do not subject the throttle bodies to excessive force. • clean the throttle bodies with a cloth which...
Page 384: Throttle Bodies
Throttle bodies 7-11 f. After removing the carbon deposits, clean the inside of the throttle bodies with a petroleum-based solvent, and then dry the throttle bodies using compressed air. G. Make sure that there are no carbon depos- its or other foreign materials in any of the passages “a” in each th...
Page 385: Throttle Bodies
Throttle bodies 7-12 c. Connect the throttle position sensor, sub- throttle position sensor and sub-throttle servo motor to the wire harness. D. Set the main switch to “off” and set the engine stop switch to “ ”. E. Simultaneously press and hold the “select” and “reset” buttons “1”, set the main swi...
Page 386: Throttle Bodies
Throttle bodies 7-13 d. Set the main switch to “on” and fully close the sub-throttle valves. E. Measure the sub-throttle position sensor voltage. F. Adjust the sub-throttle position sensor angle so that the voltage is within the spec- ified range. G. After adjusting the sub-throttle position sensor ...
Page 387: Throttle Bodies
Throttle bodies 7-14.
Page 388: Air Induction System
Air induction system 7-15 eas27040 air induction system.
Page 389: Air Induction System
Air induction system 7-16 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover).
Page 390: Air Induction System
Air induction system 7-17 removing the air cut-off valve assembly and reed valves order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Inner panel/side panel/front cowling side panel fz8sa refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on ...
Page 391: Air Induction System
Air induction system 7-18 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 392: Air Induction System
Air induction system 7-19 • reed valve assembly tip install the reed valve assembly so that the open side turns to the exhaust side of the engine. 2. Install: • reed valve cover a. Exhaust side reed valve cover bolt 10 nm (1.0 m·kgf, 7.2 ft·lbf) loctite®.
Page 393: Electrical System
8 electrical system ignition system....................................................................................... 8-1 circuit diagram................................................................................ 8-1 engine stopping due to sidestand operation .....................8-5 troub...
Page 394
Abs (anti-lock brake system) ......................................................8-127 circuit diagram............................................................................8-127 abs components chart.............................................................8-131 abs coupler location chart ...
Page 396: Ignition System
Ignition system 8-1 eas27090 ignition system eas27110 circuit diagram.
Page 397: Ignition System
Ignition system 8-2 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 21.Lean angle sensor 23.Cylinder identification sensor 24.Crankshaft position sensor...
Page 398: Ignition System
Ignition system 8-3.
Page 399: Ignition System
Ignition system 8-4 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 21.Lean angle sensor 23.Cylinder identification sensor 24.Crankshaft position sensor...
Page 400: Ignition System
Ignition system 8-5 eas39p1804 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the neutral switc...
Page 401: Ignition System
Ignition system 8-6 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. Ecu (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Neutral switch 12.Battery negative lead.
Page 402: Ignition System
Ignition system 8-7 eas27150 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (fz8sa) 4. Right inner panel (fz8sa) 5. Left side panel (fz8sa) 6. Right...
Page 403: Ignition System
Ignition system 8-8 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 7. Check the cylinder identification sensor. Refer to “checking the cylin- der identification sensor” on page 8-201. Replace the cylinder identification sensor. 8. Check the main switch. Ref...
Page 404: Ignition System
Ignition system 8-9 ng → ok ↓ 16.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 405: Ignition System
Ignition system 8-10
Page 406: Electric Starting System
Electric starting system 8-11 eas27160 electric starting system eas27170 circuit diagram.
Page 407: Electric Starting System
Electric starting system 8-12 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 56.Right handlebar switch 58.Engine stop...
Page 408: Electric Starting System
Electric starting system 8-13.
Page 409: Electric Starting System
Electric starting system 8-14 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 12.Starter relay 13.Starter motor 14.Relay unit 15.Starting circuit cut-off relay 17.Neutral switch 18.Sidestand switch 56.Right handlebar switch 58.Engine stop...
Page 410: Electric Starting System
Electric starting system 8-15 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 neut...
Page 411: Electric Starting System
Electric starting system 8-16 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 sw...
Page 412: Electric Starting System
Electric starting system 8-17 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (fz8sa) 4. Right inner panel (fz8sa) 5. Left side panel (fz8sa) 6. Right side panel (fz8sa) 7. Front...
Page 413: Electric Starting System
Electric starting system 8-18 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 7. Check the starter relay. Refer to “checking the relays” on page 8-189. Replace the starter relay. 8. Check the main switch. Refer to “checking the switches” on page 8-179. Replace the mai...
Page 414: Charging System
Charging system 8-19 eas27200 charging system eas27210 circuit diagram.
Page 415: Charging System
Charging system 8-20 fz8na 2. Rectifier/regulator 3. Ac magneto 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead.
Page 416: Charging System
Charging system 8-21.
Page 417: Charging System
Charging system 8-22 fz8sa 2. Rectifier/regulator 3. Ac magneto 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead.
Page 418: Charging System
Charging system 8-23 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fuses” on page 8-185. Replace...
Page 419: Charging System
Charging system 8-24.
Page 420: Lighting System
Lighting system 8-25 eas27240 lighting system eas27250 circuit diagram.
Page 421: Lighting System
Lighting system 8-26 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.Ecu (engine control unit) 43.Meter assembly 51.High beam indicator light 54.Meter light 61.Left handlebar switch 63.Pass switch 64.Dimmer switch 74.Headlight 75.Auxil...
Page 422: Lighting System
Lighting system 8-27.
Page 423: Lighting System
Lighting system 8-28 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.Ecu (engine control unit) 43.Meter assembly 51.High beam indicator light 54.Meter light 61.Left handlebar switch 63.Pass switch 64.Dimmer switch 74.Auxiliary light 75...
