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Yamaha FZ1-NS 2006 (Europe) Service Manual In

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Contents

1. ETIN nan mmm ETT TaD Berg DETR jJ mr ids fva i e Bony ei eva ve v Ae ef wen qH 34q7 wineHaaness WIRE HARNESS SUB WIRE HARNESS 2 WIRE HARNESS SUB WIRE HARNESS 1 IT a One 472671 eee 55 eS E H L OFF GO O gt i 1 9 Was ee reel awg
2. CIRCUIT DIAGRAM 21 5 ET2D1026 8 17 1 Main switch 6 Fuse main 7 Battery 23 ECU 49 High beam indicator light 52 Meter light 61 Pass switch 62 Dimmer switch 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight relay on off 77 Headlight relay dimmer 78 Fuse tail light 82 Fuse headlight LIGHTING SYSTEM EAS27260 TROUBLESHOOTING LIGHTING SYSTEM Any of the following fail to light headlight high beam indicator light taillight license light or meter light NOTE Before troubleshooting remove the following part s 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the each bulbs and bulb sockets condition Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 96 2
3. pep cm al a T oka L 1 eka vy I 4 5 EA 1 T 1 169 PET Tor se uw se so i mM 177 4 EL 4 os Ji A gt 4 e A i po Oo ea dedo PM TEF 7 NS 169 Bde i Core FREE Ji Cro OL i e rae A F3 3 3 1 E s 8 1 wl n e 9 in EP d sol ja aw 9 o T luces c l ET 25 55 50 ower yo Eby 7 a o 4566 OFF 10 OFF N 5 T 1 gt ILLE
4. CIRCUIT DIAGRAM 8 27 1 Main switch 6 Fuse main 7 Battery 23 ECU 38 Coolant temperature sensor 78 Fuse ignition 82 Radiator fan motor relay 83 Fuse radiator fan motor left 84 Fuse radiator fan motor right 85 Radiator fan motor left 86 Radiator fan motor right 8 28 COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE COOLING SYSTEM Before troubleshooting remove the following part s 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses Main ignition and radiator fan motor Refer to CHECKING THE FUSES on page 8 97 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 4 Check the radiator fan motor left and right Refer to CHECKING THE RADIA TOR FAN on page 8 108
5. IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM EAS27090 Te J 1141 re 198 1991 E oF 7 E LE m TEE 1 ex qus ev 21 i aa tte 5 A Ho C E a 1 UH F FESH LER m mU CENE JU ell TY ass 4 xn To d ae e I NEM NNNM 1 Exp Gi T oF K Ifo Ir Ec ge 8 1 1 Main switch 6 Fuse main 7 Battery 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Sidestand switch 17 Crankshaft position sensor 21 Lean angle sensor 23 ECU 24 Ignition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 gnition coil 4 28 Spark plug 56 Engine stop switch 60 Clut
6. E go E ie e nan OOO DODO SCHALTPLAN SCHEMA DE CABLAGE WIRING DIAGRAM 0 97216 216 wole gt A H le g ojo T zh serre L 1 Icie cieje e 1 el lel
7. O 4 S s s g c hen 9 e e ea O 0 OF all lo H i ge 6 14 10 M te ji 15 GRSI EX H AL oo 5 4 ejaj i 155 i i il o ICEA 3 a Le I 1 EFT gm le iE OBB 4 Jaaa 101 1 jeje H 00 N 2006 SCHALTPLAN 21 FZ1 N V 2006 FZ1 N V 2006 SCHEMA DE CABLAGE WIRING DIAGRAM ee 01912 DIAGRAMA DE CONEXIONES DE FZ1 S V 2006 FZ1 S V 2006 SCHE S V 2006 21 71 5 2006 FZ1 S V 2006 MA ELETTRICO
8. ale ise Ol DE le m sio m se em 20 paan coa goa eje E sie oc dele sj se e ee DIAGRAMA DE CONEXIONES DE FZ1 S V 2006 FZ1 S V 2006 S V 2006 21 71 5 2006 FZ1 S V 2006 Pun el 1o le le 0 EIC nan 0109 DODA i 2 ee SCHEMA ELETTRICO SCHALTPLAN SCHEMA DE CABLAGE WIRING DIAGRAM onog
9. 1 m T a PEE ORA OA 198 1981 t w is TERM tS T uj ampan 6 MR cm a ae DH 1 P T vp BRE p TO e mee o BEN 1 Exp OG oF _ EN Oc ESSI 8 75 8 1 Main switch 6 7 Battery Fuse main Fuse fuel injection 13 Fuel pump relay 16 Fuel pump 23 ECU 46 Multi function meter 56 Engine stop switch 78 Fuse ignition 8 76 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate NOTE FUEL PUMP SYSTEM Before troubleshooting remove the following part s 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses Main ignition and fuel injection system Refer to CHECKING THE FUSES on page 8 97 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97
10. 5 62 CHECKING THE OIE PUMP 5 er riter eat 5 62 CHECKING THE RELIEF VALVE scx 5 63 CHECKING THE OIL DELIVERY PIPES 5 63 CHECKING THE OIL STRAINEH 5 63 CHECKING THE OIL NOZZLES cen toes 5 63 ASSEMBLING THE OIL 2 0 001 5 63 INSTALLING THE OILAWATER PUMP 5 64 INSTALLING THE oot eR eb Reo n toria 5 65 CRANKCASE eh pedes se eee lae aD pecora tpa 5 66 DISASSEMBLING THE 5 68 CHECKING THE CRANKCASE 5 68 CHECKING THE BEARING AND OIL SEALS 5 68 ASSEMBLING THE 5 5 68 CRANKSHAFT e o m o peti ne ee t oes 5 70 REMOVING THE CONNECTING RODS AND PISTONS 5 72 REMOVING THE CRANKSHAFT ASSEMBLY sees 5 72 CHECKING THE CYLINDER AND 5 73 CHECKING THE PISTON RINGS eem 5 73 CHECKING THE PISTON PINS io ee te bte ac 5 74 CHECKING THE BIG END BEARINGS eee 5 75 INSTALLING THE CONNECTING ROD AND PISTON 5 78 CHECKING THE CRANKSHAFT nct ttr
11. A Degrees that the crankshaft is turned counterclockwise B Cylinder C Combustion cycle 5 Remove Camshaft NOTE e Refer to CAMSHAFTS on page 5 10 When removing the timing chain and cam shafts fasten the timing chain with a wire to retrieve it if it falls into the crankcase ENGINE 6 Adjust Valve clearance VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 CZ Valve lapper 2 90890 04101 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 valve pad 2 so that they can be installed in the correct place 11171102 11172202 b Calculate the difference between the speci fied valve clearance and the measured valve clearance Example Specified valve clearance 0 11 0 20 mm 0 004 0 008 in Measure valve clearance 0 25 mm 0 010 in 0 25 mm 0 010 0 20 mm 0 008 in 0 05 mm 0 002 in Check the thickness of the current pad NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Example If the valve pad is marked
12. lt ee NI NI 5 46 CLUTCH Removing the clutch 10 Nm 1 0 m kg 7 2 ft lb For assembly reverse the removal procedure 5 47 CLUTCH EAS25080 4 Remove REMOVING THE CLUTCH 1 1 1 Remove Erie Clutch cover 1 Friction plate 2 Gasket NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 5 Straighten the clutch boss nut rib 1 1 2 Remove Compression spring bolts 1 Compression springs Pressure plate 2 Pull rod 3 6 Loosen Clutch boss nut 1 NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder 90890 04086 YM 91042 3 Remove 7 Remove Clutch boss nut Washer Clutch boss assembly 5 48 Thrust plate 8 Remove Wire circlip 1 NOTE There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 1 and disassemble the built in damper unless there is serious clutch chattering 9 Remove Clutch plate 2 1 Friction plate 3 2 10 Remove Clutch damper spring 1 Clutch damper
13. 2 2 2 2 2 2 0 E DIAGRAMA DE CONEXIONES DE FZ1 N V 2006 SCHEMA ELETTRICO FZ1 N V 2006
14. ad Mum aD IL E E A LE E OL E 8 93 9 Main switch Horn switch Dimmer switch Pass switch Turn signal switch Hazard switch Clutch switch Sidestand switch Engine stop switch 10 Front brake light switch 11 Start switch 12 0il level switch 13 Neutral switch 14 Rear brake light switch 15 Fuse box 16 0 sensor 8 94 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 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 CAUTION Never insert the tester probes into the coupler terminal slots 1 Always insert the probes from the opposite end of the coupler taking care not to loosen or damage the leads Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Before checking for continuity set the pocket tester to 0 and to the Q x 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch position is indication by
15. 1 1 4 ER eee 2 1 Qi CCE oe 1 wa 9 4 i 1 to NN wl L ac i j al 69 i J Al a i 7 82 81 e xS a __691 zu 7 m EE l MM JO Jerem eer un gt ol 4 99 a ol z q A 8 4 1 4444 Ln 169 _ 1 1 _ 11 1 1 _ 1 ie r 3 e 1 op TEET la icon 1 eC eG eC 1 e l D i a d Pe 3l d l 971 2r WL 4 34 a d rapis E FZ1 S V 2006 FZ1 S V 2006 FZ1 S V 2006 FZ1 S V 2006 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1 S V 2006 re A nan ER T 1 anm 5 mmm fafej
16. 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 93 5 Check the relay unit fuel pump relay Refer to CHECKING THE RELAYS on page 8 100 6 Check the fuel pump Refer to CHECKING THE FUEL PRESSURE on page 7 8 7 Check the entire fuel pump sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 75 Replace the ECU NG NG gt NG gt NG gt 8 77 Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the immobilizer kit Replace the right handlebar switch Replace the relay unit Replace the fuel pump Properly connect or repair the fuel pump system s wiring FUEL PUMP SYSTEM 8 78 IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM EAS27640
17. ities 6 11 ASSEMBLING THE WATER 1 01 6 11 RADIATOR EAS26380 RADIATOR Removing the radiator 17 Nm 0 7 m kg 5 1 ft lb Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOL ANT on page 3 19 Radiator side covers Coolant reservoir hose Radiator front cover Radiator Radiator fan motor Radiator inlet hose Oil cooler outlet hose Water pump breather hose Radiator outlet hose CO A PO lt N PO 6 1 Removing the radiator 17 Nm 0 7 m kg 5 1 ft lb Job Parts to remove Water pump inlet pipe RADIATOR Remarks O ring For installation reverse the removal procedure EAS26390 CHECKING THE RADIATOR 1 Check Radiator fins Obstruction Clean Apply compressed air to the rear of the radiator Damage Repair or replace NOTE Straighten any flattened fins with a thin flat head screwdriver 14110401 2 Check Radiator hoses Radiator pipes Cracks damage Replace 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pres
18. 7 4 CHECKING THE INJECTORS tenete 7 8 CHECKING THE THROTTLE BODIES ne Sn Pee 7 8 CHECKING THE FUEL eee 7 8 ADJUSTING THE THROTTLE POSITION 7 8 ADJUSTING THE SUB THROTTLE POSITION SENSOR 7 9 CHECKING THE SUB THROTTLE SERVO 7 10 CHECKING THE THERMO WAX tnr net ree tp eerte 7 11 ADJUSTING THE THERMO WAX crei tee tee 7 11 AIR INDUCTION SYSTEM sese 7 13 CHECKING THE AIR INDUCTION SYSTEM ee 7 14 INSTALLING THE AIR INDUCTION SYSTEM 7 15 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 5 1 ft lb Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Disconnect Disconnect Disconnect Disconnect Disconnect Fuel hose Fuel sender coupler Fuel pump coupler Fuel tank drain hose Fuel tank breather hose Fuel tank Fuel tank cover Fuel pump 5 For installation reverse the removal procedure EAS26630 REMOVING THE FUEL TANK 1 Extract the fuel in the fuel tank through the fuel tank cap with a pump 2 Remove Fuel h
19. 4 17 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4 18 ADJUSTING THE REAR WHEEL STATIC 4 18 INSTALLING THE REAR WHEEL 015 4 18 FRONT BRAKE tete ed 4 20 INTRODUCTION redet pete ti ene SR eee tete nt tete ets 4 25 CHECKING THE FRONT BRAKE 5 8 2 2222222 4 25 REPLACING THE FRONT BRAKE 5 4 26 REMOVING THE FRONT BRAKE CALIPERS eee 4 27 DISASSEMBLING THE FRONT BRAKE 5 4 27 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE 4 28 INSTALLING THE FRONT BRAKE 8 2 4 28 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 29 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 30 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 30 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 30 HEAR BRAKE 4 32 255 4 37 CHECKING THE REAR BRAKE 4 37 REPLACING THE REAR BRAKE PADS 4 37 REMOVING
20. P lom em a jaw m 2 i AL aon _2 wy 1 3d z 19 409 44 Cy 12 ETE 11 1 owl we uw RL sa i E soeur ve i T Og 1 97 Lx RIA T oouo aye GO oye i8 3 DELI HO mm E E nOn 1 4 2 42 a E gl apos 4 45 Rana i 4 J i E WP om TUN 4 o Gls 1 _ ss Oan Fp dan 14 1 BEEN 474 71 il 1 dus 2d z gs 3 ove ae eee DE TNE p 922 Ye p Lore FREE 1 defe t RUN pus 100 i pn em al ER PEDE o FE E aw 1 4 BEL Ger 24 I 3 e vel er 4 4 asl Il Ep eee et es TY FEES PSE a i 8 Lm 10 i i E m v _ 2 1 E Mm EST ait p E ov
21. 6 10 EAS26520 DISASSEMBLING THE WATER PUMP 1 Remove Water pump seal 1 Water pump housing 2 NOTE Tap out the water pump seal from the inside of the water pump housing Wis 2 Remove Oil seal 1 Bearing 2 Water pump housing 3 NOTE Tap out the bearing and oil seal from the out side of the water pump housing 3 Remove Rubber damper holder 1 Rubber damper 2 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft WATER PUMP EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller 3 Rubber damper 4 Rubber damper holder 5 Water pump seals Oil seal Cracks damage wear Replace 2 Check Bearing Rough movement Replace 3 Check Water pump outlet pipe Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 2 NOTE Before installing the oil seal apply tap water or coolant onto its out surface Install the oil seal with a socket that matches its outside diameter WATER PUMP NOTE 1 1 Before installing the rubber damper apply tap 17 2 mm water or coolant onto its outer surface 0 68 in 2 2 Install Water
22. A a For installation reverse the removal procedure 5 3 ENGINE REMOVAL Disassembling the exhaust valve pipe 7 Nm 0 7 m kg 5 1 ft lb Job Parts to remove Remarks Nut Pulley Spring Spring seat For assembly reverse the disassem bly procedure 5 4 Disconnecting the leads and hoses Job Parts to remove Fuel tank Air filter case ENGINE REMOVAL Remarks Refer to FUEL TANK on page 7 1 Refer to GENERAL CHASSIS on page 4 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 Oil cooler Refer to OIL COOLER on page 6 4 Air cut off valve Refer to AIR INDUCTION SYS TEM on page 7 13 Starter motor Refer to ELECTRIC STARTER on page 5 40 Battery negative lead Battery positive lead Clutch cable Ground lead Stator coil assembly coupler 5 5 Disconnect ENGINE REMOVAL Disconnecting the leads and hoses Job Parts to remove Remarks Crankshaft position sensor lead coupler Disconnect Oil level switch connector Disconnect Neutral switch connector Disconnect Cylinder identification sensor coupler Disconnect Speed sensor coupler Disconnect For assembly reverse the removal procedure 5 6 Removi
23. 8 102 CHECKING THE RELAY UNIT DIODE 8 102 CHECKING THE IGNITION COILS eem 8 103 CHECKING THE CRANKSHAFT POSITION SENSOR 8 104 CHECKING THE LEAN ANGLE 8 105 CHECKING THE STARTOR MOTOR OPERATION 8 105 CHECKING THE STARTOR 8 106 CHECKING THE 8 106 CHECKING THE rit ad ort ihe Ru Se e nat 8 106 CHECKING THE FUEL SENDER ripe voce eode 8 107 CHECKING THE SPEED SENSOR 8 107 CHECKING THE RADIATOR FAN 8 108 CHECKING THE COOLANT TEMPERATURE SENSOR 8 108 CHECKING THE THROTTLE POSITION SENSOR 8 109 CHECKING THE SUB THROTTLE POSITION SENSOR 8 110 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 8 110 CHECKING THE ATMOSPHERIC PRESSURE SENSOR 8 111 CHECKING THE CYLINDER IDENTIFICATION SENSOR 8 111 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 112 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8 112 169 Sear E B Be IGNITION SYSTEM
24. 3 22 ADJUSTING THE FRONT DISC BRAKE 3 22 ADJUSTING THE REAR DISC BRAKE 3 22 CHECKING THE BRAKE FLUID LEVEL eee 3 23 CHECKING THE FRONT BRAKE 3 23 CHECKING THE REAR BRAKE 5 3 23 CHECKING THE FRONT BRAKE HOSES eee 3 24 CHECKING THE REAR BRAKE HOSE 3 24 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 24 BLEEDING THE HYDRAULIC BRAKE 5 3 25 ADJUSTING THE SHIFT PEDAL seme 3 26 ADJUSTING THE DRIVE CHAIN SLACK 3 26 LUBRICATING THE DRIVE CHAIN emm 3 27 CHECKING AND ADJUSTING THE STEERING HEAD 3 27 CHECKING THE FRONT enn 3 28 ADJUSTING THE FRONT FORK LEGS 3 29 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 31 CHECKING THE TIBES prp t 3 32 CHECKING THE WHEELS t es 3 34 CHECKING AND LUBRICATING THE CABLES sees 3 34 LUBRICATING THE LEVERS es 3 34 LUBRICATING THE PEDAL tte eene beo ee to 3 34 LUBRICATING TH
25. Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Recommended brake fluid DOTA A Front brake B Rear brake 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 chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of CHASSIS the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check Front brake pad Wear indicators a almost touch the brake disc Replace the brake pads as a set Refer to FRONT BRAKE on page 4 20 12220404 EAS21260 CHECKING THE REAR BRAKE PADS The following
26. 4 Diagnostic code 03 Intake air pressure sensor Orde r Item components and probable cause Intake air pressure sensor hose Check or maintenance job Check the intake air pressure sensor hose condition Repair or replace the sensor hose Connections Intake air pressure sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers f there is a malfunction repair and connect the coupler securely Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 112 8 52 Reinstatement method Starting the engine and operate it at idle FUEL INJECTION SYSTEM Fault code No 15 Symptom Throttle position sensor open or short circuit detected Diagnostic code No 01 Throttle position sensor Order Item components and probable cause Installed condition of throttle position sensor Check or maintenance job Check for looseness or pinch ing Check that is installed in the specified position Connections Throttle position sensor coupler Main wire harness ECU coupler Sub wire harness coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a mal
27. A Front side B Rear side 3 Adjust Primary opening VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a After performing the full open angle of the sub throttle position sensor turn the nut of the worm shaft clockwise measure the dimension of b section with a micrometer caliper or other device and adjust so that the dimension is in a range from 8 1 to 8 5 mm 0 32 to 0 33 in Sub throttle dimension b 8 1 8 5 mm 0 32 0 33 A Front side B Rear side MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA THROTTLE BODIES 4 Adjust Sub throttle position sensor voltage VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the sub throttle position sensor coupler to the wire harness b Connect the digital circuit tester to the sub throttle position sensor Positive tester probe Green Yellow terminal 1 Negative tester probe Black Blue terminal 2 c Move the sub throttle position sensor to adjust to be in the specified range Sub throttle position sensor voltage 0 97 1 07 V d After adjusting the sub throttle position sensor voltage tighten the sub throttle position sensor screws NOTE After setting up the sub throttle position sen sor check that the sub throttle position sen sor output voltage is 0 4 V or more with the nut of worm shaft turned to the full close side until it stop
28. Piston ring end gap Top ring 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring 0 30 0 45 mm 0 0118 0 0177 in Limit 0 80 mm 0 0315 in Cil ring 0 10 0 40 mm 0 0039 0 0157 in ET2D1016 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin Piston pin bore outside diame ter 16 991 17 000 mm 0 6689 0 6693 in Limit 16 971 mm 0 6682 in 3 Measure Piston pin bore inside diameter b The oil rin t ung expangel Spaco S Out of specification Replace the piston be measured If the oil ring rail s gap is exces sive replace all three piston rings 5 74 Piston pin bore inside diameter 17 002 17 013 mm 0 6694 0 6698 Limit 17 043 mm 0 6710 in 4 Calculate Piston pin to position clearance Out of specification Replace the position pin and piston as a set Piston pin to pistonclearance Piston pin bore size Piston pin outside diameter Piston pin to piston clearance 0 002 0 022 mm 0 0001 0 009 in Limit 0 072 mm 0 0028 in ET2D1017 CHECKING THE BIG END BEARINGS 1 Measure Crankshaft pin to big end bearing crear ance Out of specification R
29. 3 Install Intake air temperature sensor Intake air temperature sensor bolt 1 2 Nm 0 12 m kg 0 87 ft lb ELECTRICAL COMPONENTS 8 113 TROUBLESHOOTING TROUBLESHOOTING I Hon pee cmt ta 9 1 GENERAL 9 1 STARTING FAILURES teta ueber tat cod ees 9 1 INCORRECT ENGINE IDLING SPEED 5 en ito Det 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SPIETING sheer entro smt Use decem cor np 9 2 SHIFT PEDAL DOES reet ett etr rere ete 9 2 JUMPS OU TOF GEAR teet iater rette dto e uat ed 9 2 FAULTY CLUTCH BGs P 9 2 OVERHEATING 9 2 OVER GOOLIING 5 t ipt Da p eA 9 3 POOR BRAKING 9 3 FAUETYCEHONT FORK EEGIS 9 3 UNSTABLE HANDLING eR 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM EAS28450 TROUBLESHOOTING EAS28460 GENERAL INFORMATION NOTE The following guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative proce dure in this manual for checks adjustments and replacement of parts EAS28470 STARTING FAILURES Engine 1 Cylinder s and cylinder head s Loose spa
30. Compression damping WWWVVVVVVVVVVVVVVYVVVVVYVVYYVYVYY a Turn the adjusting screw 1 in direction a or b Direction a turn in Compression damping is increased suspension is harder Direction b turn out Compression damping is decreased suspension is softer Compression damping adjusting positions Minimum 26 clicks in direction b Standard 5 clicks in direction b Maximum 1 clicks in direction b With the adjusting screw fully turned in direction a 3 30 MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21620 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13590 CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust e Spring preload VV VV VV VV VV VV VV VV VV VV VY VV VV VV VY a Adjust the spring preload with the special wrench and extension bar included in the owner s tool kit b Turn the adjusting ring 1 in direction or Align the desired position on the adjusting ring with the stopper 2 Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 1 Standard 3 Maximum 7 CHASSIS MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Rebound damping ECA13590 CAUTION N
31. Reinstatement method Turning the main switch to ON however the engine can not be restarted unless the main switch is first turned to Fault code No 33 Symptom FUEL INJECTION SYSTEM 1 ignition coil Open circuit detected in the primary lead of the cylinder Diagnostic code 30 Cylinder 1 ignition coil Order Item components and probable cause Connections Cylinder 1 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 1 ignition coil coupler and ECU coupler Red Black Red Black Orange Orange Defective cylinder 1 ignition coil Execute the diagnostic mode Code No 30 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNITION COILS on page 8 103 8 60 Reinstatement method Starting the engine and operating it at idle Fault code No 34 Symptom FUEL INJECTION SYSTEM 2 ignition coil Open circuit detected in the primary lead of the cylinder Diagnostic code No 31 Cylinder 2
32. YAMAHA 2006 FZ1 N V FZ1 S V SERVICE MANUAL 2D1 28197 E0 EAS20040 FZ1 N V FZ1 S V SERVICE MANUAL 2005 by Yamaha Motor Co Ltd First edition December 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited EAS20070 NOTICE This manual was produced by the Yamaha Motor Company Ltd primarily for use by Yamaha deal ers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual Therefore anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed If there is any question about a service procedure it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is co
33. acl riche 8 Lone v v Relta v dwlun ps sw dispen 20000m onan fal Naty Eden way bl 1 l feanen ming E gps gt WIRE HARNESS 01 WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 1 WIRE HARNESS SUB WIRE HARNESS 2 WIRE HARNESS SUB WIRE HARNESS 1 bue Ems
34. i 1 idol ai T Bii NS fat ORP a 198 190 t T CBS nia n a iA 12 EE ql a amp C9 Tero 9 E 8 79 1 Main switch 4 Fuse backup 5 Immobilizer unit 6 Fuse main 7 Battery 23 ECU 41 Immobilizer indicator 46 Multi function meter 78 Fuse ignition 8 80 IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM EAS27670 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re registering codes in the standard keys This system consists of the following A code re registering key with a red bow Two standard keys with a black bow that can be re registered with new codes A transponder which is installed in each key bow An immobilizer unit e The ECU An immobilizer system indicator light The key with the red bow is used to register codes in each standard key Do not use the key with the red bow for driving It shoul
35. 0 5 12 CHECKING THE GAMSHAE VS e ete td pee aene dis 5 13 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET 5 14 CHECKING THE TIMING CHAIN GUIDES 5 14 CHECKING THE TIMING CHAIN 5 14 INSTALLING THE GAMSHAFTS iicet rot ettet 5 16 ether tur pe pr t P 5 19 REMOVING THE CYLINDER HEAD peto ntt 5 20 CHECKING THE CYLINDER HEAD 5 20 INSTALLING THE CYLINDER HEAD it tte te 5 20 VALVES AND VALVE SPRINGS 5 22 REMOVING THE VALVES PNE peri kde 5 24 CHECKING THE VALVES AND VALVE 5 25 CHECKING THE VALVE SEATS ettet ertt en eene e ah cc 5 26 CHECKING THE VALVE SPRINGS etre eed 5 28 CHECKING THE VALVE L IFTERS toe not tr rtr 5 29 INSTALLING THE VADVES raciste cte tare ib 5 29 GENERATOR tese RA IAE atem Uh p ede 5 31 REMOVING THE GENERJAEOPRL etre ero nanan tutte 5 33 INSTALLING THE 5 33 STARTER CLUTCH inni iei tu AER unsere 5 35 REMOVING THE STARTER CLUTCH eee 5 36 GHEGKING THE DAMPER ne epe tes SPUR Pe eni 5 36 CHECKING THE STARTER CLUTCH eee 5 36 INSTALLING THE STARTER
36. 3 Check the main switch Refer to CHECKING THE Replace the immobilizer kit SWITCHES on page 8 93 4 Check the entire immobilizer sys tem s wiring Properly connect or repair the immobi Refer to CIRCUIT DIAGRAM on lizer system s wiring page 8 79 Check the condition of the each immobilizer system s circuits Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 85 EAS27720 SELF DIAGNOSIS FAULT CODE INDICATION When the system failure occurred the error code number is indicated in the immobilizer system indi cator light blinks at the same time The pattern of blinking also shows the error code Detection Symptoms Trouble Measures IMMOBILIZER Cannot transmit 1 Objects that may keep 1 Keep clear of UNIT code between the off radio waves exist magnets metals key and immobilizer around the keys and and other keys unit antennas form the surround 2 Immobilizer unit failure ings of keys and 3 Key failure antennas 2 Replace the immobilizer unit 3 Replace the key 8 85 Detection IMMOBILIZER UNIT IMMOBILIZER UNIT Symptoms Codes do not match between the key and immobilizer unit Cannot transmit code between the ECU and immobi lizer unit IMMOBILIZER SYSTEM Trouble 1 Disturbed by other transponder Failed to verify continu ally for ten times 2 Unregistered sub key wa
37. 4 Nm 0 4 m kg 2 9 ft lb 2 Nm 0 2 m kg 1 4 ft lb Tail brake light bracket bolt 16 Nm 1 6 m kg 12 ft lb Rear fender bracket bolt Seat bracket bolt 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb Exhaust pipe assembly bracket bolt DO PO 20 Nm 2 0 m kg 14 ft lb Side cover screw 4 Nm 0 4 m kg 2 9 ft lb Lean angle sensor bolt Coolant reserver tank bolt 2 Nm 0 2 m kg 1 4 ft lb 5 Nm 0 5 m kg 3 6 ft lb Front wheel axle shaft 72 Nm 7 2 m kg 52 ft lb Front wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb Front brake caliper bolt 40 Nm 4 0 m kg 29 ft lb Front brake disc screw k 18 Nm 1 8 m kg 13 ft lb Brake caliper bleed screw 5 Nm 0 5 m kg 3 6 ft lb Rear wheel axle nut 150 Nm 15 0 m kg 108 ft lb Rear brake disc screw 30 Nm 3 0 m kg 22 ft lb Rear brake caliper bolt front 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt rear 22 Nm 2 2 m kg 16 ft lb Rear wheel sprocket nut 100 Nm 10 0 m kg 72 ft lb Drive chain adjusting locknut Rear brake hose union bolt 30 Nm 3 0 m kg 22 ft lb Sidestand nut 48 Nm 4 8 m kg 35 ft lb Sidestand bracket bolt 16 Nm 1 6 m kg 12 ft lb 63 Nm 6 3 m kg 46 ft lb Sidestand switch bolt 4 Nm 0 4 m kg 2 9 ft lb Footrest bracket bolt 30
38. 5 Check the radiator fan motor relay Refer to CHECKING THE RELAYS on page 8 100 6 Check the coolant temperature Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 108 7 Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM on page 8 27 This circuit is OK NG NG gt NG gt NG gt 8 29 Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the immobilizer kit The radiator fan motor is faulty and must be replaced Replace the radiator fan motor relay Replace the coolant temperature sen sor Properly connect or repair the cooling system s wiring COOLING SYSTEM 8 30 FUEL INJECTION SYSTEM 088 ORA oe ie ip d E Oti ot EON 9 Em tad 99 2 8 31 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRA
39. Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler Yellow Blue Yellow Blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 8 73 Reinstatement method Turning the main switch to ON No signals are received from the ECU within the specified Reinstatement method Turning the main switch to ON FUEL INJECTION SYSTEM Fault code Er 3 Symptom Data from the ECU cannot be received correctly Diagnostic codeNo Order Item components and probable cause Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Sub wire harness coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler Yellow Blue Yellow Blue Malfunction in meter assembly R
40. Locknut 7 Nm 0 7 5 1 ft lb ENGINE p MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 2 Remove Air filter case cover 1 3 Check Air filter element 1 Damage Replace NOTE Replace the air filter element every 40000 km 2400 mi of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 3 15 4 Install Air filter case cover ECA14400 CAUTION Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect throttle bodies synchronization leading to poor engine performance and possible overheating NOTE When installing the air filter element into the air filter case cover make sure that the sealing surfaces are aligned to prevent any air leaks 5 Install Fuel tank Refer to FUEL TANK on page 7 1 Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds 1 Remove Throttle bodies Refer to THROTTLE BODIES o
41. NG 8 25 SIGNALING SYSTEM Replace the left handlebar switch Replace the turn signal hazard relay Properly connect or repair the signal ing system s wiring Replace the neutral switch Properly connect or repair the signal ing system s wiring Replace the oil level switch Properly connect or repair the signal ing system s wiring 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 107 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is OK The speedometer fails to operate 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 107 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 Replace the meter assembly NG 8 26 SIGNALING SYSTEM Replace the fuel pump assembly Properly connect or repair the signal ing system s wiring Replace the speed sensor Properly connect or repair the signal ing system s wiring COOLING SYSTEM COOLING SYSTEM EAS27300 EAS27310
42. OUT mark facing away from the vehicle 5 51 CLUTCH Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle While holding the clutch boss assembly 1 with the clutch holding tool 3 tighten the clutch boss nut Universal clutch holder 90890 04086 YM 91042 8 Install e Friction plate 1 1 NOTE Install the last friction plate shifting half phase X 9 Install Bearing Pull rod 1 Pressure plate 2 6 Lubricate Clutch springs Friction plates Clutch spring bolts 3 Clutch plates with the recommended lubricant Clutch spring bolt SN 10 Nm 1 0 m kg 7 2 ft Ib Recommended lubricant Tighten the clutch spring bolts in stages and in 7 Install a crisscross pattern Friction plate 2 Clutch plate 1 1 5 52 CLUTCH 10 Install Pull lever NOTE Install the pull lever with the O mark facing toward lower side 11 Install Clutch cover e Clutch cover gasket NM NOTE Install the pull rod so that the teeth a face towards the rear of the vehicle Then install the clutch cover Apply oil onto the bearing Apply molybdenum disulfide grease onto the pull rod When installing the clutch cover push the pull lever and check that the punch mark on the pull lever aligns with th
43. 4 After the installation check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of installation VV VVVVV VV VV VV VV VV VV VV VY VV VY a Install the timing chain tensioner spring and timing chain tensioner rod 1 MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 15 CAMSHAFTS EAS24000 INSTALLING THE CAMSHAFTS 1 Align T mark on the pickup rotor with the crankcase mating surface b WWWVVVVVVVVVVYVVVYVVVVVVVVVYVYVYVYY a Turn the crankshaft clockwise b When position 1 is at TDC align the mark a with the crankcase mating surface 4 Install Dowel pins Intake camshaft caps Exhaust camshaft caps NOTE Make sure each camshaft cap is installed its original place Refer to the identification marks as follows P Intake side camshaft cap mark E Exhaust side camshaft cap mark Left side camshaft cap mark R Right side camshaft cap mark Make sure the arrow mark on each cam shaft points towards the right side of the engine DAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Install Intake camshaft sprocket 1 Exhaust camshaft sprocket 2 with the camshaft sprockets temporarily tightened NOTE Install the camshaft sprockets as a illustration 5 Install Camshaft cap bolts Camshaft cap bolt 3 Install N
44. M6 x 60 mm 2 4 in bolts 24 25 M6 x 50 mm 2 0 in bolts 20 26 M8 x 50 mm 2 0 in bolts 13 4 5 3 Remove Lower crankcase ECA13900 CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly 4 Remove Dowel pins 5 Remove Crankshaft journal lower bearing from the lower crankcase CRANKCASE NOTE Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place EAS25580 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves ina mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air ET2D1014 CHECKING THE BEARING AND OIL SEALS 1 Check Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check Oil seals Damage wear Replace EAS25650 ASSEMBLING THE CRANKCASE 1 Lubricate Crankshaft