Page 424: Lighting System
Lighting system 8-29 eas27260 troubleshooting any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (fz8sa) 4. Right inner pane...
Page 425: Lighting System
Lighting system 8-30 ng → ok ↓ ng → ok ↓ 7. Check the headlight relay (on/off). Refer to “checking the relays” on page 8-189. Replace the headlight relay. 8. Check the entire lighting system’s wiring. Refer to “circuit diagram” on page 8-25. Properly connect or repair the lighting system’s wiring. R...
Page 426: Signaling System
Signaling system 8-31 eas27270 signaling system eas27280 circuit diagram.
Page 427: Signaling System
Signaling system 8-32 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 17.Neutral switch 20.Fuel sender 25.Ecu (engine control unit) 40.Coolant temperature sensor 43.Meter assembly 45.Oil level warning light 46.Neutral indica...
Page 428: Signaling System
Signaling system 8-33.
Page 429: Signaling System
Signaling system 8-34 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 17.Neutral switch 20.Fuel sender 25.Ecu (engine control unit) 40.Coolant temperature sensor 43.Meter assembly 45.Oil level warning light 46.Neutral indica...
Page 430: Signaling System
Signaling system 8-35 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (fz8sa) 4. Right inner...
Page 431: Signaling System
Signaling system 8-36 check the signaling system the horn fails to sound. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the horn switch. Refer to “checking the switches” on page 8-179. Replace the left handlebar switch. 2. Check...
Page 432: Signaling System
Signaling system 8-37 the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ 1. Check the turn signal light bulb and socket. Refer to “checking the bulbs and bulb so...
Page 433: Signaling System
Signaling system 8-38 ng → ok ↓ the oil level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ 3. Check the entire signaling system’s wiring. Refer to “circuit diagram” on page 8-31. Pro...
Page 434: Signaling System
Signaling system 8-39 ng → ok ↓ tip repair or replace if there is an open or short circuit. • between rear wheel sensor coupler and abs ecu coupler. (white/red–white/red) (white–white) • between abs ecu coupler and ecu coupler. (blue/white–blue/white) (white/yellow–white/yellow) • between ecu couple...
Page 435: Signaling System
Signaling system 8-40
Page 436: Cooling System
Cooling system 8-41 eas27300 cooling system eas27310 circuit diagram.
Page 437: Cooling System
Cooling system 8-42 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.Ecu (engine control unit) 40.Coolant temperature sensor 79.Radiator fan motor relay 80.Right radiator fan motor fuse 81.Right radiator fan motor 82.Left radiator fan m...
Page 438: Cooling System
Cooling system 8-43.
Page 439: Cooling System
Cooling system 8-44 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.Ecu (engine control unit) 40.Coolant temperature sensor 80.Radiator fan motor relay 81.Right radiator fan motor fuse 82.Right radiator fan motor 83.Left radiator fan m...
Page 440: Cooling System
Cooling system 8-45 eas27320 troubleshooting tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (fz8sa) 4. Right inner panel (fz8sa) 5. Left side panel (fz8sa) 6. Right side panel (fz8sa) 7. Front cowling (fz8sa) 8. Fuel tank 9. Air filter...
Page 441: Cooling System
Cooling system 8-46 ng → ok ↓ 7. Check the entire cooling system’s wiring. Refer to “circuit diagram” on page 8-41. Properly connect or repair the cooling system’s wiring. Replace the ecu..
Page 442: Fuel Injection System
Fuel injection system 8-47 eas27331 fuel injection system eas27340 circuit diagram.
Page 443: Fuel Injection System
Fuel injection system 8-48 fz8na 1. Main switch 4. Backup fuse 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 17.Neutral switch 18.Sidestand switch 19.Fuel pump 21.Lean angle sensor 22.Atmospheri...
Page 444: Fuel Injection System
Fuel injection system 8-49.
Page 445: Fuel Injection System
Fuel injection system 8-50 fz8sa 1. Main switch 4. Backup fuse 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 17.Neutral switch 18.Sidestand switch 19.Fuel pump 21.Lean angle sensor 22.Atmospheri...
Page 446: Fuel Injection System
Fuel injection system 8-51 eas27351 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 447: Fuel Injection System
Fuel injection system 8-52 ecu detects an abnormal signal from a sensor 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 f...
Page 448: Fuel Injection System
Fuel injection system 8-53 eas30580 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 449: Fuel Injection System
Fuel injection system 8-54 eas27411 diagnostic mode setting the diagnostic mode 1. Turn the main switch to “off” and set the engine stop switch to “on”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “select” and “reset” buttons, turn the main switch ...
Page 450: Fuel Injection System
Fuel injection system 8-55 eas27462 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 451: Fuel Injection System
Fuel injection system 8-56 5 sensor installation status - check the mounting sec- tion for loose or pinched mounting. Incorrect installation → rein- stall or repair the sensor. Crank the engine, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check ...
Page 452: Fuel Injection System
Fuel injection system 8-57 3 continuity of wire harness open or short circuit → replace the wire harness. Gray–gray black/blue–black/blue crank the engine, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 4 sensor installation st...
Page 453: Fuel Injection System
Fuel injection system 8-58 2 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Place the main switch to the on positio...
Page 454: Fuel Injection System
Fuel injection system 8-59 tip if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. 6 intake air pressure sensor malfunction check in the diagnostic mode (code no. D03). When engine is stopped: atmospheric pressure at the current altitude and wea...
Page 455: Fuel Injection System
Fuel injection system 8-60 tip if fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code no. 14 item intake air pressure sensor: hose system malfunction (clogged or detached hose). Fail-safe system able to start engine able to drive vehicle...
Page 456: Fuel Injection System
Fuel injection system 8-61 fault code no. 15 item throttle position sensor: open or short circuit detected. (no normal signals are received from the throttle position sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:01 meter display throttle position sensor ...
Page 457: Fuel Injection System
Fuel injection system 8-62 tip if fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first. 6 supply voltage of throttle position sensor lead check the supply voltage. Black/blue–yellow refer to “checking the throttle position sen- sor” on page 8-199. Pl...
Page 458: Fuel Injection System
Fuel injection system 8-63 tip if fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first. Fault code no. 16 item throttle position sensor: stuck throttle position sensor detected. (signal from throttle position sensor will not change.) fail-safe system...
Page 459: Fuel Injection System
Fuel injection system 8-64 fault code no. 19 item sidestand switch: a break or disconnection of the blue/yellow lead of the ecu is detected. (no normal signals are received from the sid- estand switch.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:20 meter di...
Page 460: Fuel Injection System
Fuel injection system 8-65 5 sidestand switch malfunction diagnostic mode (code no. D20). The transmission is in gear sidestand retracted: on indi- cation sidestand extended: off indication indication is incorrect. → replace the sidestand switch. Place the main switch to the on position, and check t...
Page 461: Fuel Injection System
Fuel injection system 8-66 fault code no. 20 item intake air pressure sensor or atmospheric pressure sensor: when the main switch is set to “on”, the atmospheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Fail-safe system able to start engine able to drive vehicle...
Page 462: Fuel Injection System
Fuel injection system 8-67 3 ecu malfunction replace the ecu. Fault code no. 21 item coolant temperature sensor: open or short circuit detected. (no nor- mal signals are received from the coolant temperature sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:0...
Page 463: Fuel Injection System
Fuel injection system 8-68 3 connection of fuel injection system sub-wire harness coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Place the main s...
Page 464: Fuel Injection System
Fuel injection system 8-69 fault code no. 22 item intake air temperature sensor: open or short circuit detected. (no normal signals are received from the intake air temperature sensor.) fail-safe system able to start engine able to drive vehicle diagnostic code no. D:05 meter display displays the in...
Page 465: Fuel Injection System
Fuel injection system 8-70 5 intake air temperature sensor malfunction check in the diagnostic mode (code no. D05). Sensor inspection procedure refer to “checking the intake air temperature sensor” on page 8-202. During cold starting: a tem- perature close to the ambient temperature is indicated. Af...
Page 466: Fuel Injection System
Fuel injection system 8-71 2 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or replace the wire harness. Place the main switch to the on position, and ...
Page 467: Fuel Injection System
Fuel injection system 8-72 5 atmospheric pressure sensor malfunction check in the diagnostic mode (code no. D02). Atmospheric pressure at the current altitude and weather conditions is indicated. 0 m above sea level: approx. 101 kpa 1000 m above sea level: approx. 90 kpa 2000 m above sea level: appr...
Page 468: Fuel Injection System
Fuel injection system 8-73 fault code no. 24 item o 2 sensor: no normal signals are received from the o 2 sensor. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause check or maintenance job sensor inspectio...
Page 469: Fuel Injection System
Fuel injection system 8-74 6 o 2 sensor malfunction check the o 2 sensor for an abnormality. Refer to “engine removal” on page 5-3. O 2 sensor malfunction → replace the o 2 sensor either start and warm up the engine, and then racing it, or reset it with diagnostic code d63. No fault code indicated. ...
Page 470: Fuel Injection System
Fuel injection system 8-75 3 lean angle sensor malfunc- tion diagnostic mode (code no. D08). Sensor inspection procedure refer to “checking the lean angle sensor” on page 8-194. In vertical position: 0.4–1.4 v when turned over: 3.7–4.4 v indication is incorrect. → replace the lean angle sen- sor. Pl...
Page 471: Fuel Injection System
Fuel injection system 8-76 2 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or replace the wire harness. Start and idle the engine for approximately 5 ...
Page 472: Fuel Injection System
Fuel injection system 8-77 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 192. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...
Page 473: Fuel Injection System
Fuel injection system 8-78 2 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or replace the wire harness. Start and idle the engine for approximately 5 ...
Page 474: Fuel Injection System
Fuel injection system 8-79 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 192. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...
Page 475: Fuel Injection System
Fuel injection system 8-80 2 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or replace the wire harness. Start and idle the engine for approximately 5 ...
Page 476: Fuel Injection System
Fuel injection system 8-81 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 192. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...
Page 477: Fuel Injection System
Fuel injection system 8-82 2 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely or replace the wire harness. Start and idle the engine for approximately 5 ...
Page 478: Fuel Injection System
Fuel injection system 8-83 6 ignition coil malfunction (check the continuity of pri- mary coil.) ignition coil inspection method refer to “checking the ignition coils” on page 8- 192. Start and idle the engine for approximately 5 seconds. Then, check the fault code indication. No fault code indicate...
Page 479: Fuel Injection System
Fuel injection system 8-84 fault code no. 39 item injector: open circuit detected. (no normal signals are received from the injector.) fail-safe system able to start engine (depending on the number of faulty cylinders) able to drive vehicle (depending on the number of faulty cylinders) diagnostic co...
Page 480: Fuel Injection System
Fuel injection system 8-85 4 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Start and idle the engine for approxima...
Page 481: Fuel Injection System
Fuel injection system 8-86 6 continuity of wire harness open or short circuit → con- nect it securely, or repair/ replace the wire harness. Fuel injector #1 red/blue–red/blue red/black–red/black fuel injector #2 red/blue–red/blue green/black–green/black fuel injector #3 red/blue–red/blue blue/black–...