45. NOTE Make sure each valve is installed in its origi nal place Refer to the following embossed marks Right and left intake valve s 6VY Middle intake valve s 5 Exhaust valve s 5VY Install the valve springs with the larger pitch a facing up 11172001 b Smaller pitch 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and the valve spring compressor attach ment 3 VALVES AND VALVE SPRINGS Each valve lifter and valve pad must be rein Valve spring compressor stalled in its original position 90890 04019 YM 04019 Intake Valve spring compressor attachment 90890 04114 YM 04114 A Exhaust CE Valve spring compressor attachment 11171102 90890 04108 YM 04108 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer ECA13800 CAUTION Hitting the valve tip with excessive force could damage the valve 6 Install Valve pad 1 Valve lifter 2 NOTE Lubricate the valve lifter and pad with molybdenum disulfide oil The valve lifter must move smoothly when rotated with a finger 5 30 GENERATOR EAS24480 GENERATOR Removing the generator Q 12 Nm 1 2 8 7 ft lb 22 Nm 2 2 16 ft Ib Job Parts to r
46. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing 5 87 For assembly reverse the disassem bly procedure TRANSMISSION Disassembling the drive axle assenbly Job Parts to remove Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer Collar 2nd wheel gear Collar es 5 88 TRANSMISSION Disassembling the drive axle assenbly Job Parts to remove Remarks 21 Oil seal 1 22 Bearing 1 23 Drive axle 1 For assembly reverse the disassem bly procedure 5 89 EAS26250 REMOVING THE TRANSMISSION 1 Remove Drive axle asseembly 1 Shift drum retainers 2 Shift fork guide bars e Shift fork and R e Shift drum assembly Shift fork 2 Remove Bearing housing 1 Main axle assembly 2 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Insert two bolts 3 of the proper size as shown in the illustration into the main axle assembly bearing housing b Tighten the bolts
47. a or b to obtain the correct shift pedal position Direction a Shift pedal is raised Direction b Shift pedal is lowered c Tighten both locknuts MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D1007 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain ECA13550 CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Stand the vehicle on a level surface EW2D1005 Securely support the vehicle so that there is no danger of it falling over CHASSIS NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Spin the rear wheel several times and find the tightest position of drive chain 3 Check Drive chain slack Out of specification Adjust Drive chain slack 25 35 mm 0 98 1 38 4 Adjust Drive chain slack VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is obtained Direction a Drive chain is tightened Direction b Drive chain is loosened 3 26 NOTE To maintain the proper wheel a
48. 0 95 kgf mm 0 0 130 0 mm 0 00 5 12 43 0 1 69 0 2 0 01 Suspension oil 01 or equivalent 545 0 cm 18 43 US oz 19 18 Imp oz 91 0 mm 3 58 in Rear suspension Type Spring shock absorber type Rear shock absorber assembly travel Spring free length Installed length Spring rate K1 Spring stroke K1 Optional spring available Enclosed gas air pressure STD Swingarm link suspension Coil spring gas oil damper 60 0 mm 2 36 in 191 3 mm 7 53 in 181 8 mm 7 16 in 120 00 N mm 685 20 Ib in 12 24 kgf mm 0 0 60 0 mm 0 00 2 36 1000 kPa 142 2 psi 10 0 kgf cm Drive chain Type manufacturer Link quantity Drive chain slack 15 link length limit 50VA8 DAIDO 122 25 0 35 0 mm 0 98 1 38 in 239 3 mm 9 42 in EAS20310 ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Voltage System voltage Ignition system Ignition system Ignition timing B T D C 12V Transistorized coil ignition digital 5 0 1200 r min Engine control unit Model manufacturer TBDF20 DENSO Transistorized coil ignition Crankshaft position sensor resistance Ignition coil Model manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance 336 504 Q at 20 C 68 F F6T558 MITSUBISHI 6 0 mm 0 24 in 1 19 1 61 at 20 C 68 F 8 5 11 5 at 20 C 68 F AC magneto Model manufacturer Standard output Sta
49. 158 the pad thickness is 1 58 mm 0 062in d Calculate the sum of the values obtained in steps b and c to determine the required valve pad thickness and the valve pad number Example 1 58 mm 0 062 in 0 05 mm 0 002 in 1 63 mm 0 064 in The valve pad number is 163 e Round off the valve pad number according to the following table and then select the suitable valve pad Last digit Rounded value 0 1 2 0 3 4 5 6 5 7 8 9 10 NOTE Refer to the following table for the available valve pads Valve pad range Nos 150 240 1 50 2 40 mm Valve pad thickness 0 0591 0 0945 in 25 thicknesses in 0 05 mm 0 002 in increments Available valve pads Example Valve pad number 163 Rounded value 165 New valve pad number 165 f Install the new valve pad 1 and the valve lifter 2 NOTE Lubricate the valve lifter with engine oil Install the valve lifter and the pad in the correct place The valve lifter must turn smoothly when rotated by hand 3 6 ENGINE g Install the exhaust and intake camshafts timing chain and camshaft caps BM Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE e Refer to CAMSHAFTS on page 5 10 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshafts marks with the camshaft cap marks Turn the c
50. 3 Rare Upper bracket pinch bolt 26 Nm 2 6 m kg 19 ft lb 13680 Make sure the brake hoses are routed prop erly 4 56 STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 16 52 Nm 5 2 38 ft lb 2 18 Nm 1 8 13 ft lb 7 Job Parts to remove Remarks Front wheel Refer to FRONT WHEEL on page 4 8 Front brake calipers Refer to FRONT BRAKE on page 4 20 Front cowling FZ1 S Refer to GENERAL CHASSIS on page 4 1 Headlight and meter assembly FZ1 N Refer to GENERAL CHASSIS on page 4 1 Handlebar Refer to HANDLEBAR on page 4 43 Front fork legs Refer to FRONT FORK on page 4 48 Main switch connector Disconnect Steering stem nut Upper bracket Front brake hose joint 4 57 STEERING HEAD Removing the lower bracket 16 52 Nm 5 2 38 ft lb 2 18 Nm 1 8 13 ft lb 7 p Job Parts to remove Remarks 5 Front brake hose joint bracket 6 Horn 7 Horn bracket 8 Lock washer 9 Upper ring nut 10 Rubber washer N a a 11 Lower ring nut 12 Lower bracket 13 Lower bearing 14 Lower bearing dust seal 15 Lower bearing inner race 16 Bearing cover 17 Upper bearing inner race 18 Upper bearing 19 Bearing outer race For installation reverse the removal p
51. 4 Install 5 57 EAS24920 OIL PUMP Removing the oil pan and oil pump 10 Nm 1 0 7 2 ft lb Engine oil Job Parts to remove OIL PUMP 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb Remarks Refer to CHANGING THE ENGINE OIL on page 3 12 EXUP cables Refer to ENGINE REMOVAL on page 5 2 sensor Refer to ENGINE REMOVAL on page 5 2 Muffler Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 2 Refer to ENGINE REMOVAL on page 5 2 Clutch assembly Refer to CLUTCH on page 5 44 Water pump inlet pipe Refer to OIL COOLER on page 6 4 Water pump outlet pipe Refer to OIL COOLER on page 6 4 Oil level switch lead coupler 5 58 Disconnect OIL PUMP Removing the oil pan and oil pump 0 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 7 2 ft lb Job Parts to remove Remarks 2 Oil level switch Oil level switch lead holder Oil pan gasket Drain pipe Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil water pump assembly drive chain guide Collar Oil water pump assembly drive sprocket Washer Oil water pump assembly drive chain Dowel pin lt N 5 59 OIL PUMP Removing the oil pan and oil pump et 10 Nm 1 0 m kg 7 2 ft lb 10 Nm
52. Add the recommended brake fluid to the proper level REAR BRAKE Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 5 Check Brake pedal operation Soft or spongy feeling gt Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22600 DISASSEMBLING THE REAR BRAKE CALI PER 1 Remove Brake caliper piston 1 Brake caliper piston seals 2 REAR BRAKE Scratches wear Replace the brake cali 6 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Secure the brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the piston from the brake caliper EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton c Remove the brake caliper piston seals EAS22640 CHECKING THE REAR BRAKE CALIPER replacement schedule Brake pads If neces
53. Damaged oil seal lip Incorrect oil level high Loose damper rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 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 absorber assembly ies Faulty rear shock absorber spring Leaking oil or gas 6 Tire s Uneven tire pressures front and rear Incorrect tire pressure Uneven tire wear 7 Wheel s Incorrect wheel balance Deformed cast wheel Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 8 Frame Bent frame Damaged steering head pipe Improperly installed bearing race EAS28710 FAULTY LIGHTING OR SIGNALING
54. Ignition coils Spark plug aA 13 Nm 1 3 m kg 9 4 ft Ib NOTE Before installing the spark plug clean the spark plug and gasket surface 8 Install Radiator upper bolts Radiator lower bolt Refer to RADIATOR on page 6 1 EAS20710 MEASURING THE COMPRESSION PRES SURE The following procedure applies to all of the cylinders NOTE Insufficient compression pressure will result in a loss of performance GY Spark plug type manufacturer 1 Measure 6 CR9EK NGK Valve clearance 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cleaner or wire brush Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 2 Start the engine warm it up for several minutes and then turn it off 3 Remove Ignition coils Spark plugs ECA13340 CAUTION Before removing the spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 4 Install Compression gauge 1 Extension Compression gauge 90890 03081 Engine compression tester YU 33223 5 Measure Compression pressure Out of specification Refer to steps and d Compression pressure at sea level Minimum 1290 kPa
55. N amp For assembly reverse the disassem bly procedure 4 21 FRONT BRAKE Disassembling the front brake master cylinder Job Parts to remove Remarks Brake master cylinder kit Brake master cylinder body For assembly reverse the disassem bly procedure 4 22 FRONT BRAKE Removing the front brake calipers 40 Nm 4 0 m kg 29 ft Ib 130 Nm 3 0 m kg 22 ft Ib Job Parts to remove Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAU LIC BRAKE SYSTEM page 3 25 Union bolt Copper washer Brake hose Brake caliper For installation reverse the removal procedure 4 23 Disassembling the front brake calipers FRONT BRAKE 5 Nm 0 5 m kg 3 6 ft Ib Job Parts to remove Brake pad clip Remarks lt Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal A OIN Bleed screw A 5 N For assembly reverse the disassem bly procedure 4 24 EAS22220 INTRODUCTION 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 entire brake system must be disassembled dr
56. O 0 There is continuity between red brown blue and brown red when the switch is set to ON and between red and brown red when the switch is set to pg n Br L Br R ec f b 8 95 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 No continuity Repair or replace the bulb bulb socket or both Types of bulbs The bulbs used on this vehicle are shown in the following illustration Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turn ing them counterclockwise Bulbs c is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclock wise a b EN 2 18410603 Q 5 e Checking the condition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your ELECTRICAL COMPONENTS hands away from the bulb until it has cooled down ECA14380 CAUTION Be sure to hold the socket firmly when removing the bulb
57. Oil strainer Oil pump LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 Oil filter cartridge Oil level switch Oil pump Oil strainer Oil pipe Oil cooler LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2 32 LUBRICATION SYSTEM CHART AND DIAGRAMS a ias Y dH HERE III 2 33 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 Cylinder head 2 Crankshaft 2 34 COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 2 35 COOLING SYSTEM DIAGRAMS 1 Water pump 2 Radiator 3 Radiator fan 2 36 COOLING SYSTEM DIAGRAMS 2 37 Radiator Radiator Oil cooler Thermostat COOLING SYSTEM DIAGRAMS 2 38 CABLE ROUTING CABLE ROUTING EAS20430 FZ1 S 2 39 amp 9 Clutch cable Left handlebar switch lead Main switch lead Immobilizer le
58. Washer 3 Refer to CHECKING THE STARTER CLUTCH on page 5 36 5 37 Lubricate the engine oil to O ring CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 Crankshaft position sensor lead coupler Disconnect Crankshaft position sensor O ring Pickup rotor cover Gasket Cover For assembly reverse the removal procedure 5 38 CRANKSHAFT POSITION SENSOR EAS24530 REMOVING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor lead coupler 6 2 Remove y 29 e Crankshaft position sensor O ring C39 Pickup coil rotor cover 1 Qi NOTE CR Loosen each bolt 1 4 of a turn at a time in OR stages and in a crisscross pattern 1 After all of the bolts are fully loosened remove 2 Connect them Crankshaft position sensor lead coupler EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Gasket Pickup rotor cover 1 EN Pickup rotor cover 12 Nm 1 2 m kg 8 7 ft Ib O ring Crankshaft posision sensor Crankshaft position sensor bolt
59. When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set Brake pad lining thickness inner 6 0 mm 0 24 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 6 0 mm 0 24 in Limit 1 0 mm 0 04 in 2 Install Brake pad shims onto the brake pads Brake pads Brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set WWWVVVVVVVVVVVVVVVVYVYVYVVYVYVYVYVYY 4 37 a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 5 Nm 0 5 m kg 3 6 ft Ib d Install a new brake pad shim 3 onto each new brake pad 4 e Install new brake pads and a new brake pad spring 5 3 Install Brake caliper Brake pad pin Screw plug Brake caliper bolt front 27 Nm 2 7 m kg 20 ft Ib Brake caliper bolt rear 22 Nm 2 2 m kg 16 ft Ib 4 Check Brake fluid level Below the minimum level mark a
60. 1 0 0250 0 0350 at 20 C 68 F Insulation resistance 2 Above 1 MQ at 20 C 68 F b If any resistance is out of specification replace the starter motor 18210201 5 Measure Brush length a Out of specification Replace the brushes as a set GY lt Mica undercut 0 7 0 03 Brush length wear limit 5 0 mm 0 20 in NOTE The mica of the commutator must be undercut to ensure proper operation of the commutator a BA 18210901 4 Measure Armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor WWWVVVVVVVVVVVYVVVYVVVYVVVVVVYVYVYYY a Measure the armature assembly resis tances with the pocket tester a 18210401 6 Measure Brush spring force Out of specification Replace the brush springs as a set Brush spring force 7 65 10 0 N 780 1021 gf 27 54 36 03 oz 5 42 ELECTRIC STARTER NOTE Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers 1 2 18210602 7 Check Gear teeth Damage wear Replace the gear a b EAS24800 ASSEMBLING THE STARTER MOTOR UT 1 Install INSTALLING THE STARTER MOTOR Brush seat 1 1 Install NOTE Starter motor 1 Align the tab a on the
61. 1 10 in 27 0 mm 1 06 in 0 70 mm 0 03 in Starter relay Model manufacturer Amperage Coil resistance 2768109 A JIDECO 180 0A 4 18 4 62 Q at 20 C 68 F Horn Horn type Quantity Model manufacturer Maximum amperage Coil resistance Performance Plane 1 pcs YF 12 NIKKO 3 0A 1 15 1 25 at 20 C 68 F 105 113 dB 2m Turn signal hazard relay Relay type Model manufacturer Built in self canceling device Turn signal blinking frequency Wattage Full transistor FE218BH DENSO No 75 0 95 0 cycles min 10 W x 2 0 3 4 W Oil level gauge Model manufacturer 5VY SOMIC ISHIKAWA Servo motor Model manufacturer 2D1 YAMAHA Fuses Main fuse Headlight fuse Taillight fuse Signaling system fuse Ignition fuse Radiator fan fuse Fuel injection system fuse Backup fuse Reserve fuse Reserve fuse Reserve fuse FZ1 S lt a S gt gt gt gt gt gt gt gt gt gt gt gt N TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI CATIONS This chart specifies tightening torques for stan dard fasteners with a standard ISO thread pitch Tightening torque specifications for spe cial components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages
62. 290 kPa 2 9 kg cm 2 9 bar 42 psi Loading condition FZ1 N 90 196 kg 198 432 Ib FZ1 S 90 190 kg 198 419 Ib Front 250 kPa 2 5 kg cm 2 5 bar 36 psi Rear 290 kPa 2 9 kg cm 2 9 bar 42 psi High speed riding Front 250 kPa 2 5 kg cm 2 5 bar 36 psi Rear 290 kPa 2 9 kg cm 2 9 bar 42 psi Maximum load FZ1 N 196 kg 432 Ib FZ1 S 190 kg 419 Ib Total weight of rider passenger cargo and accessories EWA13190 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 2 Check Tire surfaces Damage wear Replace the tire 3 32 CHASSIS 12070302 1 Tire tread depth 2 Side wall 3 Wear indicator lt Minimum tire tread depth 2 1 6 mm 0 06 in EWA14080 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation When using tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement A Tire B Wheel Tube wheel Tubeless wheel Tube
63. 4 Green q Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 72 r Measure the compressed Plastigauge width on the crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings 11630702 5 77 EAS26190 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring 5 NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers face up 11221301 2 Install Piston 1 onto the respective connecting rod 2 Piston 3 e Piston pin clip 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark on the con necting rod faces left when the arrow mark b on the piston is pointing up as shown Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate Piston Piston rings Oylinder CRANKSHAFT with the recommended lubricant Recommended lubricant Engine oil 4 Offset 5 Piston ring end gaps d IS 11221202 Top ring Lowe
64. 68 F d Out of specification Replace MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS27070 INSTALLING THE AIR INDUCTION SYSTEM 1 Install 7 15 ELECTRICAL SYSTEM IGNITION SYSTEM ooa retenti ee ate 8 1 CIRCUIT DIAGDUAM metere 8 1 TROUBLESHOOTING erri pe eer e etis eese sea 8 3 ELECTRIC STARTING 5 5 8 5 CIRCUIT DIAGRAM e e ret ettam et etienne 8 5 STARTING CIRCUIT CUT OFF SYSTEM 8 7 TROUBEESHOOT ING rater c etc ced Rl 8 9 CHARGING SYSTEM en b ae ut lentes 8 11 CIRCUIT DIAGRAM iir Rue lex ea ite e 8 11 TROUBLESHOOTING ctc dotes eite e peri 8 13 LIGHTING SYSTEM aiite E Do eite teo fe ico dod ipee boten om gee 8 15 CIRCUIT DIAGRAM EZT N ioter itta tert te dde ns 8 15 CIRCUIT DIAGRAM FZ1 S tat ecu 8 17 TROUBLESHOOTING 5 itii ne a mere n tu usto Sta 8 19 SIGNALING SYSTEM eat destra ee eels 8 21 CIRCUIT IAGRAM a ats Dae tap tends a aden ada kas 8 21 TROUBLESHOOTING ntt Eb ue obe nnus 8 23 COOLING SYSTEM rne erc iter uci RES NOS Vut ma 8 27 CIRCUIT DIAGBAM rho Er Cone MR C HO ME Ebene 8 27 TROUBLESHOOTING bt retreat emet ht eate 8 29 FUEL INJECTION SYSTEM operto pete dedo ees 8 31 CIRCUIT DIAGR
65. Direction b Spring preload is decreased suspension is softer Spring preload adjusting posi tions Minimum 8 Standard 6 Maximum MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Rebound damping Right side front fork EC2D1006 CAUTION Never go beyond the maximum or mini mum adjustment positions When assembling the front forks be ful not to assemble them to the opposite position because there are two kinds of forks for the rebound side and for the compression side 1 Adjust Rebound damping VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Turn the adjusting screw 1 in direction a or Direction a turn in Rebound damping is increased suspension is harder Direction b turn out Rebound damping is decreased suspension is softer Rebound positions Minimum 26 clicks in direction b Standard 15 clicks in direction b Maximum 1 clicks in direction b damping adjusting With the adjusting screw fully turned in direction a CHASSIS TEN MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Compression damping Left side front fork ECA13590 CAUTION Never go beyond the maximum or mini mum adjustment positions When assembling the front forks be ful not to assemble them to the opposite position because there are two kinds of forks for the rebound side and for the compression side 1 Adjust
66. Horn does not sound Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness EAS28740 WIRING DIAGRAM FZ1 N V 2006 Main switch Rectifier regulator A C magneto Fuse backup Immobilizer unit Fuse main Battery Fuse fuel injection Starter relay 10 Starter motor 11 Relay unit 12 Starting circuit cut off relay 13 Fuel pump relay 14 Neutral switch 15 Sidestand switch 16 Fuel pump 17 Crankshaft position sensor 18 Oylinder identification sensor 19 Speed sensor 20 Atmospheric pressure sensor 21 Lean angle sensor 22 02 sensor 23 E C U 24 Ignition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 gnition coil 4 28 Spark plug 29 Injector 1 30 Injector 2 31 Injector 3 32 Injector 4 33 Air induction system solenoid 34 Sub throttle position sensor 35 EXUP servo motor 36 Intake air pressure sensor 37 Throttle position sensor 38 Coolant temperature sensor 39 Air temperature sensor 40 Meter assembly 41 Immobilizer indicator light 42 Fuel level warning light 43 Oil level warning light 44 Neutral indicator light 45 Tacho meter 46 function meter 47 Engine trouble warning light 48 Coolant temperature indicator light 49 Hi beam indicator light 50 Turn signal indicator light left 51 Turn signal indicator light r
67. Limit 0 22 mm 0 0087 in 2 Check Oil water pump assembly drive chain 1 Damag stiffness Replace the oil water pump assembly drive chain and oil water pump assembly drive sprocket as a set 1 Oil pump inner rotor 2 Oil pump outer rotor 3 Oil pump housing 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s 5 62 EAS24970 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Spring 3 O ring 4 Damage wear Replace the defective part s EAS24980 CHECKING THE OIL DELIVERY PIPES 1 Check Oil delivery pipe 1 Oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air lt lt gt 524990 CHECKING THE OIL STRAINER 1 Check Oil strainer 1 Damage Replace Contaminants Clean with solvent OIL PUMP ET2D1013 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check Oil nozzle 1 Damage wear Replace the oil nozzles O ring 2 Damage wear Replace Oil nozzle passage Obstruction Blow out with compressed air CON 1 2 EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2 Install Pin 1 Inner rot
68. O Tail brake light x a lt lt For installation reverse the removal procedure GENERAL CHASSIS Removing the rear fender FZ1 S 23 Nm 2 3 m kg 17 ft lb 23 Nm 2 3 m kg 17 ft lb Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Disconnect Disconnect Licence plate light lead coupler Turn signal light lead coupler Mud guard assembly Rear fender Tail brake light lead coupler Tail brake light cover Rear fender side cover left and right Rear fender bracket Tail brake light Tail cover Disconnect A N lt N For installation reverse the removal procedure GENERAL CHASSIS Removing the air filter case 1 2 Nm 0 12 m kg 0 9 ft lb 1 2 Nm 0 12 m kg 0 9 ft Ip 10 4 2 Nm 0 42 3 0 ft Ib Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Intake air temperature sensor lead cou Disconnect pler Intake air temperature sensor Air filter case cover Air filter Funnel Air filter case Air induction system hose Crankcase breather hose For installation reverse the removal procedure 4 6 EAS21840 REM
69. PO For installation reverse the removal procedure 4 15 Disassembling the rear wheel Order Job Parts to remove REAR WHEEL Remarks 1 Coller Bearing Spacer Oil seal Circlip EAS22040 REMOVING THE REAR WHEEL DISC 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Brake caliper 1 NOTE Do not depress the brake pedal when remov ing the brake caliper 3 Loosen Locknut 1 Adjusting bolt 2 4 Remove Wheel axle nut 1 Wheel axle 2 Rear wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket REAR WHEEL 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel drive hub damper Right collar EAS22090 CHECKING THE REAR WHEEL 1 Check Wheel axle Rear wheel Wheel bearings Oil seals Refer to FRONT WHEEL on page 4 8 2 Check Tire Rear wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 32 and CHECKING THE WHEELS on page 3 34 3 Measure Radial wheel runout Lateral wheel runout Refer to FRONT WHEEL on page 4 8 EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1 Ch
70. Recommended engine oil grade Engine oil quantity Total amount Without oil filter cartridge replacement Wet sump SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 API service SE SF SG type or higher 3 80 L 4 02 US qt 3 34 Imp qt 2 90 L 3 07 US qt 2 55 Imp qt 3 10 L 3 28 2 7 With oil filter cartridge replacement US qt 2 73 Imp qt Cil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance Limit Outer rotor to oil pump housing clearance Limit Oil pump housing to inner and outer rotor clearance Limit Bypass valve opening pressure Relief valve operating pressure ENGINE SPECIFICATIONS 0 010 0 100 mm 0 0004 0 0039 in 0 18 mm 0 0071 in 0 090 0 150 mm 0 0035 0 0059 in 0 22 mm 0 0087 in 0 06 0 13 mm 0 0024 0 0051 in 0 20 mm 0 0079 in 80 0 120 0 kPa 11 6 17 4 psi 0 80 1 20 kgf cm 600 0 680 0 kPa 87 0 98 6 psi 6 00 6 80 kgf cm Cooling system Radiator capacity including all routes Coolant reservoir capacity up to the maximum level mark Radiator cap opening pressure Radiator core Width Height Depth Water pump Water pump type Reduction ratio Max impeller shaft tilt limit 2 25 L 2 38 US qt 1 98 Imp qt 0 25 L 0 26 US qt 0 22 Imp qt 93 3 122 7 kPa 13 5 17 8 psi 0 93 1 23 kgf cm 222 6 mm 8 76 in 360 0 mm 14 17 in 22 0 mm 0 87 in Single suction centrifugal pump 65 43 x 25 32 1 1
71. Refer to CHECKING THE SWITCHES on page 8 93 Faulty shift drum neutral detection area Replace if defective Refer to TRANSMISSION on page 5 85 8 67 A No normal signals are received from the speed sen B Open circuit is detected in the neutral switch Speedsensor Bat Newraswih Reinstatement method Starting the engine and activating the speed sensor by operating the vehicle at 20 to 30 km h FUEL INJECTION SYSTEM Fault code No Symptom Power supply to the and fuel pump is not Diagnostic code 09 Fuel system voltage battery voltage Order Item components and probable Check or maintenance job Reinstatement cause method Connections Check the couplers for any pins Starting the Relay unit coupler fuel pump relay that may be pulled out engine and Main wire harness ECU coupler Check the locking condition of operating it at the couplers idle If there is a malfunction repair it and connect it securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between relay unit coupler and ECU coupler Blue Yellow Blue Yellow Red Blue Red Blue Between relay unit coupler and battery terminal Red Red Between relay unit coupler and engine stop switch coupler Red Black Red Black Malfunction or open circuit in fuel Execute the diagnostic mode p
72. When installing the brake hose onto the brake caliper make sure the brake pipe a touches the projection b on the brake cal iper 2 Remove Brake caliper 3 Install Brake pad shims Brake pads Brake pad spring Brake pad pin e Screw plug REAR BRAKE Brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4 37 Brake caliper bolt front 27 Nm 2 7 m kg 20 ft Ib Brake caliper bolt rear 22 Nm 2 2 m kg 16 ft Ib 4 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOTA 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 chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the p
73. on page 8 100 6 Check the relay unit diode Refer to CHECKING THE RELAYS on page 8 100 7 Check the starter relay Refer to CHECKING THE RELAYS on page 8 100 NG NG NG NG gt 8 9 Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the starter motor Repair or replace the starter motor Replace the relay unit Replace the relay unit Replace the starter relay 8 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 9 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 93 10 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 93 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 93 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 13 Check the start switch Refer to CHECKING THE SWITCHES on page 8 93 14 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 5 The starting system circuit is OK ELECTRIC STARTING SYSTEM NG NG NG NG NG NG NG 8 10 Replace the immobilizer kit Replace the right handleba
74. side the engine trou ble warning light only while the motor is runnning 8 49 FUEL INJECTION SYSTEM Diag nostic code No Actuation Checking method Sub throttle servo motor Actuate the servo motor turns Check the operating sound to close side and to open of the Sub throttle servo side motor the engine trou ble warning light only while the motor is runnning EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter Check and ser vice the items or components that are the probable cause of the malfunction following the order given After the check and service of the malfunctioning part has been completed reset the meter display according to the reinstatement method Fault code No Code number displayed on the meter when the engine failed to work normally Refer to Self Diag nostic Function table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 8 42 No normal signals are received from the cylinder identifi Fault code No Symptom cation sensor when the engine is started or while the vehicle is being driven DiagnosticcodeNo 2 07 Orde Item components and probable Reinstatement r cause method Installed condition of cylinder identifi Check for looseness or pinching Starting the c
75. uQu ju On 1 law 39 Ion Ly 1 T C 5 ISLST amp oe PSS l E Jd EE la tT id m L qu i Lge ll eo 2 ow i Jd i uh 44 RE EE ve Ove 5 1 E n M j I a 8 M ool XO a E ES 1 9 m 2 Se i Lr NN ge E coe m Ji Is PE m Tm eer Pee ew Mey ate a Fe nun eee 2 4 2 2 _ th EL 4 EE l 1 T Ly E ji mes DIAGRAMA DE CONEXIONES DE FZ1 N V 2006 FZ1 N V 2006 N V 2006 SCHALTPLAN FZ1 FZ1 N V 2006 FZ1 N V 2006 SCHEMA ELETTRICO SCHEMA DE CABLAGE WIRING DIAGRAM
76. until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter B bolt General tightening torques 2 12 EAS20340 ENGINE TIGHTENING TORQUES Spark plug Thread size TIGHTENING TORQUES Tightening torque 13 Nm 1 3 m kg 9 4 ft lb Remarks Cylinder head nut See NOTE Cylinder head bolt 12 Nm 1 2 m kg 8 7 ft lb Camshaft caps bolt 10 Nm 1 0 m kg 7 2 ft lb Cylinder head cover bolt Cylinder head stud bolt exhaust pipe 12 Nm 1 2 m kg 8 7 ft lb 15 Nm 1 5 m kg 11 ft lb Air indication system cap bolt 10 Nm 1 0 m kg 7 2 ft lb Camshaft sprocket bolt 24 Nm 2 4 m kg 17 ft lb Cylinder head and throttle body clamp 3 Nm 0 3 m kg 2 2 ft lb Connecting rod cap bolt 1st 20 Nm 2 0 m kg 14 ft lb Connecting rod cap bolt final Specified angle 150 Generator rotor bolt Timing chain tensioner bolt 60 Nm 6 0 m kg 43 ft lb 10 Nm 1 0 m kg 7 2 ft lb Water pump outlet pipe bolt Water pump inlet pipe bolt water pump side 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb Water pump inlet pipe bolt front side 10 Nm 1 0 m kg 7 2 ft lb Oil water pump drive sprocket bolt 15 Nm 1 5 m k
77. 0 16 in 0 10 mm 0 0039 in 4 5 mm 0 18 in 0 5 mm 0 02 in 4 5 mm 0 18 in 0 5 mm 0 02 in Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Recommended fluid CHASSIS SPECIFICATIONS 16 00 mm 0 63 in 30 20 mm 1 19 in 27 00 mm 1 06 in DOT 4 Rear brake Type Operation Brake pedal free play Rear disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness inner Limit Brake pad lining thickness outer Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Steering Steering bearing type Lock to lock angle left Lock to lock angle right Single disc brake Right foot operation 4 3 9 3 mm 0 17 0 37 245 0 x 5 0 mm 9 65 x 0 20 in 4 5 mm 0 18 in 0 15 mm 0 0059 in 6 0 mm 0 24 in 1 0 mm 0 04 in 6 0 mm 0 24 in 1 0 mm 0 04 in 12 7 mm 0 50 in 38 20 mm 1 50 in DOT 4 Angular bearing 33 0 33 0 Front suspension Type Spring shock absorber type Front fork travel Fork spring free length Collar length Installed length Spring rate K1 Spring stroke K1 Inner tube outer diameter Inner tube bending limit Optional spring available Recommended oil Quantity Level Telescopic fork Coil spring oil damper 130 0 mm 5 12 in 243 5 mm 9 59 in 100 0 mm 3 94 in 239 0 mm 9 41 in 9 32 N mm 53 22 Ib in
78. 0 m kg 7 2 ft l Exhaust camshaft 1 10 Nm 1 0 m kg b Intake camshafts 2 NOTE carina t Sproekete temporarily Tighten the camshaft cap bolts in stages and a crisscross pattern working from the inner NOTE caps out Make sure the punch mark a on each cam shaft faces up E CAUTION Lubricate the camshaft cap bolts with the engine oil 5 16 The camshaft cap bolts must be tightened evenly or damage to the cylinder head camshaft caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing 6 Tighten e Camshaft sprocket bolts 1 Camshaft sprocket bolt 24 Nm 2 4 m kg 17 ft Ib Vv Camshaft wrench 2 90890 04143 EC2D1002 CAUTION CAMSHAFTS Timing chain tensioner 1 Timing chain tensioner bolts 2 Timing chain tensioner bolt 10 Nm 1 0 m kg 7 2 ft lb Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 7 Align Camshaft punch mark Align the camshaft punch mark and the camshaft cap arrow mark b 8 Install Gasket TM 5 17 EC2D1003 CAUTION The arrow mark a on the timing chain ten sioner should face up EW2D1006 Always use a new gasket 9 Turn Crankshaft