Page 482: Fuel Injection System
Fuel injection system 8-87 fault code no. 41 item lean angle sensor: open or short circuit detected. (no normal sig- nals are received from the lean angle sensor.) fail-safe system unable to start engine unable to drive vehicle diagnostic code no. D:08 meter display lean angle sensor output voltage ...
Page 483: Fuel Injection System
Fuel injection system 8-88 4 lean angle sensor malfunc- tion diagnostic mode (code no. D08). Sensor inspection procedure refer to “checking the lean angle sensor” on page 8-194. Rotate the main switch to the off position first, and then rotate it to the on position again. Then, check the fault code ...
Page 484: Fuel Injection System
Fuel injection system 8-89 fault code no. 42 item a. No normal signals are received from the rear wheel sensor. B. Open or short circuit is detected in the neutral circuit of the neutral switch. C. Open or short circuit is detected in the clutch circuit of the clutch switch. A fail-safe system able ...
Page 485: Fuel Injection System
Fuel injection system 8-90 a. Rear wheel sensor system malfunction item/components and probable cause check or maintenance job sensor inspection proce- dure 1 connection of rear wheel sensor (meter) coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for be...
Page 486: Fuel Injection System
Fuel injection system 8-91 b. Neutral switch system malfunction 5 ecu malfunction replace the ecu. Check in the diagnostic code (code no. D07). With the rear wheel rotated, check the pulse input. Then, check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → che...
Page 487: Fuel Injection System
Fuel injection system 8-92 c. Clutch switch system malfunction 4 continuity of leads between neutral switch and relay unit coupler open or short circuit → replace the wire harness. Sky blue–sky blue start the engine. Ride the vehicle at a low speed (approx. 20–30 km/h). Then, check the fault code in...
Page 488: Fuel Injection System
Fuel injection system 8-93 3 connection of wire harness ecu coupler check the connection of the coupler is secure. Remove the coupler, and check each pin (for bending, wear, or locking). Poor connection → connect it securely, or repair/replace the wire harness. Start the engine. Ride the vehicle at ...
Page 489: Fuel Injection System
Fuel injection system 8-94 fault code no. 43 item fuel system voltage: incorrect voltage supplied to the fuel injector, fuel pump and main relay. Fail-safe system able to start engine able to drive vehicle diagnostic code no. D:09, d:50 d:09 meter display fuel system voltage (battery voltage) approx...
Page 490: Fuel Injection System
Fuel injection system 8-95 4 fuel pump relay malfunction check in the diagnostic mode (code no. D50). No operation sound of fuel pump relay is heard. → replace the relay unit. Place the main switch to the on position for approxi- mately 5 seconds. Then, check the fault code indication. No fault code...
Page 491: Fuel Injection System
Fuel injection system 8-96 fault code no. 44 item eeprom cylinder fault code number: an error is detected while reading or writing on eeprom (co adjustment value). Fail-safe system under certain conditions under certain conditions diagnostic code no. D:60 meter display eeprom fault code display • 00...
Page 492: Fuel Injection System
Fuel injection system 8-97 4 “03” is indicated in diagnostic mode (code no. D60) eeprom data error for adjustment of co concentra- tion of cylinder #3 change the co concentra- tion of cylinder #3, and rewrite in eeprom. Refer to “adjusting the exhaust gas volume” on page 3-11. After this adjustment ...
Page 493: Fuel Injection System
Fuel injection system 8-98 fault code no. 46 item incorrect voltage is supplied to the ecu. Fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/components and probable cause check or maintenance job sensor inspection proce- dure 1 chargi...
Page 494: Fuel Injection System
Fuel injection system 8-99 tip if fault codes 47 and 48 are indicated simultaneously, take the actions specified for fault code 47 first. 4 continuity of wire harness open or short circuit → replace the wire harness black/blue–black/blue green/yellow–green/yellow blue–blue place the main switch to t...
Page 495: Fuel Injection System
Fuel injection system 8-100 fault code no. 48 item sub-throttle servo motor: stuck sub-throttle servo motor detected. Signal from sub-throttle position sensor will not change. (sub-throt- tle servo motor will not start.) fail-safe system able to start engine able to drive vehicle diagnostic code no....
Page 496: Fuel Injection System
Fuel injection system 8-101 tip if fault codes 47 and 48 are indicated simultaneously, take the actions specified for fault code 47 first. 5 continuity of wire harness open or short circuit → replace the wire harness yellow/red–yellow/red yellow/white–yellow/white gray/black–gray/black gray/white–gr...
Page 497: Fuel Injection System
Fuel injection system 8-102 fault code no. 70 item engine idling stop: engine has been left idling. (the ecu automati- cally stops the engine after 20 minutes if it is left idling.) fail-safe system able to start engine able to drive vehicle diagnostic code no. — meter display — procedure — item/com...
Page 498: Fuel Injection System
Fuel injection system 8-103 4 abnormal meter unit opera- tion replace the meter unit. Place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 5 ecu malfunction replace the ecu fault code no. Er-...
Page 499: Fuel Injection System
Fuel injection system 8-104 4 abnormal meter unit opera- tion replace the meter unit. Place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 5 ecu malfunction replace the ecu. Fault code no. Er...
Page 500: Fuel Injection System
Fuel injection system 8-105 4 abnormal meter unit opera- tion replace the meter unit. Place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 5 ecu malfunction replace the ecu. Fault code no. Er...
Page 501: Fuel Injection System
Fuel injection system 8-106 4 abnormal meter unit opera- tion replace the meter unit. Place the main switch to the on position, and check the fault code indication. No fault code indicated. → recovered. Fault code indicated. → check the next step. 5 ecu malfunction replace the ecu. Fault code no. Er...