79. 0 m kg 7 2 ft lb 124 Nm 2 4 17 ft lb Job Parts to remove Remarks Pickup rotor cover Refer to CRANKSHAFT POSITION SENSOR on page 5 38 Camshaft sprocket bolt Loosen Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Dowel pin Refer to REMOVING THE CAM SHAFTS on page 5 12 Exhaust camshaft cap Dowel pin Refer to REMOVING THE CAM SHAFTS on page 5 12 Intake camshaft Exhaust camshaft Camshaft sprocket For assembly reverse the removal procedure 5 11 EAS23810 REMOVING THE CAMSHAFTS 1 Remove Pickup rotor cover Refer to CRANKSHAFT POSITION SEN SOR on page 5 38 2 Align T mark on the pickup rotor with the crankcase mating surface b VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pickup rotor with the crankcase mating sur face b NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Remove Timing chain tensioner 1 Gasket CAMSHAFTS 5 Remove Camshaft caps 1 Dowel pins ECA13720 CAUTION To prevent damage to the cylinder head camshafts or cams
80. 1 Check Dampers 1 Damage wear Replace STARTER CLUTCH EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation WWVVVVVVVVVVVVVVVYVVVVVVVVYYVYVYYV a Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear counterclockwise A the starter clutch and the starter clutch drive gear should engage 5 36 STARTER CLUTCH otherwise the starter clutch is faulty and 3 Install must be replaced Washer 1 c When turning the starter clutch drive gear O ring 2 clockwise it should turn freely other Spacer 3 wise the starter clutch is faulty and must be NOTE replaced MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Generator rotor 1 Damper 2 Driven gear 3 NOTE The hole side of the damper is installed to the generator side Lubricate the engine oil 4 2 Install Starter clutch drive gear 1 Collar 2
81. 1 0 7 2 ft lb Omer JobiPartstoremove y Remaks 18 Olwaler pump assembly E A For assembly reverse the removal procedure 5 60 OIL PUMP Disassembling the oil pump 10 Nm 1 0 7 2 ft Ib Job Parts to remove Remarks Oil water pump driven sprocket Collar Oil pump housing Bearing Pin Oil pump outer roter Oil pump inner roter Pin For assembly reverse the disassem bly procedure 5 61 OIL PUMP EAS24930 EAS24960 REMOVING THE OIL PAN CHECKING THE OIL PUMP 1 Remove 1 Check Oil level switch 1 Oil pump driven gear 1 Oil pan 2 Oil pump rotor housing 2 Oil pan gasket Oil pump cover Dowel pins Cracks damage wear Replace the NOTE defective part s 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 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance Inner rotor to outer roter tip ET2D1012 CHECKING THE SPROCKET AND CHAIN clearance 1 Check 0 01 0 10 mm Oil water pump assembly drive sprocket 1 0 0004 0 0039 Limit Cracks damage wear Replace the defective part s 0 18 mm 0 0071 in Outer rotor to oil pump hous ingclearance 0 09 0 15 mm 0 0035 0 0059 in
82. 133 0 153 0 13 56 15 60 kg 29 90 34 39 Ib at 32 82 mm 1 292 in MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length Out of specification gt Replace the valve spring 11171904 Valve spring free length Intake valve spring 40 5 mm 1 60 in Limit 38 5 mm 1 47 in b Installed length 3 Measure Valve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake valve spring 1 8 mm 0 07 in Exhaust valve spring 40 5 mm 1 60 in Limit 38 5 mm 1 47 in Exhaust valve spring 1 8 mm 0 07 in 5 28 EN 11171903 EAS24320 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check Valve lifter Damage scratches Replace the valve lifters and cylinder head EAS24330 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr Valve stem end with an oil stone 11170701 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil VALVES AND VALVE SPRINGS 3 Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head
83. 2 20 Nm 2 0 m kg 14 ft lb bracket bolt EXUP servo motor cover bolt M5 2 2 Nm 0 2 m kg 1 4 ft lb EXUP servo motor nut M6 1 7 Nm 0 7 m kg 5 1 ft lb Crankcase stud bolt M10 10 8 Nm 0 8 m kg 5 8 ft lb 4 1 Crankcase bolt main journal 9 10 Crankcase bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb 4 1 Crankcase bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt 8 1 24 Nm 2 4 m kg 17 ft lb 4 1 9 Crankcase bolt 8 24 Nm 2 4 m kg 17 16 Generator rotor cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Generator rotor cover bolt 8 3 22 Nm 2 2 m kg 16 ft lb Drive sprocket cover bolt M6 3 12 Nm 1 2 m kg 8 7 ft lb Crankcase cover screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Clutch cover bolt M6 7 12 Nm 1 2 m kg 8 7 ft lb Clutch cover bolt M6 1 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover bolt M6 6 12 Nm 1 2 m kg 8 7 ft lb Breather cover bolt M6 4 12 Nm 1 2 m kg 8 7 ft lb Breather plate bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Plate bolt M6 2 12 Nm 1 2 m kg 8 7 ft lb Pickup rotor cover blind bolt M8 1 15 Nm 1 5 m kg 11 ft lb Generator rotor cover plug M20 1 8 Nm 0 8 m kg 5 8 ft lb Main gallery plug oil return M16 3 8 Nm 0 8 m kg 5 8 ft lb Main gallery plug M20 1 8 Nm 0 8 m kg 5 8 ft lb Oil return pipe bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb g Oil return plug M12 2 24 Nm 2 4 m kg 17 ft lb AC magneto lead bolt M6 1 10 Nm 1 0 m kg 7
84. 2 ft lb Stator coil screw M6 3 14 Nm 1 4 m kg 10 ft lb Generator rotor cover screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Thermostat assembly stay bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter clutch idler gear bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Clutch boss nut M20 1 95 Nm 9 5 m kg 69 ft lb Stake 2 14 TIGHTENING TORQUES Thread size Clutch spring bolt 10 Nm 1 0 m kg 7 2 ft lb Use a lock washer Item Tightening torque Remarks Drive sprocket nut 85 Nm 8 5 m kg 61 ft lb Bearing plate bolt 12 Nm 1 2 m kg 8 7 ft lb Shift fork stopper plate bolt 10 Nm 1 0 m kg 7 2 ft lb Stopper screw 22 Nm 2 2 m kg 16 ft lb Shift rod locknut front 7 Nm 0 7 m kg 5 1 ft lb Shift rod locknut rear 7 Nm 0 7 m kg 5 1 ft lb Left thread Shift rod joint bolt 10 Nm 1 0 m kg 7 2 ft lb Shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb Neutral switch 20 Nm 2 0 m kg 14 ft lb Sub throttle servo motor cover 2 Nm 0 2 m kg 1 4 ft lb bolt Coolant temperature sensor 18 Nm 1 8 m kg 13 ft lb Cylinder identification sensor bolt 8 Nm 0 8 m kg 5 8 ft lb Atmospheric pressure sensor bolt 7 Nm 0 7 m kg 5 1 ft lb Crankshaft position sensor bolt 10 Nm 1 0 m kg 7 2 ft lb Oil level switch bolt 10 Nm 1 0 m kg 7 2 ft lb Starter motor bolt 10 Nm 1 0 m kg 7 2 ft lb NOTE Cylinder head nut 1 First tighten the bolts to app
85. 5 37 CRANKSHAFT POSITION SENSOR 5 38 REMOVING THE CRANKSHAFT POSITION SENSOR 5 39 INSTALLING THE CRANKSHAFT POSITION SENSOR 5 39 ELECTRIC STARTEH screen PEN 5 40 CHECKING THE STARTER MOTOR eee 5 42 ASSEMBLING THE STARTER 5 43 INSTALLING THE STARTER 5 43 GEUTGH n tob Euri sme 5 44 REMOVING THE CLUTCH iuit ode tr ood petet Stt 5 48 CHECKING THE FRICTION PLATES eem 5 49 CHECKING THE CLUTCH PLATES antreten po Pater t eee 5 49 CHECKING THE CLUTCH SPRINGS eee 5 50 CHECKING THE CLUTCH HOUSING ee 5 50 CHECKING THE CLUTCH BOSS duret ips 5 50 CHECKING THE PRESSURE PLATE eth rete seed tm 5 50 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5 50 INSTALLING THE CLUTCH 5 51 SHIET Qut addet tt ta RIT aee a a aa 5 54 REMOVING THE SHIFT SHAFT rette ete 5 56 CHECKING THE SHIFT 5 e or b tora ree 5 56 CHECKING THE STOPPER LEVER sai terim eter t tes 5 56 INSTALLING THE SHIFT SHAFT ttc erret Laeti 5 56 OIL PUMP oo ehe eo Cr ete ERO Dae sen en UP a haine e uuu 5 58 REMOVING THE OQIL PAN un oe emet 5 62 CHECKING THE SPROCKET AND
86. 9 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 93 10 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 93 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 12 Check the starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 100 13 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR page 8 105 14 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Replace the ECU NG NG NG NG NG NG NG 8 4 IGNITION SYSTEM Replace the right handlebar switch Replace the neutral switch Replace the sidestand switch Replace the clutch switch Replace the relay unit Replace the lean angle sensor Properly connect or repair the ignition system s wiring ORA le T T ice oe ie ip ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM EAS27160 EAS27170 So Se
87. CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 8 89 EAS21770 CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS on page 8 89 EAS21780 REPLACING THE HEADLIGHT BULBS 1 Remove Headlight side cover bolts 1 21 2 Disconnect 5 Remove Headlight sub wire harness coupler 2 FZ1 N B 3 Disconnect Headlight coupler 1 A WW A FZ1 N B FZ1 S 6 Remove Headlight bulb 1 3 35 A FZ1 N B FZ1 S EWA13320 7 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 7 Install e Headlight bulb YEN Secure the new headlight bulb with the headlight bulb holder ECA13690 CAUTION 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 moistened with alcohol or lacquer thinner 8 Install Headlight bulb holder 9 Install Headlight bulb cover 10 Connect Headlight coupler 11 Connect Headlight assembly coupler 12 Install Headlight assembly bolts ELECTRICAL SYSTEM EAS21800 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically vVYYYVVYYYVYYYYVYY
88. Check the fuses Main headlight and tail beake light Refer to CHECKING THE FUSES on page 8 97 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 5 Check the dimmer switch Refer to CHECKING THE SWITCHES page 8 93 6 Check the pass switch Refer to CHECKING THE SWITCHES on page 8 93 7 Check the rear brake light switch Refer to CHECKING THE SWITCHES page 8 93 NG NG gt NG 8 19 Replace the bulb s and bulb socket s Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the immobilizer kit The dimmer switch is faulty Replace the left handlebar switch The pass switch is faulty Replace the left handlebar switch The rear brake light switch is faulty Replace the rear brake light switch 8 Check the headlight relay on off Refer to CHECKING THE RELAYS on page 8 100 9 Check the headlight relay dimmer FZ1 S Refer to CHECKING THE RELAYS on page 8 100 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM FZ1 N on page 8 15 Th
89. Damper rod assembly bolt Copper washer JEW EC2D1080 CAUTION For the damper rod assembly the right side is used for the rebound operation and left side for the compression Pay attention not to mistake the right and left NOTE The left side for the compression damper rod assembly has the four holes of oil path unlike the right side ECA14210 CAUTION Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate Inner tube s outer surface Recommended oil Suspension oil 01 or equiva lent 3 Tighten Damper rod assembly bolt 1 Damper rod assembly bolt 23 Nm 2 3 m kg 17 ft lb LOCTITE NOTE While holding the damper rod assembly with the damper rod holder 2 tighten the damper rod assembly bolt Damper rod holder 90890 01423 Damping rod holder YM 01423 4 52 4 Install Dust seal 1 Oil seal clip 2 Oil seal 3 Washer 4 ECA14220 CAUTION Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during inst
90. Gray Green Gray Red Blue Black Blue Red Blue White Blue Yellow Orange Black Orange Green Orange Yellow Pink Black Pink White Red Black Red Green Red Blue Red White Red Yellow Sky blue White White Black White Red White Yellow Yellow Black Yellow Green Yellow Blue Yellow Red Yellow White FZ1 S V 2006 Main switch Rectifier regulator A C magneto Fuse backup Immobilizer unit Fuse main Battery Fuse fuel injection Starter relay 10 Starter motor 11 Relay unit 12 Starting circuit cut off relay 13 Fuel pump relay 14 Neutral switch 15 Sidestand switch 16 Fuel pump 17 Crankshaft position sensor 18 Cylinder identification sensor 19 Speed sensor 20 Atmospheric pressure sensor 21 Lean angle sensor 22 02 sensor 23 E C U 24 Ignition coil 1 25 Ignition coil 2 26 Ignition coil 3 27 gnition coil 4 28 Spark plug 29 Injector 1 30 Injector 2 31 Injector 3 32 Injector 4 33 Air induction system solenoid 34 Sub throttle position sensor 35 EXUP servo motor 36 Intake air pressure sensor 37 Throttle position sensor 38 Coolant temperature sensor 39 Air temperature sensor 40 Meter assembly 41 Immobilizer indicator light 42 Fuel level warning light 43 Oil level warning light 44 Neutral indicator light 45 Tacho meter 46 function meter 47 Engine trouble warning light 48 Coolant temperature indicator light 49 Hi beam indicator ligh
91. Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise 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 it with a cloth moistened with alcohol or lacquer thin ner 2 Check Bulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Before checking for continuity set the pocket tester to O and to the Q x 1 range a Connect the positive tester probe to termi nal 1 and the negative tester probe to ter minal 2 and check the continuity b Connect the positive tester probe to termi nal 1 and the negative tester probe to ter minal 3 and check the continuity c If either of the readings indicate no continu ity replace the bulb MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA a 18410602 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 Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE Check each bulb socket for continuity in the sam
92. PAN Oil delivery pipe 1 1 Install Dowel pi Oil delivery pipe bolt 10 Nm 1 0 m kg 7 2 46 Gasket LOCTITE Oil pan 1 Oil pan bolt 12 Nm 1 2 m kg 8 7 ft lb Oil level switch 2 Oil level switch bolt 10 Nm 1 0 m kg 7 2 ft Ib Engine oil drain bolt 3 7V Engine oil drain bolt 5 Install S 43 Nm 4 3 m kg 31 ft lb Relief valve 1 EWA12820 O ring SI Oil strainer 2 Always use new copper washers Oil strainer bolt NOTE 10 Nm 1 0 m kg 7 2 ft lb Tighten the oil pan bolts in stages and LOCTITE crisscross pattern Lubricate the oil level switch O ring with engine oil Oil pipe 3 O ring REA Drain pipe 4 19 O ring TE 5 65 CRANKCASE EAS25540 CRANKCASE Separating the crankcase 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft Ib X a Job Parts to remove Remarks Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 Engine Refer to ENGINE REMOVAL on page 5 2 Cylinder head Refer to CYLINDER HEAD on page 5 19 Generator Refer to GENERATOR on page 5 31 Starter clutch Refer to STARTER CLUTCH on page 5 35 Shift shaft Refer to SHIFT SHAFT on page 5 54 Crankshaft position sensor Refer to CRANK
93. R Y Sb W W B W R W Y Y B Y G Y L Y R YAN Green Black Green Red Green White Green Yellow Gray Green Gray Red Blue Black Blue Red Blue White Blue Yellow Orange Black Orange Green Orange Yellow Pink Black Pink White Red Black Red Green Red Blue Red White Red Yellow Sky blue White White Black White Red White Yellow Yellow Black Yellow Green Yellow Blue Yellow Red Yellow White gt YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN FZ1 N V 2006 FZ1 N V 2006 FZ1 N V 2006 FZ1 N 2006 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1 N V 2006
94. SYS TEM Headlight does not come on Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main or light switch Burnt out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light bulb Too many electrical accessories Incorrect connection Burnt out tail brake light bulb Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail orake light bulb life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness 9 4 TROUBLESHOOTING Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signal remains lit Faulty turn signal relay Burnt out turn signal bulb Turn signal blinks quickly Incorrect turn signal bulb Faulty turn signal relay Burnt out turn signal bulb
95. Self locking nut bolt Self locking nut bolt Self locking nut bolt collar Rear shock absorber assembly Oil seal bearing collar Collar self locking nut bolt Connecting arm Oil seal bearing collar Relay arm PO 4 61 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 144 Nm 4 4 m kg 32 ft lb 144 Nm 4 4 32 ft lb 6 _ d Pa 44 Nm 4 4 m kg 32 ft lb 10 Order Job Parts to remove For installation reverse the removal procedure 4 62 REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER 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 responsible for property damage or per sonal injury that may result from improper handling of the rear shock absorber Do not tamper or attempt to open the rear shock absorber Do not subject the rear shock absorber to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping per formance EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1 Gas pressure must be released befor
96. Sub throttle servo motor lock A lock of the sub throttle servo motor is detected ECU internal malfunc tion memory check error ECU memory is faulty When this mal function is detected in the ECU the fault code number might not appear on the meter Start unable warning Relay is not turned ON even if the crank signal is input while the start switch is turned ON When the start switch is turned ON while an error is detected with the fault code of No 11 12 19 30 41 or 50 Unable Unable Communication error with the meter Fault code No ECU internal malfunc tion output signal error Able unable to start Able unable to drive Symptom No signals are received from the ECU Unable Unable 8 40 output signal error ECU internal malfunc No signals are received from the ECU tion within the specified duration FUEL INJECTION SYSTEM Able unable to start Able unable to drive Symptom Unable Unable tion correctly output signal error ECU internal malfunc Data from the ECU cannot be received Unable Unable input signal error EAS27400 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Check the fault code number displayed on the meter b Identify the faulty system with the faul
97. VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Apply a coarse lapping compound to the valve face ECA13790 CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide 11171601 b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands 11171504 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 5 27 VALVES AND VALVE SPRINGS b Ww v oU RI a 11171902 h Install the valve into the cylinder head 2 Measure i Pressthe valve through the valve guide Compressed valve spring force a and onto the valve seat to make a clear Out of specification Replace the valve impression spring j Measure the valve seat width again If the valve seat width is out of specification reface and lap the valve seat Compressed valve spring force installed Intake valve spring 127 4 144 6 N 12 99 14 74 kg 28 64 32 51 Ib at 32 65 mm 1 285 in Exhaust valve spring
98. a turn ata time After all of the nuts are fully loosened remove them FR E 9 WY EAS24160 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching Spark plug bore threads Valve seats 2 Check Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust gt Eliminate 3 Measure Cylinder head warpage Out of specification Resurface the cylin der head Maximum cylinder head warpage 0 10 mm 0 0039 in 5 20 CYLINDER HEAD WWVVVVVVVVVVVVVVYVVVVVVVVYVYVYYV a Place a straightedge 1 and a thickness gauge 2 across the cylinder head Measure the warpage If the limit is exceeded resurface the cylin der head as follows Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS24240 INSTALLING THE CYLINDER HEAD 1 Check Cylinder head bolts 1 Cylinder head bolt 22 8 Nm 0 8 m kg 5 8 ft lb Retighten the cylinder head bolts to specifica tion before installing the
99. and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper bracket CHASSIS Refer to STEERING HEAD on page 4 57 4 Adjust Steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a steering nut wrench 5 NOTE Set the torque wrench at a right angle to the steering nut wrench Steering nut wrench 90890 01403 Spanner wrench YU 33975 Lower ring nut initial tightening torque 52 Nm 5 2 m kg 38 ft lb c Loosen the lower ring nut 4 completely and then tighten it to specification EWA13140 Do not overtighten the lower ring nut Lower ring nut final tightening torque 18 Nm 1 8 m kg 13 ft Ib 3 27 d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 57 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOT
100. and fit it so that the band tip is posi tioned at the vehicle front side Pass the fuel tank breather hose through the guide wire of the sidestand bracket Make sure to place the white paint position of the hose lower than the guide wire CABLE ROUTING KK LL 2 43 ONDAN 9 Clutch cable Water pump breather hose Oil level switch lead Sidestand switch lead sensor lead Coolant reservoir tank drain hose Wire harness Battery negative lead Seat lock cable 10 AC magneto lead 11 Rectifier regulator lead 12 Water pump inlet pipe 13 Radiator fan motor lead left 14 Radiator stay 15 Main switch lead 16 Immobilizer lead 17 Left handlebar switch lead 18 Horn 19 Clutch cable swaging metal 20 Throttle cable 21 Stay assembly 22 Upper bracket 23 Right handlebar switch lead 24 Brake hose 25 Horn lead 26 Throttle body 27 Stay 1 28 Drive chain case cover 29 Starter motor lead 30 Fuel tank breather hose 31 EXUP cables 32 Rear brake light switch lead 33 Rear brake fluid reservoir hose 34 Spe
101. antifreeze 13 Install Radiator cap 14 Fill Coolant reservoir tank with the recommended coolant to the max imum level mark a 15 Install Coolant reservoir cap 16 Start the engine warm it up for several minutes and then stop it 17 Check Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3 18 3 21 ENGINE NOTE Before checking the coolant level wait a few minutes until the coolant has settled 18 Install Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 EAS21140 CHASSIS EAS21160 ADJUSTING THE FRONT DISC BRAKE 1 Adjust Brake lever position distance a from the throttle grip to the brake lever NOTE While pushing the brake lever forward turn the adjusting dial 1 until the brake lever is in the desired position Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder Direction Distance a is the largest Direction Distance a is the smallest EWA13060 After adjusting the brake lever position make sure the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is oper ated the air must be removed by bleeding the brake system Air in the brake system will considerably reduce in loss of
102. as shown in the illustration Fit the white paint section of the hose pointed downward Pass the hose through the fuel tank bracket clamp There should be no bend of the hose between the fuel tank nipple and clamp Align the projection part with the pump seat nut Fit the orange double lock side to the pump side Fit the black double lock side to the engine side The fuel tank bracket shall not run on the tank flange as shown in the illustration Fit the O ring with its lip pointed upward Tightening sequence Fuel piping connector attachment direc tions fuel pump side Always perform the connection disconnection works by hand Do not use tools 1 Insert the connector until the click sound is heard and check that the connector does not come off Make sure that no foreign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equivalent coverings This part works as a dropout stopper 2 After Step N as above is finished check that the connector is completely attached by sliding the double lock orange part on the connector as shown in the illustration and seeing if it touches firmly or not 2 54 CABLE ROUTING CABLE ROUTING 2 55 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ii eng sc ia dee ttu 3 1 INT RODUG TOR oe dace etm decl dU et tte ds 3 1 ENGINE irure rss eee oo 3 4 ADJUST
103. bracket pay atten tion so that the lead is not caught by the rear frame surface V Route the battery positive lead from the inner side of the vehicle to the down side of the wire harness It is not allowed to route the lead over the wire harness W Route it so that the branch connection of the main fuse lead is placed in the upper side X To the rectifier regulator Route the AC magneto lead and rectifier regulator lead inside the battery box Y To the speed sensor Z Route the AC magneto lead under the clutch cable AA To the fuel pump AB Fit so that the engine ground lead is posi tioned below and the battery negative lead above Fit the leads so that each projection of lead is positioned on the upper side of the vehicle AC To the starter motor AD Route the leads under the throttle bodies AE Route the intake air temperature sensor by the upper side of the air filter drain hose AF To the air filter case AG Check that the radiator fan motor lead left is secured with the guide of the radia tor stay AH Positioning tape shaded area Al Fit the protector by aligning the positioning tape end and protector end for the main switch lead immobilizer lead and left han dlebar switch lead The misalignment toler ance of ends is x5 mm 0 20 in CABLE ROUTING AJ Clamp each lead at the positioning taping section white and then insert it to the cover In random order AK Clamp each lead at the positionin
104. chain guides 1 Check Timing chain guide exhaust side 1 Timing chain guide intake side 2 Timing chain guide top side 3 Damage wear Replace the defective part s EAS23960 CHECKING THE TIMING CHAIN TEN SIONER 1 Remove Timing chain tensioner housing 1 Timing chain tensioner rod 2 Timing chain tensioner spring 3 5 14 CAMSHAFTS NOTE b Squeeze the timing chain tensioner clip 2 Squeeze the timing chain tensioner clip and and push the timing chain tensioner rod 3 then remove the timing chain tensioner spring NOTE and timing chain tensioner rod When the timing chain tensioner rod 3 is pushed while holding the grip of the timing chain tensioner clip 2 make sure not to release the timing chain tensioner rod 3 before releasing the timing chain tensioner clip 2 Otherwise the timing chain tensioner rod 3 may run off 2 Check Timing chain tensioner housing Timing chain tensioner rod Timing chain tensioner spring Damage wear Replace 3 Install Timing chain tensioner spring Timing chain tensioner rod 1 NOTE Prior to installing the timing chain tensioner rod drain the engine oil from the timing chain tensioner housing c Hook the clip 4 to the timing chain ten sioner rod NOTE Hook the timing chain tensioner rod pin 5 to the center of the clip
105. corner of the con necting rod bolt 2 and the connecting rod Ec o Tighten the bolt further to reach the speci fied angle 150 7 CRANKSHAFT p After the installation check that the section MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA shown is flush with each other by touch 2 Select ing the surface Big end bearings P1 P4 Ea machined face a or The numbers stamped into the crank 1 shaft wed and the numbers 1 the When the bolt is tightened more than the necting rods are used to determine the specified angle do not loosen the bolt replacement big end bearings sizes and then retighten it P1 P4 refer to the bearings shown in the Replace the bolt with a new one and per crankshaft illustration form the procedure again If they are not flush with each other For example if the connecting rod P4 and remove the connecting rod bolt and big the crankshaft web P4 numbers 5 end bearing and restart from step e In and 2 respectively then the bearing size this case make sure to replace the con for P is necting rod bolt Peoples P4 connecting rod P4 CAUTION crankshaft Do not use a torque wrench to tighten the 5 2 3 brown nut to the specified angle Tighten the bolt until it is at the specified BIG END BEARING COLOR CODE angles 1 Blue 2 Black 3 Brown
106. cylinder head Install Gasket 1 Dowel pins 3 Install Cylinder head NOTE Pass the timing chain through the timing chain cavity 4 Tighten e Cylinder head nuts 1 Cylinder head bolts 11 12 Cylinder head bolt 12 Nm 1 2 m kg 8 7 ft lb NOTE First tighten the nuts 1 10 to approxi mately 19 Nm 1 9 m kg 14 ft lb with a torque wrench and then tighten the 67 Nm 6 7 m kg 48 ft lb Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages 1 0 Cylinder head nut 151 19 Nm 1 9 m kg 14 16 Cylinder head nut 2nd 67 Nm 6 7 m kg 48 ft lb 51 es 6 5 i ooo 5 21 5 CYLINDER HEAD Install Exhaust camshaft ntake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 16 EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs org 6 Job Parts to remove Cylinder head VALVES AND VALVE SPRINGS Remarks Refer to CYLINDER HEAD on page 5 19 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 I
107. e Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 3 Numbers are given in the order of the jobs in the exploded diagram A number indicates disas sembly step 4 Symbols indicate parts to be lubricated or replaced 5 Refer to SYMBOLS A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 6 Jobs requiring more information such as special tools and technical data are described sequen tially 7 CLUTCH CLUTCH AS25060 Removing the clutch cover AS25110 10 Remove S CHECKING THE CLUTCH PLATES Clutch damper spring 1 The following procedure applies to alll of the Clutch damper spring seat 2 clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set Measure Clutch plate warpage with a surface plate and thickness gauge Out of specification Replace the clutch plates as a set 5 0 12 Nm 1 2 m kg 8 7 ft lb Clutch plate warpage limit De Tenio 0 1 mm 0 0039 i CHECKING THE FRICTION PLATES mmt in __Job Parts to remove The following procedure applies to all of the E oil Drain friction plates Refer to 1 Check E Clutch cable Friction plate 2 Clut
108. etc Analog Pocket tester 1 Disconnect YU 03112 C eL NOTE e Coupler Connector f there is no continuity clean the terminals 2 Check When checking the wire harness perform e ead steps 1 to 3 Coupler As a quick remedy use a contact revitalizer Connector available at most part stores Moisture Dry with an air blower Rust stains Connect and disconnect several times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 Check Continuity with the pocket tester SPECIAL TOOLS 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 or both may differ depending on the country When placing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Reference Tool name Tool No Illustration pages Piston pin puller set 90890 0
109. front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches Replace 13650 A WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification gt Replace Spring free length 243 5 mm 9 59 in Limit 238 6 mm 9 39 in 12311703 3 Check Damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Damper adjusting rod Bends damage Replace ECA14200 CAUTION The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 1 lt lt EAS23030 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install Damper rod assembly 1 Inner tube 2 FRONT FORK
110. gallery bolt Pressure gauge 8 Nm 0 8 m kg 5 8 ft Ib 2 90890 03153 0 03153 5201001 Oil pressure adapter H CAUTION 90890 03139 Be careful to tighten too much 5 Measure ET2D1004 Engine oil pressure ADJUSTING THE CLUTCH CABLE FREE at the following conditions PLAY 1 Check Engine oil pressure Clutch cable free play a 230 kPa Out of specification Adjust 2 e Clutch cable free play at the end of the clutch lever Engine speed Approx 5 000 r min Engine oil temperature 100 C 212 F 10 15 mm 0 39 0 59 in 3 14 2 Adjust Clutch cable free play VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY Handlebar side a Turn the adjusting dial 1 in direction b or c until the specified clutch cable free play is obtained Direction b Clutch cable free play is increased Direction c Clutch cable free play is decreased NOTE If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY Engine side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is obtained Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased c Tighten the locknuts
111. generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age ELECTRICAL COMPONENTS c Make sure that the current is higher than the standard charging current written on the battery NOTE If the current is lower than the standard charg ing current written on the battery set the charging voltage adjust dial at 20 24 V and monitor the amperage for 3 5 minutes to check the battery Reach the standard charging current Battery is good Does not reach the standard charging rent Replace the battery Adjust the voltage so that the current is at the standard charging level Set the time according to the charging time suitable for the open circuit voltage Refer to Battery condition checking steps If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the volt age to obtain the standard charging cur rent Measure the battery open circuit voltage a
112. ignition coil Order Item components and probable cause Connections Cylinder 2 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 2 ignition coil coupler and ECU coupler Red Black Red Black Gray Red Gray Red Defective cylinder 2 ignition coil Execute the diagnostic mode Code No 31 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNITION COILS on page 8 103 8 61 Reinstatement method Starting the engine and operating it at idle Fault code No 85 Symptom FUEL INJECTION SYSTEM 3 ignition coil Open circuit detected in the primary lead of the cylinder Diagnostic code 32 Cylinder 3 ignition coil Order Item components and probable cause Connections Cylinder 3 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunctio
113. journal bearings with the recommended lubricant Recommended lubricant Engine oil 2 Apply Sealant Yamaha bond No 1215 Three Bond No 1215 5 68 90890 85505 NOTE Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the crankshaft journal bear ings 2 CTI 9640 e CO 3 Install Dowel pin 4 Setthe shift drum assembly and transmis sion gears in the neutral position 5 Install Lower crankcase 1 onto the upper crankcase 2 ECA13980 CAUTION Before tightening the crankcase bolts make sure the transmission gears shift cor rectly when the shift drum assembly is turned by hand 6 Install Crankcase bolts NOTE CRANKCASE Crankcase bolt Bolt 1 10 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft Ib 3rd 460 Bolt 11 16 24 Nm 2 4 m kg 17 ft Ib Bolt 17 26 12 Nm 1 2 m kg 8 7 ft Ib Following the tightening order loosen the bolt one by one and then retighten it to the specific torque Lubricate the bolt threads
114. main switch lead and immobilizer lead shall not be twisted in the protector The installation position is where the protector end and lead positioning tape end align AU 20 X 58 mm 0 79 X 2 28 in shaded area AV Route it between the battery box ribs in the order indicated in the figure AW Clamp the fuel hose and direct ignition coil lead Point the opening section of the clamp to the front side of the vehicle and install it at the position as shown in the illustration 2 50 CABLE ROUTING FZ1 S 2 51 21 5 Clutch cable Left handlebar switch lead Immobilizer lead Main switch lead Protector Throttle cables Right handlebar switch lead Throttle cable pull side 9 Throttle cable return side 10 Bracket 11 Wire harness 12 Turn signal light lead 13 Seat lock cable 14 Tail brake light lead 15 Battery box 16 Mud guard 17 Fender 18 Frame 19 Cover A Positioning tape shaded area B Secure the wire harness to the bracket Position the clamp head on the upper side of the vehicle and point the tip to the front side of the vehicle C Attach the clamp to the front upper cowl ing Clamp the turn signal light lead left and headlight lead D Pass the turn signal light lead left and tail brake light lead under the rear fender bracket E Pas
115. measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any resid ual air 12 Measure Front fork leg oil level from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of specification Correct Front fork leg oil level 91 mm 3 58 We H 13 Install Nut 1 Fork spring 2 Spacer 3 Damper adjusting rod 4 Cap bolt 5 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Remove the rod puller and adapter b Install the nut c Install the fork spring and spacer NOTE Install the spring with the smaller pitch fac ing up A 12311702 Press down in the spacer with the fork spring compressor 1 Pull up the rod puller and install the rod holder 2 between the damper adjusting rod locknut 3 and the spacer 4 NOTE Use the side of the rod holder that is marked B Fork spring compressor 90890 01441 YM 01441 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 55 FRONT FORK f Remove the rod puller and the rod puller attachment Install the nut 1 and position it as speci fied b GY lt Distance b e 12 mm 0 47 in g h the cap bolt distance c to specifica tion
116. medical attention ECA13660 CAUTION This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batter ies The MF battery should be charged as explained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charg ing the battery NOTE Since MF batteries are sealed it is not possi ble to check the charge state of the battery by measuring the specific gravity of the electro lyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Rider and passenger seat 2 Disconnect Battery leads from the battery terminals ECA13640 CAUTION First disconnect the negative battery lead 1 and then positive battery lead 2 8 98 ELECTRICAL COMPONENTS 3 Remove Battery 4 Check Battery charge WWWVVVVVVVVVVVVVVYVVVVVYVYVVYYVYVYY a Connect a pocket tester to the battery ter minals Positive tester probe gt positive battery terminal e Negative tester probe gt negative battery terminal NOTE The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage wh
117. mesh 6 speed Spur gear 65 43 1 512 Chain drive 45 17 2 647 Left foot operation 38 15 2 533 33 16 2 063 37 21 1 762 35 23 1 522 27 20 1 350 29 24 1 208 0 08 mm 0 0032 in 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Shift fork guide bar bending limit Guide bar 0 100 mm 0 0039 in Shift fork thickness 5 80 5 88 mm 0 2283 0 2315 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 2D1 DENSO Maximum consumption amperage 4 3A Output pressure 324 0 kPa 47 0 psi 3 24 kgf cm Fuel injection Model quantity Manufacturer 297500 0300 4 DENSO Throttle body Type quantity Manufacturer ID mark Throttle valve size Throttle position sensor Resistance Output voltage at idle SE 45EIDW B10 1 MIKUNI 2D11 00 100 4 9 5 1 0 63 0 73 V ENGINE SPECIFICATIONS Idling condition Engine idling speed 1100 1300 r min Intake vacuum 30 0 kPa 8 9 inHg 225 mmHg Water temperature 95 0 105 0 C 203 00 221 00 F Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in EAS20300 CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25 00 Trail 109 0 mm 4 29 in Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rim material Aluminum Wheel travel 130 0 mm 5 12 in Radial wheel runout l
118. on the num ber of faulty cylin ders Able depend ing on the num ber of faulty cylin ders Cylinder 4 ignition coil open circuit Primary lead of the cylinder 4 ignition coil open circuit detected 8 39 Able depend ing on the num ber of faulty cylin ders Able depend ing on the num ber of faulty cylin ders Fault code No Injector open circuit FUEL INJECTION SYSTEM Able unable to start Able depend ing on the num ber of faulty cylin ders Able unable to drive Able depend ing on the num ber of faulty cylin ders Symptom Injector open circuit detected Lean angle sensor open or short circuit Lean angle sensor open or short circuit detected Unable Unable Speed sensor No normal signals are received from the speed sensor Neutral switch Neutral switch open or short circuit detected Fuel system voltage monitoring voltage Power supply to the injectors and the fuel pump is not normal Error in writing the amount of CO adjust ment on EEPROM An error is detected while reading or writ ing on EEPROM CO adjustment value Vehicle system power supply monitoring voltage Power supply to the fuel injection system is not normal Sub throttle servo motor potention open or short circuit sub throttle servo motor potention open or short circuit detected
119. operation Refer to CHECKING THE FUEL PRES SURE on page 7 8 EAS26710 INSTALLING THE FUEL PUMP 1 Install Fuel pump IS Fuel pump bolt 4 Nm 0 4 m kg 2 9 ft lb NOTE Do not damage the installation surface of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustra tion Align the projection a on the fuel pump with the slot in the fuel pump bracket Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque ET2D1023 INSTALLING THE FUEL TANK 1 Install Fuel hose Fuel hose connector cover ECA14740 CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hose holders are in the correct posi tion otherwise the fuel hose will not be properly installed NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose To install the fuel hose from the fuel injection hose slide the cover a on the end of the hose in the direction of arrow shown 2 Install Fuel sender coupler Fuel pump coupler Fuel tank breather hose Fuel tank drain hose NOTE There is white paint mark on the fuel tank breather hose Refer to CABLE ROUTING on page 2 39 7 3 FUEL TANK THROTTLE BODIES EAS26970 THR
120. 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 characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system Once a malfunction has been detected a fault code is stored in the memory of the ECU To inform the rider that the fuel injection system is not functioning the engine trouble warning light flashes when the start switch is being pushed to start the engine f a malfunction is detected in the system by the self diagnostic function the ECU provides an appropriate substitute characteristic operation and alerts the rider of the detected malfunction by illuminating the engine trouble warning light After the engine has been stopped the lowest fault code number appears on the odometer tripme ter fuel reserve tripmeter LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and Fl system operation Warning light indica tion Flashing ECU operation FI operation Vehicle operation Warning provided Cannot be operated when unable to start engine Malfunction detected Operation stopped Remains on Operated with substi tute characteristics in accordance with the Can or cannot be oper ated depending on the fault code descri
121. pocket tester YU 03112 C Positive tester probe Green white 1 Negative tester probe 1 77725 Je b Measure the fuel sender resistance 2 MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28240 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification gt Replace Output voltage reading cycle 0 6 V to 4 8 V to 0 6 V to 4 8 V VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 8 107 Positive tester probe White Yellow 1 Negative tester probe Black Blue 2 1 A L WY oN 2 b Set the main switch to ON Elevate the rear wheel and slowly rotate it Measure the voltage DC 5 V of White Yel low and Blue With each full rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 528250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Positive tester probe Blue 1 Negative tester probe Black 2 c Measure the radiator fan motor movement MAAAAAAAAAAAAAAA
122. pressure sensor open or short circuit detected Diagnostic code 02 Atmospheric pressure sensor Order Item components and probable Check or maintenance job Reinstatement cause method Connections Check the couplers for any pins Turning the Atmospheric pressure sensor cou that may be pulled out main switch to pler e Check the locking condition of ON Main wire harness ECU coupler the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an and or sub wire harness 2 open or short circuit Between atmospheric pressure sensor coupler and ECU cou pler Black Blue Black Blue Pink Pink Blue Blue Defective atmospheric pressure sen Execute the diagnostic mode sor Code No 02 Replace if defective Refer to CHECKING THE ATMOSPHERIC PRESSURE SENSOR on page 8 111 8 58 Order Item components and probable cause Installed state of Oo sensor FUEL INJECTION SYSTEM Fault code No 24 Symptom No normal signal is received from the O sensor DiagnosticcodeNo Check or maintenance job Check for looseness or pinching Connections sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect
123. received from the sen sor Open or short circuit in wire harness Defective sensor Improperly installed sensor Malfunction in ECU No normal signal is received from the lean angle sensor Vehicle has overturned Defective lean angle sensor Improperly installed lean angle sensor Malfunction in ECU Open circuit detected in the primary lead of the cylinder 1 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in a component of ignition cut off circuit system Malfunction in ECU Open circuit detected in the primary lead of the cylinder 2 ignition coil Open circuit in wire harness Malfunction in ignition coil Malfunction in a component of ignition cut off circuit system Malfunction in ECU Open circuit detected in the primary lead of the cylinder 3 ignition coil Open or short circuit in wire harness Malfunction in ignition coil Malfunction in a component of ignition cut off circuit system Malfunction in ECU 8 44 Symptom Open circuit detected in the primary lead of the cylinder 4 ignition coil FUEL INJECTION SYSTEM Probable cause of malfunction Open or short circuit in wire harness Malfunction in ignition coil Malfunction in a component of ignition cut off circuit system Malfunction in ECU Diagnostic code No Open circuit detected in a injector Open or sho
124. several turns clockwise 10 Check T mark Make sure the mark on the pickup rotor is aligned with the crankcase mating sur face Camshaft punch mark Make sure the punch mark on the cam shaft is aligned with the camshaft cap arrow mark Out of alignment Adjust Refer to the installation steps above 11 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 12 Install Pickup coil rotor cover CRANKSHAFT POSITION SENSOR on page 5 38 5 18 CAMSHAFTS CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head s 191 19 Nm 1 9 m kg 14 ft lb 5 2nd 67 Nm 6 7 m kg 48 ft lb Job Parts to remove Remarks Engine Refer to ENGINE REMOVAL on page 5 2 Intake camshaft Refer to CAMSHAFTS on page 5 10 Exhaust camshaft Refer to CAMSHAFTS on page 5 10 Cylinder head Cylinder head gasket Dowel pin Coolant pipe O ring Thermo wax outlet hose Right front engine mounting bolt 2 For assembly reverse the removal procedure 5 19 EAS24120 REMOVING THE CYLINDER HEAD 1 Remove Intake camshaft Exhaust camshaft Refer to REMOVING THE CAMSHAFTS on page 5 12 2 Remove Cylinder head nuts Cylinder head bolts NOTE Loosen the nuts in the proper sequence as shown Loosen each nut 1 2 of
125. tester probe 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity Result Continuity No continuity between 3 to 4 between 3 to 4 Headlight relay on off FZ1 S Relay unit fuel pump relay FZ1 N FZ1 S M 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 T Headlight relay dimmer Positive battery terminal FZ1 S Negative battery terminal Positive tester probe 4 Negative tester probe on Result Continuity No continuity between 3 to 4 Headlight relay on off FZ1 N 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 between 3 to 5 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe Radiator fan motor relay 8 101 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity between 3 to 4 ELECTRICAL COMPONENTS b Turn the mai
126. tire only Tube or tubeless tire 3 33 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 given if a tire combination other than one approved by Yamaha is used on this vehi cle Front tire Size 120 70 ZR17 M C 58W Manufacturer model DUNLOP D221FA MICHELIN PILOT ROAD S Rear tire Size 190 50 ZR17 M C 73W Manufacturer model DUNLOP D221G MICHELIN PILOT ROAD D EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done NOTE For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace EWA13260 A WARNING Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or replaced always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer ca
127. to activate the diagnostic mode The diagnostic code number 401 appears on the clock LCD 6 Setthe engine stop switch to g 7 Select the diagnostic code number corresponding to the fault code number by pressing the SELECT and RESET buttons NOTE The diagnostic code number appears on the LCD meter d01 70 To decrease the selected diagnostic code number press the RESET button Press the RESET button for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the SELECT button Press the SELECT button for 1 second or longer to automatically increase the diagnostic code numbers 8 Verify the operation of the sensor or actuator Sensor operation 8 42 FUEL INJECTION SYSTEM The data representing the operating conditions of the sensor appears on the odometer tripme ter fuel reserve tripmeter LCD Actuator operation Set the engine stop switch to to operate the actuator NOTE If the engine stop switch is set to set it to and then set it to again 9 Turn the main switch to OFF to cancel the diagnostic mode Fault code table Diagnostic code No Symptom Probable cause of malfunction No normal signals are Open or short circuit in sub wire harness received from the cylin Open or short circuit in wire harness der identification
128. until they contact the crankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase DAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Remove Oil pipe 1 Bearing 2 TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 11520202 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace EWA12840 Do not attempt to straighten a bent shift fork guide bar 5 90 TRANSMISSION Out of specification Replace the main axle GY Main axle runout limit LA 0 08 mm 0 0032 in 11520401 3 Check e Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set 11650702 2 Measure Drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle EA Drive axle runout limit 0 08 mm 0 0032 in 11520101 EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check e Shift drum grooves 1 Damage scratches wear Replace the shift drum assembly Shift drum segment 2 Damage wear Replace the shift drum assembly 11650701 Shift drum bearing 3 Damage pitting Replace the sh
129. washer Damper rod assembly Inner tube Outer tube NIO A A OIN For assembly reverse the disassem bly procedure 4 49 EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTE Each front fork leg is eqipped with a spring preload adjusting bolt the right fork leg is equipped with a rebound damping force adjusting screan and left front fork is equipped with a compression damping force adjusting screw Pay attention not to mistake the right and left 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Loosen Upper bracket pinch bolts 1 Cap bolt 2 Lower bracket pinch bolts 3 EWA13640 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Cap bolt 1 from the damper adjusting rod Spacers 2 FRONT FORK Nut 3 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Press down on the spacer with the fork spring compressor 4 b Install the rod holder 5 between the nut 3 and the sp
130. 0 FEATURES OUTLINE OF THE FISYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti mum air fuel ratio in accordance with the engine operating conditions and the atmospheric tempera ture In the conventional carburetor system the air fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor Despite the same volume of intake air the fuel volume requirement varies by the engine operating conditions such as acceleration deceleration or operating under a heavy load Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection Fl system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors The ad
131. 00 INSTALLING THE GENERATOR 1 Install Idle gear shaft Idle gear 1 Washer Idle gear shaft bolt 2 Idle gear shaft bolt SN 10 Nm 1 0 m kg 7 2 ft lb 2 Remove bly 4 2 Install Generator rotor and starter clutch assem bly 4 3 Remove Idle gear shaft bolt 1 Idle shaft Idle gear 2 3 Install Generator rotor cover gasket Generator rotor cover 1 5 33 GENERATOR Generator rotor cover bolt M6 12 Nm 1 2 m kg 8 7 ft lb Generator rotor cover bolt M8 22 Nm 2 2 m kg 16 ft lb NOTE First tighten the M8 bolts and then tighten the M6 bolts Tighten the generator rotor cover bolts in stages and in a crisscross pattern 5 34 EAS24550 STARTER CLUTCH Removing the starter clutch Job Parts to remove Generator rotor STARTER CLUTCH Remarks Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O ring 5 35 For assembly reverse the removal procedure EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Spacer 1 O ring 2 Washer 3 2 Remove Starter clutch drive gear 1 Collar 2 Washer 3 3 Remove Driven gear 1 Dampers 2 Generator rotor 3 ET2D1009 CHECKING THE DAMPER
132. 04 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 2 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as shown Brake hose union bolt 30 Nm 3 0 m kg 22 ft Ib 2 Fill Brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT4 EW2D1005 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock EC2D1010 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 4 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 4 42 REAR BRAKE 5 Check Brake pedal operation Soft or spo
133. 1 7 O ring 1 8 Water jacket joint inlet hose 1 9 O ring 1 10 Water jacket joint 1 11 Stay 1 12 O ring 1 For assembly reverse the removal procedure 6 4 OIL COOLER EAS26420 3 Fill CHECKING THE OIL COOLER Cooling system 1 Check with the specified amount of the recom Oil cooler mended coolant Cracks damage Replace Refer to CHANGING THE COOLANT on page 3 19 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 12 4 Check Cooling system Leaks Repair or replace any faulty part 2 Check 5 Measure Oil cooler inlet hose Radiator cap opening pressure Oil cooler outlet hose Below the specified pressure Replace Cracks damage wear Replace the radiator cap T Refer to CHECKING THE RADIATOR on INSTALLING THE OIL COOLER page 6 3 1 Clean Mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thin ner 2 Install O ring TI Oil cooler 1 Washer 2 Oil cooler bolt 3 Oil cooler bolt 63 Nm 6 3 m kg 46 ft Ib NOTE Before installing the oil cooler lubricate the oil cooler bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection on the oil cooler with the slot b in the crankcase 6 5 EAS26440 THERMOSTAT Removing the thermos
134. 10 Nm 1 0 m kg 7 2 ft lb LOCTITEG 5 39 ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 5 Nm 0 5 3 6 ft lb Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 1 Starter motor lead 1 2 Starter motor 1 For assembly reverse the removal procedure 5 40 ELECTRIC STARTER Disassembling the starter motor gt 5 Nm 0 5 m kg 3 6 ft Ib Job Parts to remove Remarks O ring Front cover Lock washer Washer Starter motor yoke Armature assembly O ring Starter motor lead Brush holder Rear cover NIO A AOIN For assembly reverse the disassem bly procedure 5 41 EAS24790 CHECKING THE STARTER MOTOR 1 Check Commutator Dirt Clean with 600 grit sandpaper 2 Measure Commutator diameter Out of specification gt Replace the starter motor GY 24 Commutator wear limit 6 27 0 mm 1 06 3 Measure Mica undercut Out of specification gt Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator ELECTRIC STARTER Pocket tester 90890 03112 Analog pocket tester YU 03112 C Armature coil Commutator resistance
135. 11 m kg 76 ft lb Connecting arm nut connecting arm and frame 44 Nm 4 4 m kg 32 ft lb Relay arm nut relay arm and swingarm 44 Nm 4 4 m kg 32 ft lb Relay arm nut relay arm and connecting arm Main frame and rear frame nut 44 Nm 4 4 m kg 32 ft lb 41 Nm 4 1 m kg 30 ft lb Clutch cable locknut 7 Nm 0 7 m kg 5 1 ft lb Throttle cable locknut 5 Nm 0 5 m kg 3 6 ft Ib Rear shock absorber assembly upper nut 44 Nm 4 4 m kg 32 ft lb Rear shock absorber assembly lower nut 44 Nm 4 4 m kg 32 ft lb Drive chain guard bolt Drive chain guide bolt 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft lb Rear fender screw 7 Nm 0 7 m kg 5 1 ft lb Rear brake hose holder screw Thread size TIGHTENING TORQUES Tightening torque 7 Nm 0 7 m kg 5 1 16 Remarks Fuel tank bolt front 7 Nm 0 7 m kg 5 1 ft lb Fuel tank bolt rear 7 Nm 0 7 m kg 5 1 ft lb Fuel tank bracket screw Fuel tank cap bolt 6 Nm 0 6 m kg 4 3 ft lb Fuel pump bolt 4 Nm 0 4 m kg 2 9 16 Seat lock assembly nut 7 Nm 0 7 m kg 5 1 ft lb 7 0 7 m kg 5 1 ft lb Mud guard assembly bolt 16 Nm 1 6 m kg 12 ft lb License plate light screw 4 Nm 0 4 m kg 2 9 16 Rear reflector nut Mud guard assembly bracket screw PO P AINI 5
136. 12 90 kg cm 12 90 bar 183 5 psi Standard 1480 kPa 14 80 kg cm 14 80 bar 210 5 psi Maximum 1660 kPa 16 60 kg cm 16 60 bar 236 1 psi VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compres sion gauge stabilizes EW2D1002 To prevent sparking ground all spark plug leads before cranking the engine ENGINE NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm 1 bar 14 22 psi c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without ring s wear or oil damage Repair Same as without oil Piston valves cylin der head gasket or piston possibly defec tive Repair AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Spark plug Spark plug 13 Nm 1 3 mg 9 4 ft lb 7 Install Ignition coils EAS20730 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suita
137. 1304 Piston pin puller YU 01304 90890 01304 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 Radiator cap tester adapter 90890 01352 90890 01352 Radiator pressure tester adapter YU 33984 os Steering nut wrench 90890 01403 Spanner wrench YU 33975 Ring nut wrench 90890 01268 Spanner wrench YU 01268 Damper rod holder 90890 01423 Damping rod holder YM 01423 Tool name Tool No Oil filter wrench 90890 01426 YU 3841 1 Illustration SPECIAL TOOLS Reference pages Rod holder 90890 01434 Damper rod holder double ended YM 01434 Rod puller 90890 01437 Universal damping rod bleeding tool set YM A8703 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 Fork spring compressor 90890 01441 YM 01441 Fork seal driver 90890 01442 Adjust table fork seal driver 36 46 mm YM 01442 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 90890 03094 SPECIAL TOOLS Tool name Tool No Illustration pages Compression gauge 90890 03081 Engine compression tester YU 33223 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 5 23 5 29 90890 04108 Valve spring compressor adapter 22 mm YM 04108 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter YM 04114 Middle driven shaft bearing
138. 2 to tighten the engine mounting adjust bolts Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wrench adapter 90890 01476 ENGINE REMOVAL Left front engine mounting bolt 45 Nm 4 5 m kg 33 ft Ib Right front engine mounting bolt 1 45 Nm 4 5 m kg 33 ft Ib 8 Tighten Lower self locking nut 1 Upper self locking nut 2 Upper self locking nut 51 Nm 5 1 m kg 37 ft Ib Lower self locking nut 51 Nm 5 1 m kg 37 ft lb NOTE First tighten the lower self locking nut and then tighten the upper self locking nut a mA M owl 9 Tighten Left front engine mounting bolt 1 Right front engine mounting bolt 1 2 5 9 CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 13 Nm 1 3 m kg 9 4 ft lb 8 Nm 0 8 5 8 ft lb Job Parts to remove Remarks Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODIES on page 7 4 Refer to RADIATOR on page 6 1 Refer to AIR INDUCTION SYS TEM on page 7 13 Radiator assembly Air cut off valve Ignition coil 4 Spark plug 4 1 1 1 1 Cylinder head cover gasket Timing chain guide top side Cylinder identification sensor O ring For assembly reverse the removal procedure 5 10 CAMSHAFTS Removing the camshafts 10 Nm 1
139. 2 Fuel level warning light 43 01 level warning light 44 Neutral indicator light 45 Tacho meter 46 Multi function meter 48 Coolant temperature indicator light 50 Turn signal indicator light left 51 Turn signal indicator light right 53 Oil level switch 55 Front brake light switch 58 Rear brake light switch 63 Hazard switch 64 Turn signal switch 65 Horn switch 66 Horn 67 Turn signal hazard relay 68 Front turn signal light left 69 Front turn signal light right 70 Rear turn signal light left 71 Rear turn signal light right 75 Tail brake light 77 Fuse tail brake light 78 Fuse ignition 80 Fuse signal 8 22 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light turn signal light brake light or an indicator light The horn fails to sound NOTE Before troubleshooting remove the following part s SIGNALING SYSTEM 1 Rider and passenger seat 2 Fuel tank 3 Air filter case Check the fuses Main ignition signal and tail brake light Refer to CHECKING THE FUSES on page 8 97 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is OK Check the signaling system The
140. 28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to Clutch drags EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears TROUBLESHOOTING Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS28560 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drags 1 Clutch Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Broken clutch boss Burnt primary driven gear bushing Match marks not aligned 2 Engine oil Incorrect oil level Incorrect oil viscosity high Deteriorated oil EAS28600 OVERHEATING Engine 1 Clogged coolant passages e Cylinder head s and piston s Heavy carbon b
141. 2D1010 CHECKING THE SUB THROTTLE POSITION SENSOR 1 Remove Sub throttle position sensor from the throttle body 2 Check Sub throttle position sensor VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Disconnect the sub throttle motor coupler b Disconnect the sub throttle position sensor coupler c Remove the sub throttle position sensor from the sub throttle servo motor d Connect the pocket tester Q x 1k to the sub throttle position sensor as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Tester positive lead gt Blue 1 Tester negative lead gt Black Blue 2 e Check the throttle position sensor maxi mum resistance Out of specification Replace the throttle position sensor Maximum sub throttle position sensor resistance 4 6 kQ at 20 C 68 F f Connect the pocket tester Q x 1k to the throttle position sensor as shown Tester positive lead gt Green Yellow 3 Tester negative lead gt Black Blue 2 ELECTRICAL COMPONENTS 2 1 TA Fe 3 g While slowly opening the sub throttle worm nut check that the sub throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the sub throt tle position sensor NOTE Check mainly that the resistance changes gradually when turning the sub throttle worm nut since the readings from closed to wide open sub throttle ma
142. 3600 Whenever a brake caliper is disassembled replace the piston seals 4 28 FRONT BRAKE EAS22410 ASSEMBLING THE FRONT BRAKE CALI PERS 13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT4 EAS22440 INSTALLING THE FRONT BRAKE CALI PERS The following procedure applies to both of the brake calipers 1 Install Brake caliper 1 temporarily Copper washers NM Brake hose 2 Union bolt 3 EN Brake hose union bolt 30 Nm 3 0 m kg 22 ft Ib EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 ECA14170 CAUTION When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Brake caliper 3 Install Brake pads Brake pad spring Brake pad pin Brake pad clips Brake caliper Brake hose holder Brake caliper bolt 40 Nm 4 0 m kg 29 ft Ib Brake hose holder bolt Nm 0 7 m kg 5 1 ft Ib Refer to REPLACING THE FRONT BRAKE PADS on page 4 26 4 Fill Brake master cyl
143. 40 Check the air cut off valve reed Air induction valve and hose for damage system Replace the entire air induction sys tem if necessary Muffler and e Check the screw clamp for loose exhaust pipe ness Lights signals Check operation and switches Adjust headlight beam NOTE Air filter This model s air filter is equipped with a disposable oil coated paper element which must not be cleaned with compressed air to avoid damaging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 3 3 EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves NOTE Valve clearance adjustment should be made on cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle bo
144. 5 72 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear Pin Pickup rotor 5 71 For assembly reverse the disassem bly procedure EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons 1 Remove Connecting rod cap 1 Big end bearings NOTE Idetify the position of each big end bearing so that it can be reinstalled in its original place After removing the connecting rods and con necting rod caps care should be taken not to damage the mating surfaces of the connect ing rods and connecting rod caps 2 Remove Cylinder Cylinder gasket Cylinder stud bolts 3 Remove Piston pin clips 1 Piston pin 2 Piston 3 EC2D1006 CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the piston pin bore area If both areas are debarred and the pis ton pin is still difficult to remove remove it with the piston pin puller set 4 CRANKSHAFT Piston pin puller set 90890 01304 Piston pin puller YU 01304 yO UU 34 4 Remo
145. 81 0 15 mm 0 0059 in Spark plug s Manufacturer model Spark plug gap NGK CR9EK 0 6 0 7 mm 0 024 0 028 in Cylinder head Volume Warpage limit 12 20 13 00 0 74 0 79 cu in 0 10 mm 0 0039 in Camshaft Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft journal to camshaft cap clearance Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B Limit 2 2 Chain drive right 22 500 22 521 mm 0 8858 0 8867 22 459 22 472 0 8842 0 8847 0 028 0 062 mm 0 001 1 0 0024 32 500 32 600 1 2795 1 2835 32 400 1 2756 24 950 25 050 mm 0 9823 0 9862 24 850 0 9783 30 699 30 799 mm 1 2086 1 2126 30 599 mm 1 2047 22 950 23 050 0 9035 0 9075 22 850 0 8996 B Camshaft runout limit ENGINE SPECIFICATIONS 0 030 mm 0 0012 in Timing chain Model number of links Tensioning system RH2020 122 Automatic Valve valve seat valve guide Valve clearance cold Intake Exhaust Valve dimensions Valve head diameter A intake Valve head diameter A exhaust Valve face width intake Valve face width B exhaust Valve seat width intake Valve seat width C exhaust Aye Valve margin thickness D intake Valve margin thickness D exhaust 0 Valve stem diameter Limit Valve stem diam
146. AAAAAAAAAAAAAA EAS28260 CHECKING THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor ELECTRICAL COMPONENTS EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification gt Replace Coolant temperature sensor resistance 0 C 32 F 5 21 6 37 80 C 176 F 0 29 0 35 kQ VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the pocket tester Q x 1k to the coolant temperature sensor 1 as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Coolant temperature sensor terminal Negative tester probe Coolant temperature sensor terminal b Immerse the coolant temperature sensor in a container filled with coolant 2 NOTE Make sure the coolant temperature sensor ter minals do not get wet Place a thermometer 3 in the coolant 8 108 db 666464 16 12 20 0 20 40 60 80 Slowly heat the coolant and then let it cool to the specified temperature indicated in the table e Check the coolant temperature sensor for continuity at the temperatures indicated in the table MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
147. AAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace O Horn resistance 1 15 1 25 at 20 C 68 F VVVVVVVVVVVVVVVVVVVVVVVVVVVVYVY a Disconnect the horn leads from the horn terminals b Connect the pocket tester Q x 1 to the horn terminals 8 106 Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Horn terminal 1 Negative tester probe Horn terminal 2 c Measure the horn resistance 2 Check Horn sound Faulty sound Adjust or replace VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Connect a battery 12 V to the horn b Turn the adjusting screw in direction or b until the specified horn sound is obtained MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28230 CHECKING THE FUEL SENDER 1 Remove Fuel tank 2 Disconnect Fuel pump coupler Fuel sender coupler from the wire harness 3 Remove Fuel pump ELECTRICAL COMPONENTS from the fuel tank 4 Check Fuel sender resistance Fuel sender resistance Full position of the float 19 210 at 20 C 68 F Empty position of the float 139 141 at 20 C 68 F VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Connect the pocket tester Q x 10 to the fuel sender terminal as shown Pocket tester 90890 03112 Analog
148. AAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Remove Valve cotters 1 VALVES AND VALVE SPRINGS NOTE Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attach ment 3 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attachment 90890 04108 Valve spring compressor adapter 22 mm YM 04108 Valve spring compressor attachment 90890 04114 Valve spring compressor adapter 19 5 mm YM 04114 4 Remove Upper spring seat 1 Valve spring 2 Valve stem seal 3 Lower spring seat 4 Valve 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place a i aL 2 NT 5 ae J 11171203 EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure Valve stem to valve guide clearance Out of specification gt Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 0004 0 0015 Limit 0 08 mm 0 0032 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 0039 in 2 Replace Valve guide VALVES AND VALVE SPRINGS NOTE To ease valve guide removal and install
149. AM 24 eni ne 8 31 TROUBLESHOOTING ent echo ced 8 33 ECU SELF DIAGNOSTIC FUNCTION 8 37 SELF DIAGNOSTIC FUNCTION 8 38 TROUBLESHOOTING METHOD tte es 8 41 DIAGNOSTIC MODE deer tet tots 8 42 TROUBLESHOOTING DETAILS taco iut ER mes 8 50 FUEL PUMP SYSTEM otro re tek ened 8 75 EM 8 75 TROUBLESHOOTING cti intet eco eat 8 77 IMMOBILIZER SYSTEM eot c io 8 79 CIRCUIT DIAGRAM ie ta tetuer cc e coe Dead a ti be 8 79 GENERAL INFORMATION 5 pde peer iae rta teens 8 81 KEY CODES REGISTRATION 8 81 TROUBLESHOOTING n tor roster DERE 8 85 SELF DIAGNOSIS ERROR CODE 8 85 ELECTRICAL 2 8 89 CHECKING THE SWITCHES 8 93 CHECKING THE BULBS AND BULB 8 96 CHECKING THE FUSES ien roe tenis 8 97 CHECKING AND CHARGING THE 8 97 CHECKING THE BELAYS iiiter n bte pei ots 8 100 CHECKING THE TURN SIGNAL HAZARD RELAY
150. Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit 4 0 mm 0 16 in Adjust Brake disc deflection Remove the brake disc Rotate the brake disc by one bolt hole Install the brake disc NOTE Tighten the brake disc bolts in stages and ina crisscross pattern Brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE 12210101 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 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Front wheel Refer to FRONT WHEEL on page 4 8 EAS22270 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers NOTE When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set FRONT BRAKE 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 12220404 2 Install Brake pads
151. Brake pad spring NOTE Always install new brake pads and a brake pad spring as a set VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container 0 V Yee b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw INS Bleed screw 5 Nm 0 5 m kg 3 6 ft Ib d Install new brake pads and a new brake pad spring NOTE The arrow mark a on the brake pad spring must point in the direction of disc rotation 3 Install Brake pad pins Brake pad clips Brake caliper EN Brake caliper bolt 40 Nm 4 0 m kg 29 ft Ib 4 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 5 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers FRONT BRAKE NOTE Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Union bolt 1 Copper washers 2 B
152. COMPONENTS Pocket tester 90890 031 12 Analog pocket tester YU 03112 C Positive tester probe Pink 1 Negative tester probe Black Blue 2 CA eFI b Set the main switch to ON c Measure the atmospheric pressure sensor output voltage MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28390 CHECKING THE CYLINDER IDENTIFICA TION SENSOR 1 Check e Cylinder identification sensor output volt age Out of specification Replace Cylinder identification sensor output voltage When sensor is on 4 8 V or more When sensor is off 0 8 V or less a Connect the pocket tester DC 20 V to the cylinder identification sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe White Black 1 Negative tester probe Black Blue 2 8 111 b Set the main switch to ON c Rotate the crankshaft d Measure the voltage DC 20 V of White Black and Black Blue With each full rota tion of the crankshaft the voltage reading should cycle from 0 8 V to 4 8 V to 0 8 V to 4 8 V MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification gt Replace Intake air pressure sensor out put voltage 3 75 4 25 V VVVVVVVVVVVVVVVVVVVVVVVVVVV
153. Distance c 13 mm 0 51 in i Inatall the damper adjusting rod and bolt and then finger tighten the cap bolt Hold the cap bolt and tighten the damper adjusting rod locknut to specification GY A Damper adjusting rod locknut 15 Nm 1 5 m kg 11 ft Ib k Remove the rod holder and fork spring compressor j FRONT FORK EW2D1003 The fork spring is compressed Always use a new bolt O ring MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTE 3 Adjust Each front fork leg is eqipped with a spring Spring preload preload adjusting bolt the right fork leg is Rebound damping equipped with a rebound damping force Compression damping adjusting screw and left front fork is equipped Refer to ADJUSTING THE FRONT FORK with a compression damping force adjusting LEGS on page 3 29 screw Pay attension not to mistake the right and left 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE Make sure the inner fork tube is flush with the top of the handlebar holder 2 Tighten Lower bracket pinch bolt 1 EN Lower bracket pinch bolt 23 Nm 2 3 m kg 17 ft lb Cap bolt 2 Cap bolt 2 23 Nm 2 3 m kg 17 ft lb Upper bracket pinch bolt
154. E Make sure the lock washer tabs sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 57 6 Measure e Steering head tension VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY NOTE Make sure all of the cables and wires are prop erly routed a b Point the front wheel straight ahead Install a plastic locking tie 1 loosely around the end of the handlebar as shown Hook a spring gauge 2 onto the plastic locking tie C 3 28 CHASSIS Hold the spring gauge at a 90 angle from the handlebar pull the spring gauge and then record the measurement when the handlebar starts to run GY Steering head tension 200 500 9 Repeat the above procedure on oppo site handlebar If the steering head tension is out of specifi cation both handlebars should be within specification remove the upper bracket and loosen or tighten the upper ring nut Reinstall the upper bracket and measure the steering head tension again as described above Repeat the above procedure until the steer ing head tension is within specification Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA f EAS21530 CHECKING THE FRONT FORK 1 Stand the vehic
155. E LE tad 99 2 Emi 1 EEN zu H HTH FEET a HHH HHH prm FEI 8 5 1 Main switch 6 7 Battery 9 Fuse main Starter relay 10 Starter motor 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Sidestand switch 56 Engine stop switch 57 Start switch 60 Clutch switch 78 Fuse ignition ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM 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 neutral the neutral switch is closed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating
156. E SIDESTAND ee DEOR 3 34 LUBRICATING THE CENTERSTAND 21 5 3 34 LUBRICATING THE REAR 505 3 34 ELECTRICAL SYSTEM ire ir nb a EQ AA 3 35 CHECKING AND CHARGING THE 3 35 CHECKING THE FUSES 3 35 REPLACING THE HEADLIGHT 3 35 ADJUSTING THE HEADLIGHT BEAM 3 36 PERIODIC MAINTENANCE 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 reduce the need for costly overhaul work This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter Periodic maintenance and lubrication chart NOTE The annual checks must be performed every year except if a kilometer based maintenance is performed instead From 50000 km repeat the maintenance intervals starting from 10000 km Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technic
157. EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Connect the pocket tester Q x 1k to the throttle position sensor as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C ELECTRICAL COMPONENTS Tester positive lead gt Blue 1 Tester negative lead gt Black Blue 2 b Check the throttle position sensor maxi mum resistance Out of specification Replace the throttle position sensor Maximum throttle position sen sor resistance 4 6 at 20 C 68 F c Connect the pocket tester Q x 1k to the throttle position sensor as shown Tester positive lead gt Yellow 3 Tester negative lead gt Black Blue 2 2 1 A 3 d While slowly opening the throttle check that the throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the throttle position sensor Throttle position sensor resis tance 0 6 kQ at 20 C 68 F 3 Install Throttle position sensor 8 109 NOTE When installing the throttle position sensor adjust its angle properly Refer to ADJUST ING THE THROTTLE POSITION SENSOR on page 7 8 EAS
158. HAUST GAS VOLUME NOTE 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 2 Simultaneously press and hold the SELECT and RESET buttons turn the main switch to and continue to press the buttons for 8 seconds or more NOTE dl appears on the clock LCD 3 Press the SELECT button to select the CO adjustment mode Co 1 or the diag nostic mode dl ENGINE 4 After selecting simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection NOTE The selected cylinder number appears on the clock LCD To decrease the selected cylinder number press the RESET button To increase the selected cylinder number press the SELECT button 5 After selecting the cylinder simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selec tion 6 Change the CO adjustment volume by pressing the SELECT and RESET but tons NOTE The CO adjustment volume appears on the tripmeter LCD To decrease the CO adjustment volume press the RESET button To increase the CO adjustment volume press the SELECT button 7 Release the switch to execute the s
159. ICATION CHART seem 2 23 LUBRICATION DIAGRAMS ttt te ree teret ee 2 25 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING cic ce Do 2 39 EAS20280 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model 2D11 EUR 2D13 AUS 3C31 EUR 3C33 AUS 3C37 EUR 3C39 AUS Dimensions Overall length 2140 mm 84 3 in Overall width 770 mm 30 3 in Overall height 1060 mm t ny E219 1205 mm 47 4 in FZ1 S Seat height 815 mm 32 1 in Wheelbase 1460 mm 57 5 in Ground clearance Minimum turning radius 135 mm 5 31 in 3000 mm 118 1 in Weight With oil and fuel Maximum load EAS20290 ENGINE SPECIFICATIONS 214 0 kg 472 Ib FZ1 N 220 0 kg 485 Ib FZ1 S 196 kg 432 Ib FZ1 N 190 kg 419 Ib FZ1 S Engine Engine type Displacement Cylinder arrangement Bore x stroke Compression ratio Standard compression pressure at sea level Starting system Liquid cooled 4 stroke DOHC 998 0 cm 60 90 cu in Forward inclined parallel 4 cylinder 77 0 x 53 6 mm 3 03 x 2 11 in 11 50 1 1480 kPa 350 r min 210 5 psi 350 r min 14 8 kgf cm 350 r min Electric starter Fuel Recommended fuel Fuel tank capacity Fuel reserve amount Regular unleaded gasoline only 18 0 L 4 76 US gal 3 96 Imp gal 3 4 L 0 90 US gal 0 75 Imp gal Engine oil Lubrication system Type
160. ING THE VALVE CLEARANCE 3 4 SYNCHRONIZING THE THROTTLE BODIES eee 3 6 ADJUSTING THE EXHAUST GAS 3 8 ADJUSTING THE ENGINE IDLING SPEED 3 9 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 9 CHECKING THE SPARK PLUGO ein nente etur ens Ret ament 3 10 MEASURING THE COMPRESSION PRESSURE 3 10 CHECKING THE ENGINE OIL LEVEL eem 3 11 CHANGING THE ENGINE OIL deo te Dee teo 3 12 MEASURING THE ENGINE OIL PRESSURE 3 13 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 14 REPLACING THE AIR FILTER 2 0440200 3 15 CHECKING THE THROTTLE BODY JOINTS 3 16 CHECKING THE FUEL LINE ico 3 16 CHECKING THE CRANKCASE BREATHER 3 16 CHECKING THE EXHAUST 3 17 ADJUSTING THE EXUP CABLES th e tbe ee 3 17 CHECKING THE EXUP SERVO MOTOR 3 18 CHECKING THE COOLANT LEVEL cene teens 3 18 CHECKING THE COOLING SYSTEM iita rs enero rta 3 19 CHANGING THE 3 19 CHASSIS
161. Imp qt 3 28 US qt 9 Install Engine oil filler cap 10 Start the engine warm it up for several minutes and then turn it off 11 Check Engine for engine oil leaks 12 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 11 EAS20820 MEASURING THE ENGINE OIL PRESSURE 1 Check Engine oil level Below the minimum level mark a gt 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 CAUTION When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure ENGINE to measure the engine oil pressure after NOTE warming up the engine Regarding the oil pressure as its own data may 3 Remove fluctuate depending on the oil temperature and Oil gallery bolt 1 viscosity the oil pressure may fluctuate when EWA 12980 measuring The following data should be used only as reference when measuring the The engine muffler and engine oil are engine oil pressure extremely hot Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil passage Faulty oil filter Oil viscosity too high 4 Install 6 Install Oil pressure gauge 1 Oil gallery bolt 1 Adapter 2 Oil
162. M EAS27330 P jOF 1 mn it Ifo T Iola ge ET ET X u ETT3 E EELE Main switch Fuse backup Fuse main Battery 8 Fuse fuel injection 11 Relay unit 12 Starting circuit cut off relay 13 Fuel pump relay 14 Neutral switch 15 Sidestand switch 16 Fuel pump 17 Crankshaft position sensor 18 Cylinder identification sensor 19 Speed sensor 20 Atmospheric pressure sensor 21 Lean angle sensor 22 05 sensor 23 ECU 24 lgnition coil 1 25 lgnition coil 2 26 Ignition coil 3 27 gnition coil 4 28 Spark plug 29 Injector 1 30 Injector 2 31 Injector 3 32 Injector 4 34 Sub throttle position sensor 35 EXUP servo motor 36 Intake air pressure sensor 37 Throttle position sensor 38 Coolant temperature sensor 39 Air temperature sensor 46 Multi function meter 56 Engine stop switch 78 Fuse ignition NOR A 8 32 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EAS27370 TROUBLESHOOTING The ignition sy
163. NG HEAD 4 59 INSTALLING THE STEERING HEAD emm 4 60 REAR SHOCK ABSORBER ASSEMBLY 4 61 HANDLING THE REAR SHOCK ABSORBER 4 63 DISPOSING OF A REAR SHOCK 4 63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE CONNECTING ARM AND RELAY ARM 4 64 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 SWINGARM cippo de n etin Rest Barrio ad 4 65 REMOVING THE SWINGARM tiit rerit te ens 4 67 CHECKING THE SWINGARM 4 67 INSTALLING THE 0 4 68 CHAIN DRIVE bed tte diac LT ail 4 69 REMOVING THE DRIVE CHAIN terret derent 4 70 CHECKING THE DRIVE CHAIN lt lt iicet ear eret 4 70 CHECKING THE DRIVE 4 71 CHECKING THE REAR WHEEL 4 71 CHECKING THE REAR WHEEL DRIVE 4 71 INSTALLING THE DRIVE CHAIN teinte trennen 4 71 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Job Parts to remove Remarks Passenger seat Rider seat Battery band Battery cover Battery negative lead Batt
164. NGINE REMOVAL on page 5 2 3 Remove Circlip 1 Washer 2 left side of the engine 4 Remove Shift shaft 1 Shift shaft spring 2 Collar Washer 5 Remove Stopper lever spring 1 Stopper screw 2 Stopper lever 3 Washer SHIFT SHAFT 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 stopper rI 1 EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Washer Stopper lever 1 Stopper screw 2 Stopper screw 22 Nm 2 2 m kg 16 ft Ib LOCTITE SHIFT SHAFT Stopper lever spring 3 Shift rod Shift arm Refer to ENGINE REMOVAL on page 5 2 5 Install Clutch assembly Refer to CLUTCH on page 5 44 2 Install Washer Collar e Shift shaft spring 1 Shift shaft 2 NOTE __________________________ Mesh the stopper lever with the shift drum segment assembly Lubricate the oil seal lips with lithium soap base grease Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install Washer 1 Circlip 2
165. Nm 3 0 m kg 22 ft lb Rear brake fluid reserver tank bolt 4 Nm 0 4 m kg 2 9 16 Rear brake master cylinder bolt 23 Nm 2 3 m kg 17 ft lb Centerstand nut FZ1 S 56 Nm 5 6 m kg 41 ft lb Centerstand bracket nut FZ1 S Centerstand bracket adapter bolt FZ1 S PO PO PO BY PO 02 55 Nm 5 5 m kg 40 ft lb 73 Nm 7 3 m kg 53 ft lb Footrest bolt 55 Nm 5 5 m kg 40 ft lb Throttle cable adjust nut 4 Nm 0 4 m kg 2 9 ft lb TIGHTENING TORQUES Thread Clutch cable adjust nut 1 7 Nm 0 7 m kg 5 1 ft lb 1 First tighten the ring nut to approximately 52 Nm 5 2 mekg 38 ftelb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut 18 Nm 1 8 mekg 13 ftelb 2 19 LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O rings Bearings Crankshaft pins Piston surfaces Piston pins Crankshaft journals Camshaft lobes Camshaft journals Valve stems intake and exhaust Valve stem ends intake and exhaust Water pump impeller shaft Oil pump rotors inner and outer Oil pump housing Oil strainer Clutch pull rod Oil water pump drive sprocket a
166. O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket sur faces oil seal lips and O rings must be cleaned 2 During reassembly properly oil all mating parts and bearings and lubricate the oil seal lips with grease Oil Lip Spring 4 Grease on gt EAS20220 LOCK WASHERS PLATES AND COTTER PINS After removal replace all lock washers plates 1 and cotter pins After the bolt or nut has been tightened to specification bend the lock tabs along a flat of the bolt or nut EAS20230 BEARINGS AND OIL SEALS Install bearings 1 and oil seals 2 so that the manufacturers 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 appropriate ECA13300 CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives IMPORTANT INFORMATION CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester Check the leads couplers and connectors for 2 90890 03112 stains rust moisture
167. OTTLE BODIES Removing the throttle bodies Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Disconnect Disconnect Disconnect Disconnect Sub wire harness coupler Coolant temperature sensor coupler Thermo wax inret hose Thermo wax outlet hose Idle adjust screw wire Throttle body joint clamp Throttle bodies Throttle cables Throttle body joint Fuel hose Loosen Disconnect Disconnect 7 4 THROTTLE BODIES Removing the throttle bodies gt x o pe 5 T gt A 9 gt 2 2 5 55 og 7 5 Removing the injectors Job Parts to remove THROTTLE BODIES Remarks 1 Throttle position sensor coupler Disconnect Sub throttle position sensor coupler Disconnect Sub throttle motor assembly coupler Disconnect Intake air pressure sensor coupler Disconnect Cylinder 1 injector coupler Disconnect Cylinder 2 injector coupler Disconnect Cylinder 3 injector coupler Disconnect Cylinder 4 injector coupler Disconnect Sub wire harness Negative pressu
168. OVING THE COVER 1 Remove Tail cover Rear fender NOTE To remove the quick fastener push its center with a screwdriver then pull the fastener out EAS21850 INSTALLING THE COVER 1 Install Rear fender Tail cover NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cover and push the pin a in with screwdriver Make sure that the pin is flush with the fasteners head GENERAL CHASSIS FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 7 Nm 0 7 m kg 5 1 ft lb Job Parts to remove Remarks Brake hose holder left and right Front brake caliper left and right Front wheel axle pinch bolt Front wheel axle Collar left and right Dust cover Front wheel Front brake disc left and right For installation reverse the removal procedure 4 8 FRONT WHEEL Disassembling the front wheel oy TAS 0 W Order Job Parts to remove Remarks 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassem bly procedure FRONT WHEEL EAS21900 Refer to CHECKING THE TIRES on page REMOVING THE EBONY WHEEF 3 32 and CHECKING THE WHEELS on 1 Stand the vehicle on a level surface EWA13120 page 3 34 A WARNING 3 Measure Radial wh
169. Replace 8 102 Pocket tester 90890 03112 Analog pocket tester YU 03112 C NOTE The pocket tester and the analog pocket tester readings are shown in the following table Continuity Positive tester probe Sky blue 1 Negative tester probe gt Yel low Black 2 FZ1 N Black Yellow 2 FZ1 S No continuity Positive tester probe gt Yel low Black 2 FZ1 N Black Yellow 2 FZ1 S Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Blue Yellow 3 No continuity Positive tester probe Blue Yellow 3 Negative tester probe Sky blue 1 Continuity Positive tester probe Sky blue 1 Negative tester probe Sky blue White 4 No continuity Positive tester probe Sky blue White 4 Negative tester probe Sky blue 1 Continuity Positive tester probe Blue Black 5 Negative tester probe Blue Yellow 3 No continuity Positive tester probe Blue Yellow 3 Negative tester probe Blue Black 5 ELECTRICAL COMPONENTS FZ1 N FZ1 S a Disconnect the relay unit coupler from the wire harness b Connect the pocket tester 1 to the relay unit terminal as shown c Check the relay unit diode for continuity d Check the relay unit diod
170. S on page 8 93 10 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 93 11 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 93 12 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 93 13 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS on page 8 100 14 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 105 15 Check the cylinder identificatin sen sor Refer to CHECKING THE CYLIN DER IDENTIFICATION SENSOR on page 8 111 16 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 107 NG NG NG NG NG NG NG 8 34 FUEL INJECTION SYSTEM Replace the immobilizer kit Replace the right handlebar switch Replace the neutral switch Replace the sidestand switch Replace the clutch switch Replace the relay unit Replace the lean angle sensor Reeplace the cylinder identification sensor Replace the spped sensor 17 Checking the aomospheric pres sure sensor Refer to CHECKING THE ATMO SPHERIC PRESSURE SENSOR on page 8 111 18 Check the injector Refer to CHECKING THE INJEC TORS on page 7 8 19 Check the t
171. SHAFT POSITION SENSOR on page 5 38 Clutch Refer to CLUTCH on page 5 44 5 66 Separating the crankcase 12 Nm 1 2 m kg 8 7 ft lb Order Job Parts to remove Oil pump CRANKCASE 12 Nm 1 2 m kg 8 7 ft lb Remarks Refer to OIL PUMP on page 5 58 Starter motor Refer to ELECTRIC STARTER on page 5 40 Timing chain Timing chain guide intake side Pin Timing chain guide exhaust side Left side cover O ring Lower crankcase Dowel pin A BY O PO Damper Q N 5 67 For assembly reverse the removal procedure EAS25550 DISASSEMBLING THE CRANKCASE 1 Place the engine upside down 2 Remove Crankcase bolts NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustration The numbers embossed on the crankcase indicate the crankcase tightening sequence M9 x 105 mm 4 1 in bolts 1 10 M8 x 60 mm 2 4 in bolt 11 LOCTITE 8 x 60 mm 2 4 in bolts 12 16 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 65 mm 2 5 in bolts 17 18 M6 x 60 mm 2 4 in bolt and washer 22
172. THE REAR BRAKE 4 38 DISASSEMBLING THE REAR BRAKE 4 38 CHECKING THE REAR BRAKE 4 39 ASSEMBLING THE REAR BRAKE 4 39 INSTALLING THE REAR BRAKE CALIPER 4 40 REMOVING THE REAR BRAKE MASTER 4 41 CHECKING THE REAR BRAKE MASTER CYLINDER 4 41 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 41 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 41 HANDLEBAR cobro EROR E E QUK 4 43 REMOVING THE HANDLEBAR 4 45 CHECKING THE HANDLEBAR 4 45 INSTALLING THE HANDLEBAR eee 4 45 FRONT FORK oro cde cal ei rosa P ep ve atc tan 4 48 REMOVING THE FRONT FORK LEGS 4 50 DISASSEMBLING THE FRONT FORK LEGS 4 50 CHECKING THE FRONT FORK LEGS 4 51 ASSEMBLING THE FRONT FORK LEGS 4 52 INSTALLING THE FRONT FORK LEGS eene 4 56 STEERING HEAD eher pts ead py a e doct 4 57 REMOVING THE LOWER BRACKET m e 4 59 CHECKING THE STEERI
173. UEL TANK on page 7 1 Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 ECS2D003 CAUTION To install the fuel tank check that the breather hose is not folded or pinched by the fuel tank EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets 1 Check Exhaust pipe 1 Muffler 2 Cracks damage Replace Gaskets 3 Exhaust gas leaks Replace 2 Check Tightening torque Exhaust pipe nut 4 Exhaust pipe and exhaust pipe bracket bolt Exhaust pipe and muffler bolt 6 Muffler and rear footrest bracket bolt 7 ENGINE Exhaust pipe nut 20 Nm 2 0 m kg 14 ft Ib Exhaust pipe and exhaust pipe bracket bolt 20 Nm 2 0 m kg 14 ft Ib Exhaust pipe and muffler bolt 20 Nm 2 0 m kg 14 ft Ib Muffler and rear footrest bracket bolt 48 Nm 4 8 m kg 35 ft Ib NOTE When installing the EXUP cables make sure they are parallel and not twisted Upper cable White metal section 8 Lower cable Black metal section 9 ET2D1005 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 2 Check EXUP system operation VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Activate the diagnostic mode and select the diagnostic code number 53 Refer to FUEL INJECTION SYSTEM on pa
174. VVY a Connect the pocket tester DC 20 V to the intake air pressure sensor coupler wire harness side as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C ELECTRICAL COMPONENTS EAS28420 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the air filter case EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification gt Replace Intake air temperature sensor resistance 2 21 2 69 at 20 C 68 F VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the pocket tester Q x 100 to the intake air temperature sensor terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown White 1 Negative tester probe Black Blue 2 Positive tester probe Pink White 1 Negative tester probe Black Blue 2 5 b Set the main switch to c Measure the intake air pressure sensor output voltage MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Measure the intake air temperature sensor resistance
175. Y 45 6 Measure Valve stem runout Out of specification Replace the valve NOTE When installing a new valve always replace the valve guide f the valve is removed or replaced always replace the oil seal Valve stem runout 0 01 mm 0 0004 in 11172103 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 Out of specification gt Replace the cylinder head 5 26 gt Y Valve seat width gt Intake 0 90 1 10 mm 0 0354 0 0433 Exhaust 0 90 1 10 mm 0 0354 0 0433 Limit 1 6 mm 0 063 in a 11171603 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Apply Mechanic s blueing dye b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impression d Measure the valve seat width NOTE Where the valve seat and valve face contacted one another the blueing will have been removed MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Lap Valve face Valve seat VALVES AND VALVE SPRINGS NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped
176. YSTEM 1 LIGHTING SYSTEM nt 11 wi LIGHTING SYSTEM CIRCUIT DIAGRAM FZ1 N EAS27240 EAS27250 tad o jee Em IT Ear iNuva3uM 2553 553 EZ FEET a nzas FE CER F 8 15 1 Main switch 6 Fuse main 7 Battery 23 ECU 49 High beam indicator light 52 Meter light 61 Pass switch 62 Dimmer switch 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight relay on off 77 Fuse tail light 81 Fuse headlight LIGHTING SYSTEM LIGHTING SYSTEM
177. YYYYYYYYYYYYYYYY a Turn the adjusting screw 1 in direction a or Direction a Headlight beam is raised Direction b Headlight beam is lowered s OLO v 1 Ap 21 FZ1 S 2 Adjust Headlight beam horizontally WWVVVVVVVVVVVVVVYVVVVVVVVYYVYVYY a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right 3 36 ELECTRICAL SYSTEM MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 37 CHASSIS GENERAL CHASSIS RU een ees 4 1 REMOVING THE COVER to tereti 4 7 INSTALLING THE COVER iii tret terti eer xe 4 7 FRONT WHEEL dedica tree Ru hee tr caso 4 8 REMOVING THE FRONT 0 ttti ten ees 4 10 CHECKING THE FRONT WHEEL teret RR 4 10 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 11 INSTALLING THE FRONT WHEEL 015 4 12 REAR ORO EDD OR RR ERU ome 4 14 REMOVING THE REAR WHEEL 0 5 4 17 CHECKING THE REAR WHEEL e re tr C dete ts 4 17 CHECKING THE REAR WHEEL DRIVE
178. ace the rear shock absorber assembly absorber assembly Bushings 44 Nm 4 4 m kg 32 ft lb Damage wear Replace Dust seals Damage wear Replace Rear shock absorber assembly Bolts lower nut Bends damage wear Replace 44 Nm 4 4 m kg 32 ft lb EAS23260 Relay arm to swingarm nut CHECKING THE CONNECTING ARM AND RELAY ARM Relay arm to swingarm nut 1 Check 44 Nm 4 4 m kg 32 ft lb Connecting arms 1 Relay arm 2 Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Coller Damage scratches Replace EAS23300 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Spacers Bearings Recommended lubricant Lithium soap based grease 2 Install Rear shock absorber assembly NOTE When installing the rear shock absorber assembly lift up the swingarm 4 64 EAS23330 SWINGARM Removing the swingarm 105 Nm 10 5 76 ft Ib Job Parts to remove Rear wheel SWINGARM 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 5 1 ft lb Remarks Refer to REAR WHEEL on page 4 14 Rear brake caliper Refer to REAR BRAKE on page 4 32 Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4 61 Drive sprocket Refer to ENGINE REMOVAL on page 5 2 Rear fender cover Drive chain guard Brake hose holder Drive chain adjust
179. acer 2 Fork spring compressor 90890 01441 YM 01441 Rod holder 90890 01434 Damper rod holder double ended YM 01434 NOTE Use the side of the rod holder that is marked B c Hold the spring preload adjusting bolt 6 and loosen the nut 3 d Remove the cap bolt e Remove the rod holder and fork spring compressor f Remove the spacer and nut DAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Drain Fork oil NOTE Stroke the damper rod 1 several times while draining the fork oil 4 50 e5 3 Remove e Oil seal clip 1 with a flat head screwdriver ECA14180 CAUTION Do not scratch the inner tube 1 2 4 Remove Damper rod assembly bolt Damper rod assembly EC2D1080 CAUTION For the damper rod assembly the right side is used for the rebound operation and left side for the compression Pay attention not to mistake the right and left NOTE The left side for the compression damper rod assembly has the four holes of oil path unlike the right side A c Te So FRONT FORK A Compression side B Rebound side NOTE While holding the damper rod with the damper rod holder 1 loosen the damper rod assem bly bolt Damper rod holder 90890 01423 Damping rod holder YM 01423 EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the
180. ad Horn lead Horn stay assembly Throttle cable pull side Throttle cable return side Wire harness 10 Brake hose 11 Throttle cables 12 Right handlebar switch lead A B Wire is connected to the meter Route the stay assembly above central cable guide After branching the lead from the left han dlebar switch route it under the stay assembly and upper guide wire from the vehicle front side to the rear side Route the stay assembly below central cable guide Clamp the horn lead to the stay assembly Position the binding section in front of the vehicle body and cut the tip to be between 2 to 4mm 0 08 to 0 16in Clamp the wire harness at the place of the white tape and insert it to the stay assem bly Point the clamp opening to the outside of the vehicle Lay on the front brake light switch lead above the throttle cables Secure the brake hose to the front fork Secure the horn lead to the front fork Cut the tip of the clamp head leaving 2 to 4mm 0 08 to 0 16in toward the outside of the vehicle The center position of the clamp shall be within this numeric range The outside of the vehicle The inside of the vehicle Pass the brake hose in the space by the right side of the vehicle from this wire and pass the throttle cables and right handle bar switch lead in the left side space Next route the right handlebar switch lead to the vehicle re