Page 502: Fuel Injection System
Fuel injection system 8-107 eas30660 diagnostic code table tip the following tables contain information about diagnostic code numbers that do not have a corre- sponding fault code number. (these items are not listed in “troubleshooting details”.) diag- nostic code no. Item meter display/actuation pr...
Page 503: Fuel Injection System
Fuel injection system 8-108 set the main switch to “off” to cancel the diagnostic mode. Tip information about each diagnostic code no. Is organized in this manual as follows: • if a diagnostic code no. Has a corresponding fault code no., the information is shown in trou- bleshooting details. (refer ...
Page 504: Fuel Pump System
Fuel pump system 8-109 eas27550 fuel pump system eas27560 circuit diagram.
Page 505: Fuel Pump System
Fuel pump system 8-110 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 19.Fuel pump 25.Ecu (engine control unit) 56.Right handlebar switch 58.Engine stop switch 85.Ignition fu...
Page 506: Fuel Pump System
Fuel pump system 8-111.
Page 507: Fuel Pump System
Fuel pump system 8-112 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 11.Fuel injection system fuse 14.Relay unit 16.Fuel pump relay 19.Fuel pump 25.Ecu (engine control unit) 56.Right handlebar switch 58.Engine stop switch 86.Ignition fu...
Page 508: Fuel Pump System
Fuel pump system 8-113 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Left inner panel (fz8sa) 4. Right inner panel (fz8sa) 5. Left side panel (fz8sa) 6. Right side panel (fz8sa) 7. Front cowl...
Page 509: Fuel Pump System
Fuel pump system 8-114 ng → ok ↓ 7. Check the entire fuel pump sys- tem’s wiring. Refer to “circuit diagram” on page 8-109. Properly connect or repair the fuel pump system’s wiring. Replace the ecu..
Page 510: Immobilizer System
Immobilizer system 8-115 eas27640 immobilizer system eas27650 circuit diagram.
Page 511: Immobilizer System
Immobilizer system 8-116 fz8na 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.Ecu (engine control unit) 43.Meter assembly 44.Immobilizer system indicator light 48.Multi-function meter 85.Ignition fuse.
Page 512: Immobilizer System
Immobilizer system 8-117.
Page 513: Immobilizer System
Immobilizer system 8-118 fz8sa 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 25.Ecu (engine control unit) 43.Meter assembly 44.Immobilizer system indicator light 48.Multi-function meter 86.Ignition fuse.
Page 514: Immobilizer System
Immobilizer system 8-119 eas27671 general information this vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) tha...
Page 515: Immobilizer System
Immobilizer system 8-120 eas27691 part replacement and key code registration requirements in the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Tip each standard key is registered during production...
Page 516: Immobilizer System
Immobilizer system 8-121 standby mode: to enable the immobilizer system, turn the ignition key to “off”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the im...
Page 517: Immobilizer System
Immobilizer system 8-122 standard key registration voiding the standard key code: if a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the los...
Page 518: Immobilizer System
Immobilizer system 8-123 eas27701 troubleshooting when the main switch is turned to “on”, the immobilizer system indicator light does not come on nor flashes. Ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, and backup) refer to “checking the fuses” on page 8-185. Replace...
Page 519: Immobilizer System
Immobilizer system 8-124 eas27721 self-diagnosis fault code indication when a system failure occurs, the error code number is indicated in the lcd display of meter and the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code. Fault code part s...
Page 520: Immobilizer System
Immobilizer system 8-125 immobilizer system indicator light fault code indication digit of 10 : cycles of 1 sec. On and 1.5 sec. Off. Digit of 1 : cycles of 0.5 sec. On and 0.5 sec. Off. Example: fault code 52 55 immobilizer unit key code registra- tion malfunction. Same standard key was attempted t...
Page 521: Immobilizer System
Immobilizer system 8-126.
Page 522: 8-127
Abs (anti-lock brake system) 8-127 eas28790 abs (anti-lock brake system) eas27730 circuit diagram.
Page 523: 8-128
Abs (anti-lock brake system) 8-128 fz8na 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 25.Ecu (engine control unit) 43.Meter assembly 48.Multi-function meter 53.Abs warning light 56.Right handle...
Page 524: 8-129
Abs (anti-lock brake system) 8-129.
Page 525: 8-130
Abs (anti-lock brake system) 8-130 fz8sa 1. Main switch 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10.Negative battery ground lead 14.Relay unit 15.Starting circuit cut-off relay 25.Ecu (engine control unit) 43.Meter assembly 48.Multi-function meter 53.Abs warning light 56.Right handle...
Page 526: 8-131
Abs (anti-lock brake system) 8-131 eas27740 abs components chart.
Page 527: 8-132
Abs (anti-lock brake system) 8-132 1. Hydraulic unit assembly (abs ecu) 2. Abs warning light 3. Rear wheel sensor rotor 4. Rear wheel sensor 5. Front wheel sensor 6. Front wheel sensor rotor 7. Abs test coupler 8. Fuse box 1.
Page 528: 8-133
Abs (anti-lock brake system) 8-133 eas27750 abs coupler location chart.
Page 529: 8-134
Abs (anti-lock brake system) 8-134 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. Abs test coupler 4. Front wheel sensor coupler 5. Abs ecu coupler.
Page 530: 8-135
Abs (anti-lock brake system) 8-135 eas27770 maintenance of the abs ecu checking the abs ecu 1. Check: • terminals “1” of the abs ecu cracks/damages → replace the hydraulic unit assembly and the brake pipes that are con- nected to the assembly as a set. • terminals “2” of the abs ecu coupler connecti...
Page 531: 8-136
Abs (anti-lock brake system) 8-136 self-diagnosis and servicing the abs ecu has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the abs ecu also stores the malfunction history. The multi-function...
Page 532: 8-137
Abs (anti-lock brake system) 8-137 eas27810 basic process for troubleshooting.
Page 533: 8-138
Abs (anti-lock brake system) 8-138 warning ewa4b56008 when maintenance or checks have been performed on components related to the abs, be sure to perform a final check before delivering the vehicle to the customer. (refer to “[d-3] final check” on page 8-174.) eas27830 [a] checking the abs warning l...
Page 534: 8-139
Abs (anti-lock brake system) 8-139 eas4b56016 [b-4] the abs warning light comes on for 2 seconds, then goes off remove the protective cap from the abs test coupler “1”, and then connect the test coupler adapter “2” to the coupler. The t/c terminal (sky blue) is now grounded. 1. The fault code “1” is...
Page 535: 8-140
Abs (anti-lock brake system) 8-140 eas4b56017 [b-5] malfunction are currently detected connect the test coupler adapter to the abs test coupler. When the test coupler adapter is connected to the abs test coupler, the fault codes will be displayed in the multi-function display. Record all of the disp...
Page 536: 8-141
Abs (anti-lock brake system) 8-141 eas4b56020 [c-3] the abs warning light remains on 1. The battery voltage is low. • check the condition of the battery. Refer to “checking and charging the battery” on page 8-186. • if the battery voltage is low, clean the battery terminals and recharge it, or repla...
Page 537: 8-142
Abs (anti-lock brake system) 8-142 eas4b56022 [c-5] diagnosis using the fault codes connect the test coupler adapter to the abs test coupler, and then turn the main switch to “on”. Information for the fault codes from the abs ecu is contained in the following table. Refer to this table for troublesh...
Page 538: 8-143
Abs (anti-lock brake system) 8-143 abs_24 brake light signal is not received prop- erly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). • brake light bulbs • wire harness (brake light circuit) • brake light system couplers and connectors abs_31 solenoid...
Page 539: 8-144
Abs (anti-lock brake system) 8-144 * a fault code is indicated if the rear wheel rotates for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25) with the front wheel stopped (e.G., when the vehicle is on the suitable stand). Tip fault codes...
Page 540: 8-145
Abs (anti-lock brake system) 8-145 tip with front wheel stopped, rear wheel was rotated for longer than about 20 seconds (fault code no. Abs_11) or for longer than about 2 seconds (fault code no. Abs_25). Fault code no. Abs_11 abs_25 symptom front wheel sensor signal is not received prop- erly. Orde...
Page 541: 8-146
Abs (anti-lock brake system) 8-146 fault code no. Abs_12 symptom rear wheel sensor signal is not received prop- erly. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace the ...
Page 542: 8-147
Abs (anti-lock brake system) 8-147 tip vehicle possibly ridden on uneven roads. Fault code no. Abs_13 abs_26 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of ...
Page 543: 8-148
Abs (anti-lock brake system) 8-148 tip vehicle possibly ridden on uneven roads. Fault code no. Abs_14 abs_27 symptom incorrect signal from the rear wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of w...
Page 544: 8-149
Abs (anti-lock brake system) 8-149 2 wire harness continuity. • check for continuity between the blue terminal “1” and the blue terminal “3” and between the green terminal “2” and the green terminal “4”. • if there is no continuity, the wire harness is defective. Properly repair or replace the wire ...
Page 545: 8-150
Abs (anti-lock brake system) 8-150 3 defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the abs ecu coupler and front wheel sensor coupler, and then delete the fault codes. If fault code no. Abs_15 could not be deleted, the front wheel sensor is defec...
Page 546: 8-151
Abs (anti-lock brake system) 8-151 2 wire harness continuity. • check for continuity between the white terminal “1” and the white terminal “3” and between the white/red terminal “2” and the white/red terminal “4”. • if there is no continuity, the wire harness is defective. Properly repair or replace...
Page 547: 8-152
Abs (anti-lock brake system) 8-152 3 defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the abs ecu coupler and rear wheel sensor coupler, and then delete the fault codes. If fault code no. Abs_16 could not be deleted, the rear wheel sensor is defecti...
Page 548: 8-153
Abs (anti-lock brake system) 8-153 fault code no. Abs_18 abs_46 symptom missing pulses detected in the rear wheel sen- sor signal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel bearings, axle, sensor housing, and se...
Page 549: 8-154
Abs (anti-lock brake system) 8-154 fault code no. Abs_22 symptom start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 engine startability. Check the...
Page 550: 8-155
Abs (anti-lock brake system) 8-155 fault code no. Abs_24 symptom brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order item/components and probable cause check or maintenance job reinstatement confirmation met...
Page 551: 8-156
Abs (anti-lock brake system) 8-156 fault code no. Abs_31 symptom solenoid relay is defective. Power is not supplied to the solenoid relay. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “...
Page 552: 8-157
Abs (anti-lock brake system) 8-157 fault code no. Abs_32 symptom hydraulic unit solenoid relay is short-circuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in solenoid relay. Replace the hydraulic unit assem- bly. • turn the ...
Page 553: 8-158
Abs (anti-lock brake system) 8-158 fault code no. Abs_33 symptom abs motor is defective. Power is not supplied to the abs motor. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking a...
Page 554: 8-159
Abs (anti-lock brake system) 8-159 fault code no. Abs_34 symptom hydraulic unit abs motor relay is short-cir- cuited. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in abs motor relay. Replace the hydraulic unit assem- bly. • turn ...
Page 555: 8-160
Abs (anti-lock brake system) 8-160 fault code no. Abs_41 symptom front wheel will not recover from the locking tendency even though the signal is continu- ously transmitted from the abs ecu to release the hydraulic pressure (when the battery volt- age is normal) order item/components and probable ca...