181. adiator inlet hose 2 Radiator outlet hose 3 Oil cooler 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Water jacket joint 7 Water jacket joint inlet hose 8 Water pump inlet pipe 9 Water pump outlet pipe 10 Cracks damage Replace Refer to RADIATOR on page 6 1 ENGINE EAS21130 CHANGING THE COOLANT Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 2 Remove Coolant reservoir tank Coolant reservoir hose 3 Disconnect Coolant reservoir cap 1 ENGINE 4 Drain Coolant from the coolant reservoir 5 Remove Radiator cap 1 EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove The following procedure applies to all of the coolant drain bolts and copper washers 6 Remove Coolant drain bolts 1 along with the copper washers 7 Drain Coolant from the water p
182. ained cleaned properly filled and bled after reassembly Never use solvents on internal brake components Use only clean or new brake fluid for cleaning brake components up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury THE EYES Flush with water for 15 minutes and get immediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 8 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit 0 1 mm 0 004 in Brake fluid may damage painted surfaces and plastic parts Therefore always clean FIRST AID FOR BRAKE FLUID ENTERING FRONT BRAKE 12210202 WWWVVVVVVVVVVVVVYVVVYVYVVVYVYVYVYVYY a b Place the vehicle on a suitable stand so that the front wheel is elevated Before measuring the front brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is sta tionary Remove the brake caliper Hold the dial gauge at a right angle against the brake disc surface Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 5 Measure
183. al skills ODOMETER READ CHECK OR MAINTENANCE JOB ING X 1000 km 1 10 20 40 Check fuel hoses for cracks dam age Check condition Spark plugs Clean and regap Replace Check valve clearance Adjust Fuel line Valves Air filter ele ment Clutch Replace Check operation Adjust Check operation fluid level and vehi Front brake cle for fluid leakage Replace brake pads Whenever worn to the limit Check operation fluid level and vehi Rear brake cle for fluid leakage ee ad 4 Replace brake pads Whenever worn to the limit Check for cracks or damage Vivi V Replace Every 4 years Wheels Check runout and for damage Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary Check bearing for looseness or dam age Check operation and for excessive play Viv v J Brake hoses Tires Wheel bearings 12 Swingarm 3 1 PERIODIC MAINTENANCE ODOMETER READ CHECK OR MAINTENANCE JOB ING X 1000 km 1 10 20 30 40 Check chain slack alignment and condition Every 1000 km and after wash Drive chain Adjust and lubricate chain with a ing the motorcycle or riding in special O ring chain lubricant thor the rain oughly Che
184. allation 5 Install Oil seal 1 with the fork seal driver 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 FRONT FORK 6 Install Oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 1 m N 12310403 7 Install Dust seal 1 with the fork seal driver weight 2 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 8 Install Rod puller 1 Rod puller attachment 10 2 onto the damper rod 3 4 53 Rod puller 90890 01437 Rod puller attachment M10 90890 01436 9 Fill Front fork leg with the specified amount of the recom mended fork oil Quantity 545 0 cm 18 43 US oz 19 18 Imp oz Recommended oil Suspension oil 01 or equiva lent ECA14230 CAUTION Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork NOTE Be sure to bleed the front fork 10 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil NOTE Be sure to stroke the damper rod slowly because the fork oil may spurt out FRONT FORK 11 Before
185. aphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint Union bolt Copper washer Brake hose Brake master cylinder PO 2 N k For installation reverse the removal procedure 4 33 REAR BRAKE Disassembling the rear brake master cylinder Job Parts to remove Remarks Brake master cylinder kit Hose joint Bushing Brake master cylinder body For assembly reverse the disassem bly procedure 4 34 REAR BRAKE Removing the rear brake caliper Job Parts to remove Remarks Union bolt Copper washer Brake hose Barke caliper For installation reverse the removal procedure 4 35 REAR BRAKE Disassembling the rear brake caliper 5 Nm 0 5 m kg 3 6 ft Ib Job Parts to remove Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly reverse the disassem bly procedure 4 36 EAS22560 INTRODUCTION 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 entire brake sy
186. ar side where the throttle cables are routed 2 40 CABLE ROUTING CABLE ROUTING OO FZ1 S 2 41 Wire harness Right handlebar switch lead Throttle cable Radiator inlet hose Wire guide Brake fluid reservoir hose Fuel tank breather hose EXUP cable wire bending attachment 9 EXUP cables 10 Rear brake light switch lead 11 Radiator fan motor lead Right 12 Coolant reservoir tank hose 13 Brake hose 14 Clutch cable 15 Radiator stay 16 Throttle cable return side 17 Throttle cable pull side 18 Frame 19 Rear brake light switch stay 20 Footrest bracket Right 21 Rear brake light switch A Wire is connected to the meter B Clamp the brake hose to the stay assem bly Clamping position should be 5 mm 0 20 in or more away and less than 10 amp mm 0 39 in from the top end of the brake hose protector Cut the tip to be between 2 to 4 mm 0 08 to 0 16 in C To the throttle bodies D Clamp the coolant reservoir hose and radi ator inlet hose Point the clamp opening to the outside of the vehicle and the tip of the clamp to the front upper side of the vehicle and pay attention so that the tip does not protrude from t
187. ation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Remove the valve guide with the valve guide remover 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 4 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 11170601 NOTE After replacing the valve guide reface the valve seat 5 25 Valve guide remover 04 90890 04111 YM 04111 Exhaust Valve guide remover 04 5 90890 04116 YM 04116 Intake Valve guide installer 04 90890 04112 YM 04112 Exhaust Valve guide installer 04 5 90890 04117 YM 04117 Intake Valve guide reamer 04 90890 04113 YM 04113 Exhaust Valve guide reamer 04 5 90890 04118 YM 04118 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Valve margin thickness a Out of specification Replace the valve GY Valve margin thickness 0 5 0 9 0 0197 0 0354 Limit 0 5 mm 0 02 in VALVES AND VALVE SPRINGS mel N
188. ation sensor engine and Connections Check the coupler for any pins Operate it at Oylinder identification sensor cou that may be pulled out idle pler Check the locking condition of Main wire harness ECU coupler the couplers Sub wire harness coupler If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is open or short circuit Between the cylinder identifica tion sensor coupler and ECU coupler Blue Blue White Black White Black Black Blue Black Blue Defective cylinder identification sen Replace if defective sor Refer to CHECKING THE CYLINDER IDENTIFICATION SENSOR on page 8 111 Check or maintenance job 8 50 FUEL INJECTION SYSTEM Fault code No Symptom No normal signals are received from the crankshaft posi tion sensor DiagnosticcodeNo lt o Orde Item components and probable cause Installed condition of crankshaft posi tion sensor Check or maintenance job Check for looseness or pinching Connections Crankshaft position sensor coupler Main wire harness ECU coupler Check the couplers for any pins that may have pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there i
189. ble stand Make sure the vehicle is upright 2 Start the engine warm it up for several minutes and then turn it off 3 Check Engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmo spheric temperatures API standard SE or higher grade ACEA standard G4 or G5 ECA13360 CAUTION Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CON SERVING or higher Do not allow foreign materials to enter the crankcase NOTE Before checking the engine oil level wait a few minutes until the oil has settled gt I SAE10W 30 l I l l 1 gt l 5 1 l l 1 SAE10W 40 SAE15W 40 1 SAE20W 40 I SAE20W 50 11750704 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the oil has settled EAS20790 CHANGING THE ENGINE OIL 1 S
190. bles EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate Recommended lubricant Engine oil or a suitable cable lubricant NOTE Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal to metal moving parts of the levers Recommended lubricant Lithium soap based grease 3 34 CHASSIS EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal Recommended lubricant Lithium soap based grease EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithium soap based grease EAS21730 LUBRICATING THE CENTERSTAND 21 5 Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap based grease EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Molybdenum disulfide grease ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND
191. brush seat with the tab Starter motor bolts 2 b in the starter motor rear cover ES tor bolt arter motor bo 10 Nm 1 0 m kg 7 2 ft lb 2 Connect Starter motor lead 3 2 Install Armature 1 3 Install Starter motor yoke 1 O rings 2 VM Starter motor rear cover 3 e Starter motor assembling bolts Starter motor assembling bolt 5 Nm 0 5 m kg 3 6 ft Ib 5 43 CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm 1 2 8 7 1 10 Job Parts to remove Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation reverse the removal procedure 5 44 Removing the pull lever shaft Job Parts to remove Circlip CLUTCH Remarks Pull lever Pull lever spring Pull lever shaft Oil seal Bearing 5 45 For installation reverse the removal procedure CLUTCH Removing the clutch Job Parts to remove Remarks Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire circlip Clutch plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat Clutch boss nut Washer Clutch boss assembly Thrust plate Clutch housing Bearing
192. ce Lean angle sensor output volt age Less than 65 0 4 1 4 V More than 65 3 7 4 4 V VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the lean angle sensor coupler to the wire harness b Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Yellow Green 1 Negative tester probe Black Blue 2 ELECTRICAL COMPONENTS c When turn the lean angle sensor to 65 d Measure the lean angle sensor output volt age MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D1034 CHECKING THE STARTOR MOTOR OPERA TION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step5 Refer to TROUBLESHOOTING on page 8 9 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity 18210801 b Check the starter motor operation 2 Check Startor coil resistance 8 105 Out o
193. ch cover Damage wear Replace the friction 3 Clutch cover gasket phres amp leasure a E Friction plate thickness Oil filler cap Out of specification Replace the friction For installation reverse the removal plates as a set procedure NOTE Measure the friction plate at four places EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the 2 9 3 1 mm 0 114 0 122 oe nee Limit 2 Clutch spring 2 8 mm 0 110 in Damage gt Replace the clutch springs as a set Measure Clutch spring free length Out of specification Replace the clutch springs as a set Friction plate thickness SYMBOLS 16 Replace the part The following symbols are used in this manual for easier understanding NOTE The following symbols are not relevant to every vehicle 9 cj 8 eee New Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITEG amp GENERAL INFORMATION 1 SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS I CHASSIS le COOLING SYSTEM
194. ch switch 78 Fuse ignition IGNITION SYSTEM IGNITION SYSTEM EAS27150 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark NOTE Before troubleshooting remove the following part s 1 Rider and passenger seat 2 Fuel tank 1 Check the fuses NG5 Main and ignition Refer to CHECKING THE FUSES on page 8 97 Replace the fuse s 2 Check the battery Refer to CHECKING AND Clean the battery terminals CHARGING THE BATTERY on Recharge or replace the battery page 8 97 3 Check the spark plugs Refer to CHECKING THE SPARK NG gt PLUGS on page 3 10 Re gap or replace the spark plugs 4 Check the ignition spark gap Refer to CHECKING THE IGNI Ignition system is OK TION COILS on page 8 103 5 Check the ignition coils Refer to CHECKING THE IGNI Replace the ignition coils TION COILS on page 8 103 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITION SEN SOR on page 8 104 Replace the crankshaft position sen sor 7 Check the main switch Refer to CHECKING THE Replace the immobilizer kit SWITCHES on page 8 93 8 3 8 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 93
195. ck bearing play and steering for Glog Steering bear roughness 14 ings Lubricate with lithium soap based g ubricate with lithium soap base Every 20000 km grease 15 Chassis fasten Make sure that all nuts bolts and viviviy 5 screws properly tightened 16 Sidestand Chac Lubricate 17 Sidestand Check operation v ost eo ur switch 18 Front fork Check operation and for oil leakage Shock 19 absorber Check operation and shock absorber viviviv for oil leakage assembly Rear suspen sion relay arm 20 connect Check operation ing arm pivot ing points Adjust engine idling speed and syn 21 Fuel injection chronization Change 22 Engine oil Check oil level and vehicle for oil V leakage 23 Engine oil filter Replace cartridge Check coolant level and vehicle for 24 Cooling system coolant leakage Change Every 3 years 25 Front and rear Check operation VILIS V brake switches 26 Moving parts cate Vivivivlov and cables Check operation and free play Throttle grip Adjust the throttle cable free play if 27 housing and necessary Viv lo iv 4 cable Lubricate the throttle grip housing and cable 3 2 PERIODIC MAINTENANCE ODOMETER READ CHECK OR MAINTENANCE JOB ING X 1000 km 1 10 20 30
196. conditions To set the brightness Turn the key to OFF Push and hold the SELECT button Turn the key to and then release the SELECT button after five seconds Push the RESET button to select the desired brightness level Push the SELECT button to confirm the selected brightness level The display will return to the odometer or tripmeter mode INSTRUMENT FUNCTIONS EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISAS SEMBLY 1 Before removal and disassembly remove all dirt mud dust and foreign material 2 Use only the proper tools and cleaning equipment Refer to SPECIAL TOOLS on page 1 11 3 When disassembling always keep mated parts together This includes gears cylin ders pistons and other parts that have been mated through normal wear Mated parts must always be reused or replaced as an assembly 4 During disassembly clean all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality IMPORTANT INFORMATION EAS20210 GASKETS OIL SEALS AND
197. control and possibly an accident Therefore check and if necessary bleed the brake system ECA13490 CAUTION After adjusting the brake lever position make sure there is no brake drag CHASSIS EAS21190 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained Direction a Brake pedal is raised Direction b Brake pedal is lowered EWA13070 After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specification EN Locknut 18 Nm 1 8 m kg 13 16 EWA13050 A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance ECA13510 CAUTION After adjusting the brake pedal position make sure there is no brake drag d a DAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Adjust Rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 24 3 22 EAS21240 CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface NOTE
198. ct ignition coil lead coupler 12 Immobilizer anti safety alarm coupler 13 Engine ground lead 14 Neutral switch lead 15 Rear brake light switch lead 16 EXUP cable 17 EXUP servo motor 18 Main fuse 19 Atmospheric pressure sensor 20 Battery positive lead 21 Radiator fan motor relay 22 Starting circuit cut off relay 23 Fuse box 24 Lean angle sensor 25 Turn signal light lead right 26 License plate light lead 27 Turn signal relay 28 Turn signal light lead left 29 Seat lock cable 30 Tail brake light lead 31 Tail brake light lead coupler 32 Headlight relay 33 Turn signal light lead coupler left 34 Starter relay 35 Fuel tank breather hose 36 Battery negative lead 37 AC magneto lead 38 Starter motor lead 39 Coolant reservoir tank drain hose 40 Fuel hose bend R section 41 Idle adjust screw wire 42 Throttle body lead 43 Air cut off valve hose 44 ECU engine control unit 45 Water pump breather hose 46 Radiator fan motor lead left 47 Clutch cable 48 Left handlebar switch lead 49 Main switch lead 50 Immobilizer lead 51 Frame 52 Cover 2 48 CABLE ROUTING 53 Direct ignition coil lead 54 Speed sensor lead 55 Lean angle sensor lead 56 Battery box 57 Turn signal light relay lead 58 Rear frame 59 Battery 60 Sidestand switch lead 61 01 level switch lead 62 0 sensor lead 63 Velcro 64 Protector 65 Mad guard 66 Fender 67 Fuel hose A Check that it is secured with th
199. d and turn signal light lead under the turn signal relay mm O TAC 2 CABLE ROUTING 47 48 49 1 2 2 5 zu MS AM 2 49 Q Pass the turn signal light lead right and license plate light lead under the rear fender bracket and route between the ribs of the battery box R Pass the turn signal light lead left and tail brake light lead under the rear fender bracket and route between the ribs of the battery box S Route the tail brake light lead by the inner side of the rear fender bracket and the out side of the battery box ribs When installing the tail cover assembly pay attention so that it does not catch anything between rear frame and rear fender bracket surface T After wiring the coupler make sure to cover the connector with the squid shaped protective cover on the wire harness side and then insert it to the space made by the external side of rear frame and tail cover assembly At this time the lead should be pushed in so that the lead does not hook on the seat loading accepter U Route the tail brake light lead in the space made by the top surface of the rear frame and the bottom face of the seat bracket When installing the seat
200. d only be used for re registering new codes in the standard keys The immobilizer system cannot be operated with a new key until the key registered with a code If you lose the code re registering key the ECU and main switch included with an immobilizer unit needs to be replaced Therefore always use a standard key for driving See caution below NOTE Each standard key is registered during production therefore re registering at purchase is not neces sary ECA14970 CAUTION DO NOT LOSE THE CODE RE REGISTERING KEY If the code re registering key is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly recommended to use either standard key after any code re registering and keep the code re registering key in a safe place Do not submerse either of the keys in water Do not expose the keys to excessively high temperatures Do not place either of the keys close to magnets this includes but not limited to products such as speakers etc Do not place heavy items on either key Do not grind either key or alter their shape Do not disassemble the plastic part of either key Keep other immobilizer keys away for this unit s code re registering key and main sw
201. d the wheel sur e Tire face Front wheel Damage wear Replace 4 10 c Remove the wheel bearings 3 with a gen eral bearing puller 12010201 d Install the new wheel bearings and oil seals in the reverse order of disassembly ECA14130 CAUTION Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE After replacing the tire wheel or both the front wheel static balance should be adjusted 4 11 FRONT WHEEL Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand vVYYVVVYYYVYYYYYYYYYYYYYYYYYYYYYY a Spin the front wheel b When the front wheel stops put an X4 mark at the bottom of the wheel e c Turn the front wheel 90 so that the mark is positioned as shown d Release the front wheel e When the wheel stops put an X gt mark at the bottom of the wheel f Repeat steps c through e several times until all the marks come to rest at the same spot g The spot where all the marks come to rest i
202. der 1 intake air pressure Set the engine stop switch to then operate the throttle while pushing the start switch If the dis play value changes the performance is OK Intake air temperature Displays the intake air tem perature Compare the actually mea sured air temperature with the meter display value Coolant temperature Displays the coolant tempera ture Compare the actually mea sured coolant temperature with the meter diaplay value Vehicle speed pulse Check that the number increases when the rear wheel is rotated The num ber is cumulative and does not reset each time the wheel is stopped Lean angle sensor Upright Overturned 8 46 Remove the lean angle sensor and incline it more than 65 degrees FUEL INJECTION SYSTEM Diag nostic code No Meter display Checking method Fuel system voltage Approximately 12 0 Set the engine stop switch battery voltage to and then compare with the actually measured battery voltage If the bat tery voltage is lower recharge the battery Sidestand switch Set ON OFF the sidestand Stand retracted switch with the transmis Stand extended sion in gear Neutral switch Set ON OFF the neutral Neutral ON switch shift the transmis gear OFF sion EEPROM fault cylinder No No fault 00 Fault detected 01 04 fault cylinder No If more than o
203. driver 90890 04058 Bearing driver 40 mm YM 04058 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A Universal clutch holder 90890 04086 90890 04086 8 1 BD YM 91042 30 119 P 156 Tool name Tool No Valve guide remover 04 90890 04111 Valve guide remover 4 0 mm YM 044 11 Illustration SPECIAL TOOLS Reference pages Valve guide remover 04 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide installer 04 90890 04112 Valve guide installer 4 0 mm YM 04112 Valve guide installer 04 5 90890 04117 Valve guide installer 4 5 mm YM 04117 Valve guide reamer 04 90890 04113 Valve guide reamer 4 0 mm YM 04113 Valve guide reamer 04 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 Ignition checker 90890 06754 Opama pet 4000 spark checker YU 34487 SPECIAL TOOLS Reference Tool name Tool No Illustration pages Yamaha bond No 1215 Three Bond No 1215 90890 85505 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 Pivot shaft wrench 90890 01518 Frame spanner socket YM 01518 Pivot shaft wrench adapter 90890 01476 Pocket tester 1 10 5 41 8 90890 03112 teks 95 8 96 8 97 Analog pocket tester VE 8 100 8 102 8 YU 03112 C Xf 103 8 104 8 el A 105 8 106 8 107 8 108 8 109 8 110 8 111 8 112 Oil pressur
204. dy assembly Refer to THROTTLE BODIES on page 7 4 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 13 Radiator Radiator fan motor Refer to RADIATOR on page 6 1 2 Remove gnition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5 10 3 Remove Pickup rotor cover 1 4 Measure ENGINE Valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 11 0 20 mm 0 0043 0 0079 in Exhaust valve 0 21 0 25 mm 0 0083 0 0098 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Turn the crankshaft counterclockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the pickup rotor with the crankcase mating sur face NOTE 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 1 NOTE f the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 4 gt 3 1 2 3 4 A Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the crankshaft counterclockwise as specified in the following table Cylinder 2 Cylinder 4 Cylinder 3
205. e 150 aligned Geo eT Ade n gt jede lates C 593 ee 150 1 e After the installation check that the section shown is flush with each other by touch ing the surface 12 Tighten Connecting rod bolts N Connecting rod bolt A 20 Nm 2 0 m kg 14 ft Ib 150 5 80 Side machined face EWA13990 When the bolt is tightened more than the specified angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the proce dure again If they are not flush with each other remove the connecting rod bolt and big end bearing and restart from step 9 In this case make sure to replace the con necting rod bolt ECA14680 CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angles MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D1018 CHECKING THE CRANKSHAFT 1 Measure Crankshaft runout Out of specification gt Replace the crank shaft p lt Crankshaft runout Less than 0 03 mm 0 0012 in 11631006 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches wear Replace the crankshaft ET2D1019 CHECKING THE CRANKSHAFT DRIVE SPROCKET 1 Check Crankshaft drive sprocket 1 Cracks damage wear Replace the defective part
206. e for no continu ity EAS28100 CHECKING THE IGNITION COILS The following procedure applies to all of the ignition coils 1 Check Primary coil resistance Out of specification Replace Primary coil resistance 1 19 1 61 at 20 C 68 F VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Disconnect the ignition coil leads from the wire harness b Connect the pocket tester Q x 1 to the ignition coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C 8 103 Positive tester probe Ignition coil terminal Negative tester probe Ignition coil terminal c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace Secondary coil resistance 8 5 11 5 at 20 C 68 F WWWVVVVVVVVVVVVVYVVVYVYYVVYVYVYVYVYY a Disconnect the ignition coil leads from the wire harness b Connect the pocket tester O x 1k to the ignition coil as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Negative tester probe Ignition coil terminal 1 Positive tester probe Spark plug terminal 2 c Measure the secondary coil resistance MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ELECTRICAL COMPONENTS 3 Check Ignition spark gap Out
207. e dis posing of a rear shock absorber To release the gas pressure drill a 2 3mm 0 079 0 118 in hole through the rear shock absorber at a point 15 20 mm 0 59 0 79 in from its end as shown EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips 15 20mm 0 59 0 79in EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Rear shock absorber assembly lower bolt 4 Relay arm to swingarm bolt 2 Connecting arm to relay arm bolt 3 NOTE While removing the rear shock absorber assembly lower bolt hold the swigarm so that it does not drop down 3 Remove Rear shock absorber assembly upper bolt 4 Rear shock absorber assembly NOTE Raise the swigarm and then remove the rear shock absorber assembly from between the swingarm EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber 4 63 REAR SHOCK ABSORBER ASSEMBLY Gas leaks oil leaks gt Replace the rear 3 Tighten shock absorber assembly Rear shock absorber assembly upper nut Spring Damage wear Repl
208. e gauge 3 14 90890 03153 Pressure gauge YU 03153 Oil pressure gauge adapter 90890 03139 M16xP1 5 Tool name Tool No Vacuum pressure pump gauge set 90890 06756 Illustration SPECIAL TOOLS Reference pages Valve lapper 90890 04101 Valve lapping tool YM A8998 Fuel pressure adapter 90890 03176 YM 03176 Pressure gauge 90890 03153 YU 03153 Camshaft wrench 90890 04143 YM 04143 SPECIAL TOOLS SPECIFICATIONS GENERAL 8 2 1 ENGINE 68 2 1 CHASSIS SPECIFICATIONS 2 2 8 ELECTRICAL 8 2 10 TIGHTENING TORQUES cuss e tette tea eges 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING 1 1 122 0 1 4 0 2 13 CHASSIS TIGHTENING 5 24422 1221 2 17 LUBRICATION POINTS AND LUBRICANT 2 20 ENGINE etl E 2 20 85 Miner 2 02 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBR
209. e guide of the radiator stay B To the direct ignition coil lead C Make sure to install the air filter after checking that the leads are positioned out side of the vehicle from the throttle body side cover To the engine Direct ignition coil lead protector edge Bind the left handle bar switch leads main switch leads right handle bar switch leads immobilizer leads radiator fan motor leads right wire harness and direct ignition leads in random order Make sure to set the clamping position to be ahead of the immobilizer anti safety alarm coupler and rear brake switch leadAfs branch position and to be within a range of 0 to 30 mm 0 to 1 18 inches away from the protector end of the direct ignition coil lead Install the band pointing its tip end downward inside the vehicle G Route the pickup coil lead below the fuel hose throttle body hoses and air filter drain hose H Route the wire harness below the clutch cable and route the coupler branched from the wire harness below the clutch cable and then connect it l Insert the wire harness wrapping clamp to the hole of the frame To the rear brake light switch Open to the air Insert the main fuse to the battery band Soapy water can be spread Route the battery positive lead under the relays Route the fuse box lead under the radiator fan motor relay Route the battery positive lead above the fuse box lead P Pass the license plate light lea
210. e manner as described in the bulb section however note the following VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28000 CHECKING THE FUSES The following procedure applies to all of the fuses ECA13680 CAUTION To avoid a short circuit always set the main switch to OFF when checking or replac ing a fuse 1 Remove Rider and passenger seat 2 Check Fuse VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Q x 1 Pocket tester 90890 03112 Analog pocket tester YU 03112 C b If the pocket tester indicates replace the fuse MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ELECTRICAL COMPONENTS 3 Replace Blown fuse VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Seton the switches to verify if the electrical circuit is operational d If the fuse immediately blows again check the electrical circuit Amperage rating Main Headlight FZ1 N Headlight FZ1 S Signaling system Tail brake light Ignition Buckup Radiat
211. e mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged Tighten the clutch cover bolts in stages and in a crisscross pattern 12 Tighten Clutch cover bolts 1 Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft Ib Clutch cover bolt 2 Clutch cover bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE NOTE Tighten the clutch cover bolts in a stages and crisscross pattern 13 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 14 EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Job Parts to remove Clutch assembly SHIFT SHAFT Remarks Refer to CLUTCH on page 5 44 Shift arm and shift rod Refer to ENGINE REMOVAL on page 5 2 Circlip Washer Shift shaft Collar Shift shaft spring Washer Stopper screw NI A Stopper lever Washer Oil seal Bearing Bearing Stopper lever spring 5 54 mk a ee SHIFT SHAFT Removing the shift shaft and stopper lever Order Job Parts to remove For installation reverse the removal procedure 5 55 ET2D1011 REMOVING THE SHIFT SHAFT 1 Remove Clutch assembly Refetr to CLUTCH on page 5 44 2 Remove Shift arm Shift rod Refetr to E
212. e oil NOTE Align the projections on the crankshaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 4 3 Install Crankshaft 4 Install Crankcase lower Refer to CRANKCASE on page 5 66 5 Install Pin Pickup rotor 1 Drive sprocket 2 Drive sprocket bolt 60 Nm 6 0 m kg 43 ft lb 5 84 CRANKSHAFT TRANSMISSION EAS26240 TRANSMISSION Removing the transmission shift assembly and shift forks 10 Nm 1 0 7 2 ft lb Job Parts to remove Remarks Crankcase lower Separate Refer to CRANKCASE on page 5 66 Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork L Shift fork R 1 Shift drum assembly 1 13 Main axle retainer 5 Ni 4 4 NI NI N a 5 85 TRANSMISSION Removing the transmission shift drum assembly and shift forks 10 Nm 1 0 7 2 ft lb Job Parts to remove Remarks Main axle assembly Oil pipe O ring Oil baffle plate For installation reverse the removal procedure 5 86 Disassembling the main axle assenbly 15 Job Parts to remove 2nd pinion gear TRANSMISSION Remarks
213. earance c between the handlebar grip and the grip end 10 Install Front brake master cylinder assembly Front brake master cylinder holder 1 Front brake master cylinder bracket bolt 10 Nm 1 0 m kg 7 2 ft lb ECS2D1010 CAUTION Install the brake master cylinder bracket with the UP mark facing up First tighten the upper bolt then the lower bolt NOTE Align the end of the brake master cylinder holder with the punch mark a on the handle bar 11 Adjust Throttle cable free play 4 47 HANDLEBAR FRONT FORK EAS22950 FRONT FORK Removing the front fork legs y 26 Nm 2 6 m kg 19 ft lb 123 Nm 2 3 m kg 17 ft lb 16 Nm 0 6 m kg 4 3 ft lb Job Parts to remove Remarks Front wheel Refer to CHECKING THE TIRES Front brake calipers on page 3 32 and CHECKING THE WHEELS on page 3 34 Front fender Cap bolt Loosen Upper bracket pinch bolt Loosen Lower bracket pinch bolt Loosen Front fork leg For installation reverse the removal procedure 4 48 FRONT FORK Disassembling the front fork legs 123 Nm 2 3 17 ft lb Ig 15 Nm 1 5 11 23 Nm 2 3 17 ft lb Job Parts to remove Remarks Cap bolt O ring Damper adjusting rod Nut Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper
214. eck Rear wheel drive hub 1 Cracks damage gt Replace Rear wheel drive hub dampers 2 Damage wear Replace 7 NX 0 929 522120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth gt Replace the rear wheel sprocket 12560103 b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace Rear wheel sprocket vVYYVVYYVYYYYVYYYYYYYYYYYYYYYYYY a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c Install the new rear wheel sprocket Rear wheel sprocket self lock ing nut 100 Nm 10 m kg 72 ft lb NOTE Tighten the self locking nuts in stages and in a crisscross pattern REAR WHEEL MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE 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 Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 11 EAS22160 INSTALLING THE REAR WHEEL DISC 1 Lubricate Wheel axle Wheel bearings Oil seal lips Recommended lubricant Lithi