Page 556: 8-161
Abs (anti-lock brake system) 8-161 warning ewa4b56001 the front brakes will not function properly if the connections are reversed. • brake pipe/joint assembly “1” outlet: to the front brake calipers • brake pipe/joint assembly “2” inlet: from the front brake master cylinder 4 brake lines • check the...
Page 557: 8-162
Abs (anti-lock brake system) 8-162 tip • if the brake pipe inlet and outlet connections are incorrect on the hydraulic unit, the front brake lever will be pulled to its full-stroke position without responding, and then it will be pushed back slowly without pulsating when the final check on page “[d-...
Page 558: 8-163
Abs (anti-lock brake system) 8-163 fault code no. Abs_42 abs_47 symptom rear wheel will not recover from the locking ten- dency even though the signal is continuously transmitted from the abs ecu to release the hydraulic pressure. Order item/components and probable cause check or maintenance job rei...
Page 559: 8-164
Abs (anti-lock brake system) 8-164 warning ewa4b56002 the rear brake will not function properly if the connections are reversed. • brake pipe/joint assembly “1” inlet: from the rear brake master cylinder • brake pipe/joint assembly “2” outlet: to the rear brake caliper tip • if the brake pipe inlet ...
Page 560: 8-165
Abs (anti-lock brake system) 8-165 fault code no. Abs_43 symptom incorrect signal from the front wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace...
Page 561: 8-166
Abs (anti-lock brake system) 8-166 fault code no. Abs_44 symptom incorrect signal from the rear wheel sensor is detected. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 installed condition of wheel sensor. Check for looseness. Repair or replace ...
Page 562: 8-167
Abs (anti-lock brake system) 8-167 fault code no. Abs_53 symptom power voltage is too low. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking and charging the battery” on page 8-186...
Page 563: 8-168
Abs (anti-lock brake system) 8-168 fault code no. Abs_54 symptom power voltage is too low. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 battery voltage recharge or replace the battery. Refer to “checking and charging the battery” on page 8-186...
Page 564: 8-169
Abs (anti-lock brake system) 8-169 fault code no. Abs_56 symptom hydraulic unit sensor power monitor circuit is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 defective internal monitor circuit (sen- sor power). Replace the hydraulic u...
Page 565: 8-170
Abs (anti-lock brake system) 8-170 fault code no. Abs_63 symptom front wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in wire harness. • check that there is no short cir- cuit between the blue termin...
Page 566: 8-171
Abs (anti-lock brake system) 8-171 fault code no. Abs_64 symptom rear wheel sensor power is abnormal. Order item/components and probable cause check or maintenance job reinstatement confirmation method 1 short circuit in wire harness. • check that there is no short cir- cuit between the white/red te...
Page 567: 8-172
Abs (anti-lock brake system) 8-172 eas4b56023 [d-1] deleting the fault codes eca4b56026 since the fault codes remain in the memory of the abs ecu until they are deleted, always delete the fault codes after the ser- vice has been completed. 1. Connect the test coupler adapter “1” to the abs test coup...
Page 568: 8-173
Abs (anti-lock brake system) 8-173 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester (dc 20 v) to the abs ecu coupler. B. Measure the abs ecu voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: • abs-ecu-to-start-switch-lead continuity no continuity → replace or repair the wire harn...
Page 569: 8-174
Abs (anti-lock brake system) 8-174 eas4b56024 [d-3] final check checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir. Refer to “checking the brake fluid level” on page 3-14. 2. Check the wheel sensor housings and wheel sensors for proper installation. Refer to “i...
Page 570: Electrical Components
Electrical components 8-175 eas27973 electrical components.
Page 571: Electrical Components
Electrical components 8-176 1. Main switch 2. Immobilizer unit 3. Front brake light switch 4. Clutch switch 5. Ignition coil 6. Fuse box 2 7. Main fuse 8. Battery 9. Fuse box 1 10.Fuel injection system fuse 11.Starter relay 12.Rear brake light switch 13.O 2 sensor 14.Sidestand switch 15.Rectifier/re...
Page 572: Electrical Components
Electrical components 8-177.
Page 573: Electrical Components
Electrical components 8-178 1. Intake air temperature sensor 2. Ecu (engine control unit) 3. Intake air pressure sensor 4. Fuel pump 5. Atmospheric pressure sensor 6. Relay unit 7. Lean angle sensor 8. Turn signal/hazard relay 9. Headlight relay 10.Radiator fan motor relay 11.Rear wheel sensor 12.Co...
Page 574: Electrical Components
Electrical components 8-179 eas27981 checking the switches.
Page 575: Electrical Components
Electrical components 8-180 fz8na 1. Clutch switch 2. Pass switch 3. Dimmer switch 4. Hazard switch 5. Turn signal switch 6. Horn switch 7. Main switch 8. Oil level switch 9. Sidestand switch 10.Front brake light switch 11.Engine stop switch 12.Start switch 13.Neutral switch 14.Rear brake light swit...
Page 576: Electrical Components
Electrical components 8-181.
Page 577: Electrical Components
Electrical components 8-182 fz8sa 1. Clutch switch 2. Pass switch 3. Dimmer switch 4. Hazard switch 5. Turn signal switch 6. Horn switch 7. Main switch 8. Oil level switch 9. Sidestand switch 10.Front brake light switch 11.Engine stop switch 12.Start switch 13.Neutral switch 14.Rear brake light swit...
Page 578: Electrical Components
Electrical components 8-183 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from t...
Page 579: Electrical Components
Electrical components 8-184 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 580: Electrical Components
Electrical components 8-185 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. Tip check each bulb socket for continuity in the same manner as described in t...
Page 581: Electrical Components
Electrical components 8-186 ignition systems to malfunction and could possibly cause a fire. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • rider seat refer to “general chassis” on page 4-1. Eas28031 checking and charging the battery warning ewa13290 batteries generate explosive hydrogen gas and conta...
Page 582: Electrical Components
Electrical components 8-187 voltage when the positive battery terminal is disconnected). • 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...
Page 583: Electrical Components
Electrical components 8-188 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to the bat- tery and st...
Page 584: Electrical Components
Electrical components 8-189 7. Connect: • battery leads (to the battery terminals) eca13630 first, connect the positive battery lead “1”, and then the negative battery lead “2”. 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery...
Page 585: Electrical Components
Electrical components 8-190 relay unit (fuel pump relay) headlight relay radiator fan motor relay eas39p1801 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 couple...
Page 586: Electrical Components
Electrical components 8-191 b. Turn the main switch to “on”. C. Measure the turn signal/hazard relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • turn signal/hazard relay output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (dc 20 v)...
Page 587: Electrical Components
Electrical components 8-192 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the wire harness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminal as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no continu- ity. ▲▲▲▲▲...
Page 588: Electrical Components
Electrical components 8-193 2. Check: • secondary coil resistance out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1 k) to the ignition coil as shown. B. Measure the secondary coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • ignition spark ...
Page 589: Electrical Components
Electrical components 8-194 b. Measure the crankshaft position sensor resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28131 checking the lean angle sensor 1. Remove: • lean angle sensor (from the battery box.) 2. Check: • lean angle sensor output voltage out of specification → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 590: Electrical Components
Electrical components 8-195 eas28150 checking the stator coil 1. Disconnect: • stator coil coupler (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the stator coil. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester to the sta- tor coil coup...
Page 591: Electrical Components
Electrical components 8-196 2. Check: • rectifier/regulator output voltage out of specification → replace the recti- fier/regulator. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil of cylinder #1. B. Connect the pocket tester (ac 20 v) to the rectifier/regulator coup...
Page 592: Electrical Components
Electrical components 8-197 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 100) to the oil level switch terminal as shown. B. Measure the oil level switch resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas39p1802 checking the fuel sender 1. Disconnect: • fuel pump coupler • fuel sende...
Page 593: Electrical Components
Electrical components 8-198 eas28250 checking the radiator fan motors 1. Check: • radiator fan motor faulty/rough movement → replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the radiator fan motor coupler from the wire harness. B. Connect the battery (dc 12 v) as shown. C. Measure the radiator ...
Page 594: Electrical Components
Electrical components 8-199 3. Install: • coolant temperature sensor eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( Ω × 1 k) to the thrott...
Page 595: Electrical Components
Electrical components 8-200 c. Connect the pocket tester ( Ω × 1 k) to the sub-throttle position sensor as shown. D. While slowly turning the sub-throttle posi- tion sensor shaft, check that the sub-throt- tle position sensor resistance is within the specified range. The resistance does not change o...
Page 596: Electrical Components
Electrical components 8-201 b. Connect the digital circuit tester (dcv) to the test harness s-pressure sensor 5s7 (3p). C. Set the main switch to “on”. D. Measure the atmospheric pressure sensor output voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ eas28390 checking the cylinder identifica- tion sensor 1. ...
Page 597: Electrical Components
Electrical components 8-202 eca16730 pay attention to the installing direction of the test harness s-pressure sensor 5s7 (3p) coupler. B. Connect the digital circuit tester (dcv) to the test harness s-pressure sensor 5s7 (3p). C. Set the main switch to “on”. D. Measure the intake air pressure sensor...
Page 598: Electrical Components
Electrical components 8-203.
Page 599: Troubleshooting
9 troubleshooting troubleshooting .................................................................................. 9-1 general information ..................................................................... 9-1 starting failures ......................................................................
Page 600: Troubleshooting
Troubleshooting 9-1 eas28451 troubleshooting eas28460 general information tip 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, ad...
Page 601: 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 602: Troubleshooting
Troubleshooting 9-3 2. Engine oil • incorrect oil level • incorrect oil viscosity (high) • deteriorated oil eas30480 overheating engine 1. Clogged coolant passages • cylinder head(s) and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil qua...
Page 603: Troubleshooting
Troubleshooting 9-4 3. Front fork leg(s) • uneven oil levels (both front fork legs) • unevenly tensioned fork spring (both front fork legs) • broken fork spring • bent or damaged inner tube • bent or damaged outer tube 4. Swingarm • worn bearing or bushing • bent or damaged swingarm 5. Rear shock ab...
Page 604: Wiring Diagram
Eas28740 wiring diagram fz8na 2011 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10. Negative battery ground lead 11. Fuel injection system fuse 12. Starter relay 13. Starter motor 14. Relay unit 15. St...
Page 605
Fz8sa 2011 1. Main switch 2. Rectifier/regulator 3. Ac magneto 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Frame ground 8. Engine ground 9. Battery 10. Negative battery ground lead 11. Fuel injection system fuse 12. Starter relay 13. Starter motor 14. Relay unit 15. Starting circuit cut-off r...
Page 606
Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.
Page 607: Wiring Diagram
Wiring diagram fz8na schema de cablage fz8na schaltplan fz8na schema elettrico fz8na diagrama de conexiones de fz8na.
Page 608: Wiring Diagram
Wiring diagram fz8na schema de cablage fz8na schaltplan fz8na schema elettrico fz8na diagrama de conexiones de fz8na.
Page 609: Wiring Diagram
Wiring diagram fz8sa schema de cablage fz8sa schaltplan fz8sa schema elettrico fz8sa diagrama de conexiones de fz8sa.
Page 610: Wiring Diagram
Wiring diagram fz8sa schema de cablage fz8sa schaltplan fz8sa schema elettrico fz8sa diagrama de conexiones de fz8sa.