215. eck Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Lifting the brake light switch hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS TEM EWA13100 Bleed the hydraulic brake system when ever The system is disassembled A brake hose is loosened disconnected or replaced The brake fluid level is very low Brake operation is faulty NOTE Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system WWWVVVVVVVVVVYVVVYVYVYVVVVYVVVVVYYY a Fill the brake fluid res
216. ed sensor lead A B C Route in the concavity section of the radia tor stay To the coolant reservoir tank Clamp the wire harness AC magneto lead rectifier regulator lead starter motor lead and battery negative lead Point the clamp head to the inside of the vehicle and fit it so that the band tip is pointed downward Pass the sensor lead through the vehi cle inner side of the hose assembly 1 junc tion pipe of the water pump inlet pipe and route it by the outer down side of the hose assembly 1 and to the upper direction as shown in the illustration To the exhaust Route the sensor lead to the vehicle rear side where the water pump inlet pipe is routed Physical relationship between the coolant reservoir tank drain hose tip and sidestand switch lead can be in random order 2 44 2 x lt Y 7 CABLE ROUTING Route the hose assembly 1 by the vehicle front side where the water pump inlet pipe is routed For the hose tip position route the hose so that 10 mm 0 39 in or more can be assured as shown in the illustration More than 10 mm 0 39 in Route the sidestand switch lead by the vehicle front side where the hose assembly 1 and water pump inlet pipe are routed Pass the oil level switch lead to the vehicle front side of the water pump breather hose and water pipe Route the AC magneto lead by the inside of the frame There should be n
217. eel runout 1 Securely support the vehicle so that there Lateral wheel runout 2 S ho danger obiEms Ing over Over the specified limits Replace NOTE Radial wheel runout limit Place the vehicle on a suitable stand so that 1 0 mm 0 04 in the front wheel is elevated Lateral wheel runout limit 2 Remove 0 5mm 0 02 in Left brake caliper Right brake caliper f Refer to FRONT BRAKE on page 4 20 bp 2 NOTE 1 Do not apply the brake lever when removing the brake calipers 3 Elevate Front wheel NOTE 4 12010402 Place the vehicle on a suitable stand so that 4 Check the front wheel is elevated Wheel bearings 4 Loosen Front wheel turns roughly is loose gt Front wheel axle pinch bolt Lain the wheel bearings 5 Remove Oil seals Front wheel axle Damage wear Replace Front wheel EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace EWA13460 A WARNING 12010101 Do not attempt to straighten a bent wheel 5 Replace 25 E Wheel bearings Oil seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head V screwdriver NOTE To prevent damaging the wheel place a rag 2 2 Check between the screwdriver an
218. ehicle AB Route the coolant reservoir tank drain hose so that it is positioned at the inner most part in hoses and leads AC The rear side of the vehicle AD To the radiator AE Open to the air CABLE ROUTING KK LL 2 45 AF The coolant reservoir tank drain hose shall cross with the speed sensor lead under the rear arm bracket The coolant reservoir tank drain hose shall be positioned above the vehicle 2 46 CABLE ROUTING CABLE ROUTING 47 48 49 1 2 2 5 zu MS AM 2 47 Throttle cables Right handlebar switch lead Wire harness Throttle cable pull side Throttle cable return side Radiator fan motor lead Right Coolant reservoir tank hose Radiator inlet hose 9 Air filter drain hose 10 Crankshaft position sensor lead 11 Dire
219. elec tion 8 Simultaneously press the SELECT and RESET buttons to return to the cylinder selection step 5 9 Turn the main switch to OFF to cancel the mode EAS20610 ADJUSTING THE ENGINE IDLING SPEED NOTE Prior to adjusting the engine idling speed the throttle bodies synchronization should be adjusted properly the air filter element should be clean and the engine should have ade quate compression 1 Start the engine and let it warm up for sev eral minutes 2 Install Digital tachometer onto the spark plug lead of cylinder 1 3 Check Engine idling speed Out of specification Adjust pm Engine idling speed 1 100 1 300 r min 4 Adjust Engine idling speed VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Turn the idle adjusting screw 1 in direction or b until the specified engine idling speed is obtained Direction a Engine idling speed is increased Direction b Engine idling speed is decreased MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 9 ENGINE Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 12 0 20 520630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted properly 1 Check Throttle cable free pla
220. emains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value AIR INDUCTION SYSTEM A From the air cleaner B To the cylinder head 1 Check Hoses Loose connections Connect properly Cracks damage Replace Pipes Cracks damage Replace 2 Check Reed valve 1 Reed valve stopper Reed valve seat Cracks damage Replace the reed valve 1 3 Measure Reed valve bending limit 7 14 AIR INDUCTION SYSTEM Out of specification Replace the reed Plate valve Reed valve assembly Reed valve cap GY 24 Reed valve bending limit 2 Install 0 4 0 016 Air cut off valve Air cut off valve hose 1 1 Air cut off valve hose 2 Air cut off valve hose a Air cut off valve coupler 14710301 4 Check Air cut off valve Cracks damage Replace 5 Check Air induction system solenoid VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Remove the air induction system solenoid coupler from the wire harness b Connect the pocket tester Q x 1 to the air induction system solenoid terminals as shown Positive tester probe Brown terminal 1 Negative tester probe Brown Red terminal 2 c Measure the air induction system solenoid resistance Air induction system solenoid resistance 18 220 at 20 C
221. emove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 Disconnect Stator coil assembly lead coupler Plug Generator rotor cover Gasket Dowel pin Generator rotor assembly Stator coil assembly Dowel pin Bearing housing Collar A CG PO N N 5 31 GENERATOR Removing the generator P 12 Nm 1 2 8 7 ft lb 22 Nm 2 2 m kg 16 10 12 Nm 1 2 8 7 ft lb ex Qu Qv 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb H0 miko 112 Nm 1 2 8 7 ft lb 22 Nm 2 2 16 ft Ib Job Parts to remove Remarks 11 Bearing 12 Stator coil assembly lead holder 13 Idler gear 14 Idler gear shaft 15 Washer 16 Bearing For assembly reverse the removal procedure 5 32 GENERATOR EAS24490 REMOVING THE GENERATOR 1 Remove Plug Generator rotor cover 1 ____ _____ _______________ _______ 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 EAS245
222. en the coolant temperature is displayed EC2D1011 CAUTION Do not operate the engine if it is over heated Air intake temperature mode Fob L reb 0D Q 1 Air intake temperature display The air intake temperature display indicates the temperature of the air drawn into the air fil ter case Push the RESET button to switch the coolant temperature display to the air intake temperature display NOTE Even if the air intake temperature is set to be displayed the coolant temperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is automatically displayed even if the air intake temperature was displayed prior to turning the key to OFF When the air intake temperature display is selected A is displayed for one second and then the air intake temperature is dis played Self diagnosis device Hi c m RESET THE 00 1 Error code display This model is equipped with a self diagnosis device for various electrical circuits If any of those circuits are defective the engine trouble warning light will come on and then the display will indicate a two digit error code e g 11 12 13 This model is also equipped with a self diagno sis device for the immobilizer system If any of the immobilizer system circuits are defective the immobilizer system ind
223. en the positive bat tery 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 Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge of the battery 20 30 DAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Charge Battery refer to the appropriate charging method illustration EWA13300 Do not quick charge a battery ECA13670 CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may
224. eplace the big end bearings Crankshaft pin to big end bear ing clearance 0 034 0 058 mm 0 0013 0 0023 in Limit 0 09 mm 0 0035 in The following procedure applies to all of the connecting rods ECA14900 CAUTION Do not interchange the big end bearings and connecting rods To obtain the correct creankshaft pin to big end bearing clear ance and prevent engine damage the big CRANKSHAFT end bearings must be installed in their orig inal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rods halves b Install the big end upper bearing into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections on the big end bear ings with the notches b in the connecting rod and connecting rod cap 11630301 Puta piece of Pleastigauge 1 on the crankshaft pin d Assemble the connecting rod halves NOTE Do not move the connecting rod crank shaft until the clearance measurement has been completed Lubricate the bolt threads with molybdenum disulfide grease Make sure that the Y mark on the con necting rod faces towards the left side of the crankshaft Make sure that the characters d on both the connecting rod and connecting rod cap are aligned e Tighten
225. eplace the meter assembly Malfunction in ECU Replace the ECU Reinstatement method Turning the main switch to ON Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnostic code Order Item components and probable cause Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Sub wire harness coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler Yellow Blue Yellow Blue Malfunction in meter assembly Replace the meter assembly Malfunction in ECU Replace the ECU 8 74 Reinstatement method Turning the main switch to ON FUEL PUMP SYSTEM FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM EAS27550
226. ervoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylin der reservoir or brake fluid reservoir CHASSIS c Connect a clear plastic hose 1 tightly to the bleed screw 2 A Front brake caliper B Rear brake caliper d Place the other end of the hose into a con tainer e Slowly apply the brake several times Fully pull the brake lever or fully press down the brake pedal and hold it in posi tion g Loosen the bleed screw NOTE 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 Tighten the bleed screw then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw SN 5 Nm 0 5 m kg 3 6 ft Ib k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 EWA13110 After bleeding the hydraulic brake system check the brake operation ET2D1 006 ADJUSTING THE SHIFT PEDAL 1 Adjust e Shift pedal position VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Loosen both locknuts 1 b Turn the shift rod 2 in direction
227. ery positive lead Battery Battery seat For installation reverse the removal procedure 4 1 GENERAL CHASSIS Removing the headlight and meter assembly FZ1 N 1 3 Nm 0 13 0 94 ft Ib Job Parts to remove Remarks Headlight side cover bolt left and right 4 Headlight coupler 1 Disconnect Headlight sub wire harness coupler Disconnect Headlight assembly Headlight bracket Headlight side cover left and right Meter cover Meter coupler Meter assembly Headlight and meter stay AION a NI NI For installation reverse the removal procedure 4 2 GENERAL CHASSIS Removing the front cowling FZ1 S Order Job Parts to remove Q ty Remarks 1 Inner panel Headlight assembly coupler 1 Disconnect Front cowling assembly 1 1 1 1 Cowling stay Meter assembly Headlight unit For installation reverse the removal procedure Removing the rear fender FZ1 N Job Parts to remove Rider and passenger seat GENERAL CHASSIS Remarks Refer to GENERAL CHASSIS on page 4 1 Licence plate light lead coupler Disconnect Turn signal light lead coupler Disconnect Mud guard assembly Rear fender Tail brake light lead coupler Disconnect Tail cover Rear fender bracket 5
228. eter exhaust 0 11 0 20 mm 0 0043 0 0079 in 0 21 0 25 mm 0 0083 0 0098 23 40 23 60 mm 0 9213 0 9291 24 90 25 10 0 9803 0 9882 1 760 2 900 mm 0 0693 0 1142 in 1 760 2 900 0 0693 0 1142 m 0 0354 0 0433 0 90 1 10 0 90 1 10 mm 0 0354 0 0433 0 50 0 90 0 0197 0 0354 0 50 0 90 mm 0 0197 0 0354 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553 in 4 460 4 475 mm 0 1756 0 1762 in Limit Valve guide inside diameter intake Limit Valve guide inside diameter exhaust Limit Valve stem to valve guide clearance intake Limit Valve stem to valve guide clearance exhaust Limit Valve stem runout Cylinder head valve seat width intake Cylinder head valve seat width exhaust ENGINE SPECIFICATIONS 4 425 mm 0 1742 in 4 000 4 012 mm 0 1575 0 1580 in 4 050 mm 0 1594 in 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 1791 in 0 010 0 037 mm 0 0004 0 0015 in 0 080 mm 0 0032 in 0 025 0 052 mm 0 0010 0 0020 0 100 mm 0 0039 0 010 mm 0 0004 m 0 0354 0 0433 0 90 1 10 m 0 90 1 10 mm 0 0354 0 0433 Valve spring Inner spring Free length intake Free length exhaust Installed length intake Installed length exhaust Spring rate K1 intake Spring rate K2 intake Spring rate K1 exhaust Spring rate K2 exhaust Installed compression spring force intake Installed compressio
229. eter select it by pushing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Fuel meter INSTRUMENT FUNCTIONS 1 Loc 05 TRIPA RESET sELECT 1 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the fuel level decreases When only one segment is left near E refuel as soon as possible NOTE This fuel meter is equipped with a self diagno sis system If the electrical circuit is defective the following cycle will be repeated until the malfunction is corrected E Empty F Full and symbol will flash eight times then go off for approximately 3 seconds If this occurs have a Yamaha dealer check the electrical cir cuit Coolant temperature mode 1 a E L eb TRPA n RESET sELECT 1 Coolant temperature display The coolant temperature display indicates the temperature of the coolant Push the RESET button to switch the coolant temperature display to the air intake tempera ture display NOTE When the coolant temperature display is selected C is displayed for one second and th
230. ever go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV a Turn the adjusting screw 1 in direction a or p Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Rebound position Minimum 12 clicks in direction b Standard 6 clicks in direction b Maximum 1 clicks in direction b damping adjusting With the adjusting screw fully turned in direction a MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate 12070102 EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE CHASSIS GY lt e cold tires Basic weight with oil and a full fuel tank FZ1 N 214kg 47216 FZ1 S 220kg 485 Loading condition 0 90 kg 0 198 Ib Front 250 kPa 2 5 kg cm 2 5 bar 36 psi Rear
231. ever the steering head is disassem bled replace the rubber seal amp a 12460503 12460504 MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 59 STEERING HEAD 4 Check Upper bracket gt Steering stem nut Lower bracket SN 113 Nm 11 3 m kg 82 ft Ib along with the steering stem Bends cracks damage Replace EAS23140 INSTALLING THE STEERING HEAD 1 Lubricate Upper bearing Lower bearing Bearing races Recommended lubricant Lithium soap based grease 2 Install Lower ring nut 1 Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to INSTALLING THE STEERING HEAD on page 4 60 3 Install Front brake hose joint bracket Front brake hose joint 4 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 5 Install Front fork legs Refer to FRONT FORK on page 4 48 NOTE Temporarily tighten the upper and lower bracket pinch bolts 6 Tighten Steering stem nut 4 60 REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 144 Nm 4 4 m kg 32 ft lb Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Side cover left and right Refer to GENERAL CHASSIS on page 4 1 Brake fluid reservoir tank bolt Refer to REAR BRAKE on page 4 32 Self locking nut bolt
232. f specification Replace the startor coil EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the wire harness 2 Check Stator coil resistance Out of specification Replace the startor coil O Stator coil resistance 0 14 0 18 at 20 C 68 F VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the pocket tester Q x 1 to the startor coil coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe White 1 Negative tester probe White 2 Positive tester probe White 1 Negative tester probe White 3 Positive tester probe White 2 Negative tester probe White 3 b Measure the stator coil resistance MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28170 CHECKING THE RECTIFIER REGULATOR 1 Check ELECTRICAL COMPONENTS Charging voltage Out of specification Replace the rectifier regulator Charging voltage 14 V at 5000 r min VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Set the engine tachometer to the ignition coil of cylinder 1 b Connect the pocket tester AC 20 V to the rectifier regulator coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Red 1 Negative tester probe Black 2 c Start the engine and let it run at approxi mately 5000 r min d Measure the charging voltage MAA
233. fer to Sensor operation table and Actuator operation table Throttle position sensor throttle angle Atmospheric pressure sensor Intake air pressure sensor Coolant temperature sensor Vehicle speed pulse Fuel system voltage battery bolt Neutral switch Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Injector 1 Injector 2 Injector 3 Injector 4 Al system solenoid EXUP servo motor Sub throttle servo motor 8 41 FUEL INJECTION SYSTEM If a malfunction is detected in the sensors If no malfunction is detected in the sensors or actuators repair or replace all faulty and actuators check and repair inner parts parts of the engine EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1 Turn the main switch to OFF and set the engine stop switch to 2 Disconnect the wire harness coupler from the fuel pump 3 Press and hold the SELECT and RESET buttons turn the main switch to and continue to press the buttons for 8 seconds or more All displays the meter disappear except the odometer tripmeter fuel reserve tripmeter display dl appears on the odometer tripmeter fuel reserve tripmeter LCD 4 Press the SELECT button to select the diagnostic mode dl 5 After selecting dl simultaneously press the SELECT and RESET buttons for 2 seconds or more
234. fter leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required WWWVVVVVVVVVVVVVVVVVVYVYYVYVYVYVYY Charging method using a variable current voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charged and AMP meter to the battery and start charging NOTE Set the charging voltage at 16 17 V If the set ting is lower charging will be insufficient If too high the battery will be over charged 8 99 Under 12 0 V Replace the battery MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA WWWVVVVVVVVVVVVVYVVVYVVYVVYVYVYVYVYY Charging method using a constant voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charger and AMP meter to the battery and start charging c Make sure that the current is higher than the standard charging current written on the battery NOTE If the current is lower than the standard charg ing current written on the battery this type of battery charger cannot charge the MF battery A variable voltage charger is recommended d Charge the battery until the battery s charg ing voltage is 15 V NOTE Set the charging time at 20 hours maximum e Measure the battery open ci
235. function repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between EXUP servo motor coupler and ECU coupler Black Green Black Green Black Red Black Red Defective EXUP servo motor Execute the diagnostic mode Code No 53 Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR on page 3 18 Fault code No 19 Symptom Order Defective EXUP valve pulley and cables Item components and probable cause Connections Main wire harness ECU coupler Replace if defective Check or maintenance job Execute the diagnostic mode Code No 20 Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness or sub lead Repair or replace if there is an open or short circuit 2 Between sidestand switch cou pler and ECU coupler Black Black Defective sidestand switch Replace if defective 3 Refer to CHECKING THE SWITCHES on page 8 93 8 55 Reinstatement method Turning the main switch to ON Open circuit is detected in the input line of ECU No 24 ter minal is difected when the start switch is pressed Diagnostic code 20 Sidestand switch Reinstatement method If the trans
236. function repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler Black Blue Black Blue Yellow Yellow Blue Blue Throttle position sensor lead wire open circuit output voltage check Check for open circuit and replace the throttle position sen sor Black Blue Yellow Open circuit Output voltage item Ground wire 5V open circuit Output wire open circuit Power supply OV wire open circuit Defective throttle position sensor Execute the diagnostic mode Code No 01 Replace if defective Refer to CHECKING THE THROTTLE POSITION SEN SOR on page 8 109 8 53 Reinstatement method Turning the main switch to ON FUEL INJECTION SYSTEM Fault code No 16 Symptom Stuck throttle position sensor detected Diagnostic code 01 Throttle position sensor Order Reinstatement method Reinstated by starting the engine operat ing itat idle and then racing it Item components and probable cause Installed condition of throttle position sensor Defective throttle position sensor Check or maintenance job Check the installed area for looseness or pinching Check that is installed in the specified position Refer to THROTTLE BODIES on page 7 4 section Execute t
237. g 11 ft lb Water pump bolt 12 Nm 1 2 m kg 8 7 ft lb Thermostat cover nut 10 Nm 1 0 m kg 7 2 ft lb Thermostat inlet pipe bolt Oil cooler bolt 10 Nm 1 0 m kg 7 2 ft lb Engine oil drain bolt Oil pipe bolt 63 Nm 6 3 m kg 46 ft Ib 43 Nm 4 3 m kg 31 ft lb 10 Nm 1 0 m kg 7 2 ft lb Oil strainer bolt 10 Nm 1 0 m kg 7 2 ft lb Oil delivery pipe bolt 10 Nm 1 0 m kg 7 2 ft lb Oil filter union bolt Oil filter 70 Nm 7 0 m kg 51 ft lb 17 Nm 1 7 m kg 12 ft lb Oil pan bolt 12 Nm 1 2 m kg 8 7 ft lb Oil pan bolt 12 Nm 1 2 m kg 8 7 ft lb Air filter case cover screw 1 2 Nm 0 12 m kg 0 9 ft lb Throttle body and throttle body joint clamp 3 Nm 0 3 m kg 2 2 ft lb Throttle body and funnel bolt 4 2 Nm 0 42 m kg 3 0 ft Ib Throttle cable adjusting bolt 4 5 Nm 0 45 m kg ft lb TIGHTENING TORQUES Item Tightening torque Remarks Cylinder head and exhaust pipe 8 8 20 Nm 2 0 m kg 14 ft lb nut Exhaust pipe and muffler bolt M8 1 20 Nm 2 0 m kg 14 ft lb EXUP pulley and shaft arm nut M6 1 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt M6 2 14 Nm 1 4 m kg 10 ft lb EXUP cable nut M6 2 6 Nm 0 6 m kg 4 3 ft lb Exhaust pipe and exhaust pipe M8
238. g depending on the conditions Self Diagnostic Function table Cylinder identifica tion sensor Symptom No normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driven Able unable to start Unable Able unable to drive Crankshaft position sensor No normal signals are received from the crankshaft position sensor Unable Unable Intake air pressure sensor open or short circuit Intake air pressure sensor open or short circuit detected Able Able Intake air pressure sensor hose line piping system Intake air pressure sensor faulty intake air pressure sensor system Throttle position sen sor open or short circuit Throttle position sensor open or short circuit detected Throttle position sen sor stuck Throttle position sensor is stuck EXUP servo motor potention circuit open or short circuit EXUP servo motor potension circuit open or short circuit detected Able Able EXUP servo motor stuck EXUP servo motor is stuck Able Able Sidestand switch open circuit in the wire to the ECU Open circuit in the input line of ECU No 24 terminal is detected when start switch is pressed from the sidestand switch to the ECU Unable Unable Intake air pressure sensor or atmo spheric pressure sen sor When the main switch is turned to ON
239. g taping section blue and then insert it to the cover For routing leads the wire harness shall be downside but others can be in ran dom order Positioning tape is only used for the wire harness and right handlebar switch AL The upper side of the vehicle AM The inside of the vehicle AN Secure the leads with a clamp The cut position of the tip of the clamp shall be on the upper side of the vehicle Cut it leaving 2 to 4mm 0 08 to 0 16in of the tip Route the leads over the frame plate and insert them through the hole into the inside of the vehicle AO Route the lean angle sensor lead at the uppermost side of the vehicle Also it must not be protruded from the battery box ribs toward the upper side AP Routing can be in random order AQ Push the wire harness securely in as far as it will go AR Secure the leads with a clamp The cut position of the tip of the clamp shall be on the upper side of the vehicle Cut it leaving 2 to 4mm 0 08 to 0 16in of the tip Route the leads over the frame plate and insert them through the hole into the inside of the vehicle Route the wire harness at the posi tion shown in the illustration and other leads can be in random order Inserting the band can be in any direction AS 15 X 20 mm 0 59 X 0 79 in shaded area AT Installation procedure 1 Secure the main switch lead and immobilizer lead with Vel cro strap 2 Secure the left handlebar switch lead with Velcro strap The
240. garm up and down SWINGARM If swingarm vertical movement is not smooth or if there is binding check the spacers bearings washers and dust cov ers MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage gt Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace 13770 Do not attempt to straighten bent pivot shaft 12010701 3 Wash Pivot shaft Dust covers Spacer Washers Bearings Recommended cleaning solvent Kerosene 4 Check Dust covers 1 Spacer 2 Bearings 3 Damage pitting Replace 5 Check Connecting arms 1 Relay arm 2 Damage wear Replace 6 Check Bearings 3 Oil seals 4 Damage pitting Replace 7 Check Collars 5 Damage scratches Replace et 2 5 C 15090 umm 523380 INSTALLING THE SWINGARM 1 Lubricate Bearings Spacers Dust covers Pivot shaft Recommended lubricant Lithium soap based grease 2 Install Swingarm Pivot shaft 1 Pivot shaft nut 2 SWINGARM 3 Install Rear shock absorber assembly Rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY on page 4 64 and INSTALLING THE REAR WHEEL DISC on page 4 18 4 Adjust Drive c
241. ge 8 31 Set the engine stop switch to O Check that the EXUP valve operates prop erly 3 Check EXUP cable free play at the EXUP valve pulley a and b Maximum EXUP cable free play at the EXUP valve pulley a Less than 3 mm 0 12 in b Less than 3 mm 0 12 in 4 Adjust EXUP cable free play VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY Turn the main switch to ON Check the EXUP pulley position Loosen the locknut 1 Loosen the locknut 3 Turn the adjusting nut 2 in or out Tighten the locknut Turn the adjusting nut 4 in or out Tighten the locknut EXUP cable locknut 6 Nm 0 6 m kg 4 3 ft Ib 3 18 ENGINE 5 Install EXUP valve pulley cover EAS28360 CHECKING THE EXUP SERVO MOTOR 1 Check EXUP servo motor operation Out of specification Replace VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Check whether or not the EXUP valve is seized Disconnect the EXUP cable and check that the EXUP valve is moved smoothly by hand When the valve is not moved smoothly repair or replace it Refer to ADJUSTING THE EXUP CABLES on page 3 17 When the EXUP va
242. ge wear gt Replace the drive chain Drive chain side plates 3 Damage wear Replace the drive chain Cracks Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm 12510201 5 Lubricate Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EAS23460 CHECKING THE DRIVE SPROCKET 1 Check CHAIN DRIVE Drive sprocket More than 1 4 tooth a wear Replace the drive chain sprockets as a set Bent teeth gt Replace the drive chain sprockets as a set 12560103 b Correct 1 Drive chain roller 2 Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 18 ET2D1031 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 17 EAS28800 INSTALLING THE DRIVE CHAIN 1 Lubricate Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains 2 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 2 Drive sprocket nut 85 Nm 8 5 m kg 61 ft Ib ENGINE ENGINE REMOVAL oae peret EDU og aie 5 2 INSTALLING THE ENGINE e pet rc ir 5 8 5 10 REMOVING THE 6
243. haft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 6 Remove Intake camshaft 1 Exhaust camshaft 2 NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire 3 5 12 EAS23850 CHECKING THE CAMSHAFTS 1 Check Camshaft lobes Blue discoloration pitting scratches gt Replace the camshaft 2 Measure Camshaft lobe dimensions and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 32 50 32 60 mm 1 280 1 284 Limit 32 40 mm 1 276 in Intake camshaft b 24 95 25 05 mm 0 982 0 986 Limit 24 85 mm 0 978 in Exhaust camshaft a 30 70 30 80 mm 1 209 1 213 Limit 30 60 mm 1 205 in Exhaust camshaft b 22 95 23 05 mm 0 904 0 908 Limit 22 85 mm 0 900 in 11151001 5 13 CAMSHAFTS 11151002 3 Measure Camshaft runout Out of specification Replace GY Camshaft runout limit 0 03 mm 0 0012 in 4 Measure Camshaft journal to camshaft cap clear ance Out of specification Measure the cam shaft journal diameter Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 001 1 0 0024 in Install the camshaft into the cylinder head wi
244. hain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 GY Drive chain slack 25 35 mm 0 98 1 38 4 68 CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Job Parts to remove Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 2 Drive chain guard Drive chain For installation reverse the removal procedure 4 69 EAS23410 REMOVING THE DRIVE CHAIN 1 Stand the vehicle on a level surface EWA13120 A WARNING Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Drive chain with the drive chain cutter NOTE Only cut the drive chain if it or the swingarm is to be replaced EAS23440 CHECKING THE DRIVE CHAIN 1 Measure Measure the dimension between 15 links on the inner side a and outer side b of the roller and calculate the dimension between pin centers Dimension between pin centers Inner dimension a Outer dimension b 2 15 link section of the drive chain Out of specification Replace the drive chain front drive sprocket and rear drive sprocket as a set 15 link drive chain section limit maximum 239 3 mm 9 42 in NOTE While measuring the 15 link section push down on the drive chain to increase its ten sion Perf
245. he brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 5 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 6 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22550 REAR BRAKE Removing the rear brake pads Order Job Parts to remove Screw plug REAR BRAKE w 5 Nm 0 5 3 6 ft lb 22Nm 2 2 m kg 16 ft lb 27Nm 2 7 20 ft lb Remarks Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring For installation reverse the removal procedure 4 32 REAR BRAKE Removing the rear brake master cylinder 30 Nm 3 0 m kg 22 ft lb 7 Nm 0 7 m kg 5 1 ft lb Job Parts to remove Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAU LIC BRAKE SYSTEM page 3 25 Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir di
246. he diagnostic mode Code No 01 Replace if defective Refer to THROTTLE BODIES on page 7 4 section Fault code No Symptom EXUP servo motor circuit open or short circuit detected Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Connections EXUP servo motor coupler Main wire harness ECU coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between EXUP servo motor coupler and ECU coupler Blue Blue White Red White Red Black Blue Black Blue tion circuit Defective EXUP servo motor poten Execute the diagnostic mode Code No 53 Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR on page 3 18 8 54 Reinstatement method Turning the main switch to ON FUEL INJECTION SYSTEM Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable cause Connections EXUP servo motor coupler Main wire harness ECU coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the coupler If there is a mal
247. he immobilizer system indicator light signals the standby mode 2 Using the code re registering key turn the main switch then OFF and then remove the key within 5 seconds 3 Insert the first standard key to be registered into the main switch then turn the key to within 5 seconds to activate the key registration mode NOTE The existing standard key code is erased from the memory when the key registration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 seconds insert the second standard key to be registered into the main switch NOTE If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is regis tered the registration mode is deactivated If this occurs the second standard key cannot be regis tered and steps 2 to 4 need to be repeated to register both standard keys 5 Turn the main switch to ON NOTE When the indicator light goes off the registration is complete 6 Check that the engine can be started with the two registered standard keys 8 83 IMMOBILIZER SYSTEM Standard key registration e e e f g h o flashing when the registration of the second Code re registering key standard key is comple
248. he radiator cover E Route the fuel tank breather hose by the wire guide The white paint position of the hose shall be lower than the wire guide F To the EXUP G Pass the fuel tank breather hose and EXUP cable through the wire guide of the rear brake light switch stay H The clamp position shall be at the center of bending section of the brake fluid reservoir hose as shown in the illustration Bind the two EXUP cables with the clamp For the clamping position a part of the clamp should be located within a range of 10 mm 0 39 in from the end of wire bend ing attachment Any direction of the clamp opening can be accepted To the wire harness K To the coolant reservoir tank L Route the radiator fan motor lead right so that there is no slack as much as possible in this section 2 42 CABLE ROUTING Pass the radiator fan motor lead right above the coolant reservoir hose and route it to the inside of the frame Pass the coolant reservoir hose to the vehi cle inner side of the radiator inlet hose and route it to the lower outside of the vehicle of the thermostat assembly Route in the concavity section of the radia tor stay Route the wire guide of the radiator stay as shown in the illustration Twisting not allowed The outside of the vehicle The inside of the vehicle The front side of the vehicle Point the clamp head to the outside of the vehicle
249. horn fails to sound 1 Check the horn switch Refer to CHECKING THE SWITCHES on page 8 93 Check the horn Refer to CHECKING THE HORN on page 8 106 NG gt NG gt NG 8 23 Replace the fuse s Clean the battery terminals Recharge or replace the battery Replace the immobilizer kit Properly connect or repair the signal ing system s wiring Replace the left handlebar switch Replace the horn SIGNALING SYSTEM 3 Check the entire signaling system s wiring Properly connect or repair the signal Refer to CIRCUIT DIAGRAM on ing system wiring page 8 21 OK This circuit is OK The tail brake light fails to come on 1 Check the tail brake light bulb and NG gt socket Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 96 Replace the tail brake light bulb socket or both 2 Check the front brake light switch NG5 Refer to CHECKING THE Replace the front brake light switch SWITCHES on page 8 93 Check the rear brake light switch NG5 Refer to CHECKING THE Replace the rear brake light switch SWITCHES on page 8 93 4 Check the entire signaling system s wiring Properly connect or repair the signal Refer to CIRCUIT DIAGRAM on ing system
250. hort circuit Between speed sensor coupler and ECU coupler Blue Blue White Yellow White Yellow Black Blue Black Blue Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 107 8 66 A No normal signals are received from the speed sen B Open circuit is detected in the neutral switch A 07 Speedsensor Bat Newmlswih Reinstatement method Starting the engine and activating the speed sensor by operating the vehicle at 20 to 30 km h Fault code No 22 Diagnostic code Order Item components and probable cause Installed state of neutral switch FUEL INJECTION SYSTEM sor Check or maintenance job Check for looseness or pinch ing Connections Neutral switch coupler Main wire harness ECU coupler Check the couplers for pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open circuit in neutral switch lead Repair or replace if there is an open or short circuit Between neutral switch coupler and relay unit coupler Sky blue Sky blue Between relay unit coupler and ECU coupler Blue Yellow Blue Yellow Defective neutral switch Execute the diagnostic mode Code No 21 Replace if defective
251. hrottle position sensor Refer to CHECKING THE THROT TLE POSITION SENSOR on page 8 109 20 Check the sub throttle position sen sor Refer to CHECKING THE SUB THROTTLE POSITION SENSOR on page 8 110 21 Check the intake air pressure sen sor Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 112 22 Check the coolant temperature sensor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 8 108 23 Check the inatke air temperature sensor Refer to CHECKING THE INTAKE AIR TEMPERATURE SENSOR on page 8 112 NG gt NG NG gt NG gt 8 35 FUEL INJECTION SYSTEM Replace the atomospheric pressure sensor Replace the injector Replace the throttle position sensor Replace the sub throttle position sen sor Replace the intake air pressure sensor Replace the coolant temperature sen sor Replace the intake air temperature sensor 24 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Replace the ECU NG 8 36 FUEL INJECTION SYSTEM Properly connect or repair the ignition system s wiring FUEL INJECTION SYSTEM EAS27350 ECU SELF DIAGNOSTIC FUNCTION The ECU is equipped with a self diagnostic function in
252. hten the connecting rod bolt while checking that the sections shown and b are flush with each other by touching the surface NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment a Side machined face b Thrusting faces 4 places at front and rear 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 AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAA 10 Install Piston assemblies 1 into the cylinder NOTE While compressing the piston rings with one hand install the connecting rod assembly into the cylinder with the other hand 5 79 CRANKSHAFT ECA14980 CAUTION Tighten the connecting rod bolts using the plastic region tightening angle method a Clean the connecting rod bolts b Tighten the connecting rod bolts Puta mark 1 on the connecting rod bolt 2 and the connecting rod cap 3 2 me d 11 Install Cylinder assembly 1 5 Connecting rod caps 2 NOTE Make sure that the Y marks on the con 3 necting rods face towards the left side of the crankshaft Make sure that the characters on both the d Tighten the bolt further to reach the speci connecting rod and connecting rod cap are fied angl
253. i function meter unit The multi function meter unit is equipped with the following a speedometer which shows the riding speed a tachometer which shows engine speed an odometer which shows the total distance traveled two tripmeters which show the distance trav eled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled since the left segment of the fuel meter started flashing a clock a fuel meter a coolant temperature display an air intake temperature display a self diagnosis device an LCD and tachometer brightness control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET buttons For the U K only To switch the speedometer and odometer tripmeter displays between INSTRUMENT FUNCTIONS kilometers and miles press the SELECT button for at least one second Tachometer 1 Tachometer 2 Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachome ter needle will sweep once across the r min range and then return to zero r min in order to test the electrical circuit EC2D1007 CAUTION Do not operate the engine in the tachome ter red zone Red zone 12000 r min and above Clock mode RESET SELECT 1 Clock 2 Speedometer The clock is displayed whe
254. icator SELECT 10 INSTRUMENT FUNCTIONS light will flash and then the display will indicate a two digit error code e g 51 52 53 NOTE If the display indicates error code 52 this could be caused by transponder interference If this error code appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobilizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interference which may prevent the engine from starting 2 If the engine starts turn it off and try start ing the engine with the standard keys 3 If one or both of the standard keys do not start the engine take the vehicle the code re registering key and both standard keys to a Yamaha dealer and have the standard keys re registered If the display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle EC2D1012 CAUTION If the display indicates an error code the vehicle should be checked as soon as pos sible in order to avoid engine damage LCD and tachometer brightness control mode 1 Tachometer panel 2 Tachometer needle 3 LCD 4 Brightness level This function allows you to adjust the bright ness of the LCD and the tachometer panel and needle to suit the outside lighting
255. ift drum Check Transmission gears Blue discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s EAS26280 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 5 91 ET2D1022 INSTALLING THE TRANSMISSION 1 Install Bearing 1 NOTE Make the seal side of bearing face to the out side and install it close to the right end face of the crankcase Oil pipe 2 2 Install Main axle assembly 1 Bearing housing 2 Bearing housing bolt 12 Nm 1 2 m kg 8 7 ft Ib LOCTITE Shift fork Shift drum assembly Shift fork guide bar e Shift fork guide bar retainer Shift fork guide bar retainer bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITEG NOTE The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence OE Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle TRANSMISSION 3 Install Shift fork L 1 and R 2 Drive axle assembly 3 Shift fork guide bar Shift fork guide bar retainer 4 Shift fork guide ba
256. ight 52 Meter light 53 Oil level switch 54 Right handlebar switch 55 Front brake light switch 56 Engine stop switch 57 Start switch 58 Rear brake light switch 59 Left handlebar switch 60 Clutch switch 61 Pass switch 62 Dimmer switch 63 Hazard switch 64 Turn signal switch 65 Horn switch 66 Horn 67 Turn signal relay 68 Front turn signal light left 69 Front turn signal light right 70 Rear turn signal light left 71 Rear turn signal light right 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight relay on off 77 Fuse tail light 78 Fuse ingition 79 Anti safety alarm option 80 Fuse signal 81 Fuse headlight 82 Radiator fan motor relay 83 Fuse radiator fan motor left 84 Fuse radiator fan motor right 85 Radiator fan motor left 86 Radiator fan motor right 87 Ground EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue Lg Light green Pink R Red Sb Sky blue W White Y Yellow B G Black Green B L Black Blue B R Black Red B W Black White B Y Black Yellow Br G Brown Green Br L Brown Blue Br R Brown Red Br W Br Y G B G R G W G Y Gy G Gy R L B L R L W L Y O B O G O Y P B P W R B R G R L R W R Y Sb W W B W R W Y Y B Y G Y L Y R Y W Brown White Brown Yellow Green Black Green Red Green White Green Yellow
257. imit Lateral wheel runout limit 1 0 mm 0 04 in 0 5 mm 0 02 in Rear wheel Wheel type Rim size Rim material Wheel travel Radial wheel runout limit Lateral wheel runout limit Cast wheel 17M C x MT6 00 Aluminum 130 0 mm 5 12 in 1 0 mm 0 04 in 0 5 mm 0 02 in Front tire Size Manufacturer model Manufacturer model Wear limit front 120 70 ZR17M C 58W MICHELIN Pilot Road S DUNLOP D221FA 0 8 mm 0 03 in Rear tire Size Manufacturer model Manufacturer model Wear limit rear 190 50 ZR17M C 73W MICHELIN Pilot Road D DUNLOP D221G 0 8 mm 0 03 in Tire air pressure measured on cold tires Loading condition Front Rear Loading condition Front Rear High speed riding Front Rear 0 90 kg 0 198 Ib 250 kPa 36 psi 2 50 kgf cm 2 50 bar 290 kPa 42 psi 2 90 kgf cm 2 90 bar 90 196 kg 198 432 Ib FZ1 N 90 190 kg 198 419 Ib FZ1 S 250 kPa 36 psi 2 50 kgf cm 2 50 bar 290 kPa 42 psi 2 90 kgf cm 2 90 bar 250 kPa 36 psi 2 50 kgf cm 2 50 bar 290 kPa 42 psi 2 90 kgf cm 2 90 bar Front brake Type Operation Front brake lever free play Front disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness inner Limit Brake pad lining thickness outer Limit Dual disc brake Right hand operation 2 3 11 5 mm 0 09 0 45 in 320 0 x 4 5 mm 12 60 x 0 18 in 4 0 mm
258. inder reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT4 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 chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock 4 29 FRONT BRAKE ECA13540 CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 7 Check Brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22490 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE Before removing the front brake master cylin der drain the brake fluid from the entire brake system 1 Disconnect Brake switch couplers 1 from the bra
259. ing 2 Check Thermostat housing cover 1 6 8 THERMOSTAT Thermostat housing 2 Cracks damage Replace EAS26460 ASSEMBLING THE THERMOSTAT ASSEM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 RM Thermostat housing cover 4 IN Thermostat housing cover nut 2 10 Nm 1 0 m kg 7 2 ft lb NOTE Install the thermostat with its breather hole a facing up EAS26480 INSTALLING THE THERMOSTAT 55 BLY 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure THERMOSTAT Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 6 9 WATER PUMP EAS26500 WATER PUMP Removing the impeller shaft 112 Nm 1 2 m kg 8 7 ft Ib Job Parts to remove Remarks Oil water pump assembly Refer to OIL PUMP on page 5 58 Oil pump roter Refer to OIL PUMP on page 5 58 Water pump cover O ring Pin Impeller shaft along with the impeller Water pump seal Oil seal Bearing O ring AI lt N For installation reverse the removal procedure
260. ing bolt locknut Pivot shaft nut washer Pivot shaft Swingarm 4 65 SWINGARM Removing the swingarm 105 Nm 10 5 76 ft Ib 17 Nm 0 7 m kg 5 1 ft Ib Job Parts to remove Remarks Drive chain Dust cover Drive chain guide Spacer Bearing For installation reverse the removal procedure 4 66 EAS23350 REMOVING THE SWINGARM 1 Stand the vehicle on a level surface EWA13120 A WARNING Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove Relay arm to swingarm bolt 1 Connecting arm bolt 2 Rear shock absorber assembly lower bolt When removing the rear shock absorber assembly lower bolt hold the swingarm so that it does not drop down 3 Measure Swingarm side play Swingarm vertical movement VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Measure the tightening torque of the pivot shaft nut Pivot shaft nut 105 Nm 10 5 m kg 76 ft lb b Measure the swingarm side play A by moving the swingarm from side to side c Ifthe swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swingarm 1 0 mm 0 04 in d Check the swingarm vertical movement B by moving the swin
261. ing dogs will cause erratic clutch operation CLUTCH 2 Check Bearing Damage wear Replace the bearing and clutch housing EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause erratic clutch operation EAS25170 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 Cracks damage Replace Bearing 2 Damage wear Replace EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check CLUTCH Pull lever shaft pinion gear teeth 1 Pull rod teeth 2 Damage wear gt Replace the pull rod and pull lever shaft pinion gear as a set 3 Install 1 Wire circlip 1 2 11412102 2 Check Pull rod bearing Damage wear Replace 6 4 Install Clutch housing 1 NOTE INSTALLING THE CLUTCH Align the projection of clutch housing a and 1 Install hollow of the oil pump drive gear e Clutch damper spring seat 1 Clutch damper spring 2 5 Install Thrust plate e Clutch boss assembly 1 Washer e Clutch boss nut 2 TM Clutch boss nut Ww Qi 95 Nm 9 5 m kg 69 ft lb 2 Install Friction plate 3 1 Clutch plate 2 2 NOTE Lubricate the engine oil NOTE Install the washer on the main axle with the
262. int rod moving parts Shift pedal pivoting parts Rear footrest ball and metal to metal moving parts Centerstand metal to metal moving parts FZ1 S Front wheel oil seal left and right Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface 2 22 LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART o 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil strainer Oil pump Relief valve Oil cooler Oil filter Main gallery AC magneto drive gear shower Shift fork upper 9 Main axle 10 Mission shower 11 Drive axle 12 AC magneto axle 13 Piston cooler 14 Chain tensioner 15 Intake camshaft 16 Exhaust camshaft 2 24 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 92 NA UR E UST N 4 53 2 _ X j M Intake camshaft Exhaust camshaft Oil filter cartridge Oil level switch LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 Intake camshaft Exhaust camshaft Crankshaft Oil cooler Relief valve Cil pipe
263. is circuit is OK NG 8 20 LIGHTING SYSTEM Replace the headlight relay Replace the headlight relay Properly connect or repair the lighting system s wiring SIGNALING SYSTEM SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM EAS27270 re T eem m zur US GB 198 1981 Et z a 2 at fa te Ho 1 Ao Ert gt anra 1 o E p m __ 8 1 ee ER WW ea ee oo 8 21 1 Main switch 6 Fuse main 7 Battery 11 Relay unit 14 Neutral switch 16 Fuel pump 19 Speed sensor 23 ECU 4
264. is supplied The injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor coolant temperature sensor speed sensor and sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft posi tion sensor As a result the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions Illustration is for reference only 6 LUE ef 00 ECU engine control unit Intake air temperature sensor Throttle position sensor Sub throttle position sensor sensor 9 Catalytic converter 10 Coolant temperature sensor 11 Crankshaft position sensor 12 Intake air pressure sensor Fuel pump 13 Throttle body Fuel injector 14 Air filter case Ignition coil A Fuel system B Air system C Control system ET2D1002 INSTRUMENT FUNCTIONS Multi function meter unit Coolant temperature display air intake tem perature display Speedometer Tachometer Odometer tripmeter fuel reserve tripmeter SELECT button RESET button Clock 8 Fuel meter EW2D1005 Be sure to stop the vehicle before making any setting changes to the mult
265. itch 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 NOTE Each standard key is registered during production therefore re registering at purchase is not neces sary Parts to be replaced Main switch immo Key registration bilizer unit Standard ECU requirement Main Immobi key y 4 switch lizer unit Standard key is lost Pow New standard key 8 81 IMMOBILIZER SYSTEM Parts to be replaced Main switch immo bilizer unit Standard Main Immobi key switch lizer unit All keys have been Code re registering lost including code key and standard re registering key keys Code re registering ECU is defective key and standard keys Code re registering key and standard keys Code re registering key and standard keys Acces Key registration sory lock requirement and key Immobilizer unit is defective Main switch is defec tive Accessory lock is defective No required Accessory locks mean the seat lock fuel tank cap or the helmet holder Code re registering key registration When the immobilizer unit or ECU is replaced the code re registering key must be registered to the unit To register a code re registering key 1 Turn the main switch to ON w
266. ith the code re registering key NOTE Check that the immobilizer system indicator light comes on for one second then goes off When the immobilizer system indicator light goes off the code re registering key has been registered 2 Check that the engine can be started 3 Register the standard key following the instructions in the section below 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 immobilizer system is still enabled 8 82 IMMOBILIZER SYSTEM Standby mode 30s 24h a pm M a Main switch d LED off b Main switch OFF e Standby mode on LED on f Standby mode off Standard key registration Standard key registration is required when a standard key is lost and needs to be replaced or when the code re registering key is re registered after the immobilizer unit or ECU are replaced NOTE Do not start the engine with a standard key that has not been registered If the main switch is turned with a standared key that has not been registered the immobilizer system indicator light flashes to indicate fault code 52 Refer to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 85 1 Check that t
267. ke switch 2 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage 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 Replace 3 Check Brake master cylinder reservoir Cracks damage Replace Brake master cylinder reservoir diaphragm Damage wear gt Replace 4 Check Brake hoses Cracks damage wear Replace FRONT BRAKE EAS22520 ASSEMBLING THE FRONT BRAKE MAS TER CYLINDER EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid e Never use solvents on internal brake components Recommended fluid DOT4 EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder bracket 2 Brake master cylinder bracket bolt 4 30 10 Nm 1 0 m kg 7 2 ft Ib NOTE Install the brake master cylinder holder with the UP mark a facing up Align the end of the brake master cylinder holder with the punch mark b on the han d
268. lb Wheel axle pinch bolt INS Wheel axle pinch bolt 23 Nm 2 3 m kg 17 ft lb ECA14140 CAUTION Before tightening the front wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly 6 Install Brake caliper Brake caliper bolt 40 Nm 4 0 m kg 29 ft Ib EWA13490 Make sure the brake cable is routed prop erly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers onto the brake discs 4 13 FRONT WHEEL REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 27 Nm 2 7 m kg 20 ft lb 22 Nm 2 2 m kg 16 16 Job Parts to remove Remarks Rear brake caliper Locknut left and right Adjusting bolt left and right Wheel axle nut Washer Rear wheel axle Adjusting block left Adjusting block right Rear wheel Brake caliper bracket Loosen Loosen Oo A N For installation reverse the removal procedure 4 14 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 Nm 3 0 22 ft lb Job Parts to remove Remarks Rear brake disc Rear wheel sprocket Coller left and right Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel A
269. le on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube 1 Damage scratches Replace Oil seal 2 Oil leakage Replace 5 amp 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK on page 4 48 EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs NOTE Each front fork leg is equipped with a spring preload adjusting bolt the right front fork leg is equipped with a reboumd damping force adjusting screw and left front fork leg with a compression damping force adjusting screw 3 29 CHASSIS EWA13150 Always adjust both front fork legs evenly Uneven adjustment can result in poor handling and loss of stability Securely support the vehicle so that there is no danger of it falling over Spring preload ECA13570 CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions Adjust e Spring preload WWWVVVVVVVVVVVVVVVVYVVYVYVYVVYYVYY a Turn the adjusting bolt 1 in direction a or 1 Direction Spring preload is increased suspension is harder
270. le position sensor angle tighten the throttle position sensor screws MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA THROTTLE BODIES ET2D1024 ADJUSTING THE SUB THROTTLE POSI TION SENSOR 1 Check Sub throttle position sensor Refer to CHECKING THE SUB THROT TLE POSITION SENSOR on page 8 110 2 Adjust Sub throttle position sensor full open angle Turn the nut 1 of the worm shaft of the sub throttle counterclockwise until it con tacts with the full open stopper b When the dimension of sections of the throttle bodies 3 and 4 is measured with a micrometer caliper adjust with the adjuster 2 of the output shaft section of the sub throttle servo motor so that the dimension is in a range from 24 2 to 24 6 mm 0 95 to 0 97 in Sub throttle dimension 24 2 24 6 mm 0 95 0 97 in c After adjusting the dimension of a sec tions of the throttle bodies 3 and 4 mea sure the dimension of sections of 1 and 2 d If the dimension of a sections of the throt tle bodies 1 and 2 is different from the dimension of a sections of the throttle bodies 3 and 4 adjust it to the same dimension as the measurement value adjusted for the throttle bodies 3 and 4 using the tuning screw 3 located between the throttle bodies 2 and 3
271. lebar 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 brake master cylinder bracket Also the punch mark should be seen a 2 Install Copper washers NM Brake hose Union bolt NS Brake hose union bolt 30 Nm 3 0 m kg 22 ft Ib EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 NOTE While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary EC2D1004 CAUTION Attach the brake hose so that its angle is 23 to 33 against the straight line in paral lel with the ceiling plane of the master inder 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid Recommended fluid DOT4 EWA13540 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 chemical reaction leading to poor brake perfor mance FRONT BRAKE When refilling be careful that water does not enter t
272. lignment adjust both sides evenly d Tighten both locknuts to specification Locknut 16 Nm 1 6 m kg 12 16 e Tighten the wheel axle nut to specification EN Wheel axle nut 150 Nm 15 m kg 108 ft Ib MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D10 08 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained prop erly it will wear out quickly Therefore the drive chain should be serviced especially when the vehicle is used in dusty areas This vehicle has a drive chain with small rub ber O rings between each side plate Steam cleaning high pressure washing certain sol vents and the use of a coarse brush can dam age these O rings Therefore use only kerosene to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain sol vents that could damage the O rings Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EAS21510 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs
273. ls the engine trou ble warning light Injector 4 Actuates the injector 4 five Check the operating sound times at one second inter of the injector 4 five times vals Illuminates the engine trou ble warning light Air induction system sole Actuates the Air induction Check the operating sound noid system solenoid five times at of the Air induction system one second intervals solenoid five times Illuminates the engine trou ble warning light Fuel injection system relay Actuates the fuel injection Check the operating sound system relay five times at of the fuel injection system one second intervals relay five times the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Radiator fan motor relay Actuates the radiator fan Check the operating sound motor relay five times at one of the Radiator fan motor second intervals ON 2 sec relay five times onds OFF 3 seconds the engine trou ble warning light Headlight relay Actuates the headlight relay Check the operating sound for five times every five sec of the headlight relay five ond ON 2 seconds OFF 3 times seconds Illuminates the engine trou ble warning light Exup servo motor Actuate the servo motor turns Check the operating sound to close side and to open of the EXUP servo motor
274. lve is moved smoothly replace the EXUP servo motor Perform the self diagnosis mode and check the operation of EXUP valve by visual inspection Code No 53 The operation should be carried out as 3 second drive in the full open direction 2 second stop and 3 second drive in the full close direction Check that the EXUP servo motor pulley rotates several times EXUP valve pulley cover bolt 14 Nm 1 4 m kg 10 ft Ib MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Check Coolant level The coolant level should be between the maximum level mark a and minimum level mark Below the minimum level mark Add the recommended coolant to the proper level ECA13470 CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used pa 3 Start the engine warm it up for several minutes and then turn it off 4 Check Coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS21120 CHECKING THE COOLING SYSTEM 1 Check Radiator 1 R
275. m 0 0012 0 0026 0 80 x 2 75 mm 0 03 x 0 11 in 0 30 0 45 mm 0 0118 0 0177 in 0 020 0 055 mm 0 0008 0 0022 in 1 50 x 2 25 mm 0 06 x 0 09 in 0 10 0 40 mm 0 0039 0 0157 in Connecting rod Oil clearance using plastigauge Bearing color code 0 034 0 058 mm 0 0013 0 0023 1 Blue 2 Black 3 Brown 4 Green Crankshaft Width A Width B Runout limit C Big end side clearance D 55 20 56 60 mm 2 173 2 228 298 75 300 65 11 76 11 84 0 030 mm 0 0012 0 160 0 262 0 0063 0 0103 Journal oil clearance using plastigauge Bearing color code ENGINE SPECIFICATIONS 0 014 0 037 mm 0 0006 0 0015 in 0 White 1 Blue 2 Black 3 Brown 4 Green Clutch Clutch type Clutch release method Clutch lever free play Friction plate thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring free length Spring quantity Wet multiple disc Outer pull rack and pinion pull 10 0 15 0 mm 0 39 0 59 2 90 3 10 0 114 0 122 2 80 0 1102 9 pcs 1 90 2 10 mm 0 075 0 083 in 8 pcs 0 10 mm 0 0039 in 52 50 mm 2 07 in 6 pcs Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd 4th 5th 6th Main axle runout limit Drive axle runout limit Constant
276. mis sion is in gear retracting the sidestand If the transmis sion is in neu tral reconnecting the wiring Fault code No H FUEL INJECTION SYSTEM voltage differ greatly When the main switch is turned to ON the atmospheric Symptom pressure sensor voltage and intake air pressure sensor Atmospheric pressure sensor Diagnostic code No Intake air pressure sensor Orde r Item components and probable cause Defective intake air pressure sensor or atmospheric pressure sensor Check or maintenance job Execute the diagnostic mode Code Nos 02 03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 112 or CHECKING THE ATMO SPHERIC PRESSURE SEN SOR on page 8 111 Reinstatement method Turning the main switch to ON Fault code No Symptom Coolant temperature sensor open or short circuit detected Diagnostic code 06 Coolant temperature sensor Order Item components and probable cause Connections Coolant temperature sensor coupler Main wire harness ECU coupler e Sub wire harness coupler Check or maintenance job Check the coupler for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Be
277. n repair it and connect the coupler securely Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 3 ignition coil coupler and ECU coupler Red Black Red Black Orange Green Orange Green Defective cylinder 3 ignition coil Execute the diagnostic mode Code No 32 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNITION COILS on page 8 103 8 62 Reinstatement method Starting the engine and operating it at idle Fault code No 36 Symptom FUEL INJECTION SYSTEM 4 ignition coil Open circuit detected in the primary lead of the cylinder Diagnostic code 33 Cylinder 4 ignition coil Order Item components and probable cause Connections Cylinder 4 ignition coil coupler Main wire harness ECU coupler Sub wire harness 1 coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness and or sub wire harness 1 Repair or replace if there is an open or short circuit Between cylinder 4 ignition coil coupler and ECU coupler Red Black Red Black Gray Green Gray Green Defective cylinder 4 igniti
278. n this malfunction is detected in the ECU the fault code number might not appear on the meter Malfunction in ECU The program and data are not properly written on or read from the internal memory No signals are received from the ECU Open or short circuit in wire harness Malfunction in meter Defective wire connection of the ECU cou pler Malfunction in ECU 8 45 Symptom No signals are received from the ECU within the specified duration FUEL INJECTION SYSTEM Probable cause of malfunction Improper connection in wire harness Malfunction in meter Malfunction in ECU Diagnostic code No Data from the ECU cannot be received correctly Improper connection in wire harness Malfunction in meter Malfunction in ECU Non registered data has been received from the meter Sensor operation table Diag nostic code No Throttle position sensor sig nal Fully closed position Fully opened position Improper connection in wire harness Malfunction in meter Malfunction in ECU Meter display 15 18 95 100 Checking method Check with throttle valve fully closed Check with throttle valve fully opened Atmospheric pressure Displays the atmospheric pressure Compare the actually mea sured atmospheric pres sure with the meter display value Intake air pressure Displays the cylin
279. n page 7 4 2 Check Throttle body joints 1 Cracks damage Replace 3 Install Throttle bodies Refer to THROTTLE BODIES on page 7 4 EAS21030 CHECKING THE FUEL LINE The following procedure applies to all of the fuel vacuum and breather hoses ENGINE 1 Remove Rider and passenger 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 hose 3 Cracks damage Replace Loose connection Connect properly NOTE Before removing the fuel hoses place a few rags in the area under where it will be removed ECA14940 CAUTION Make sure the fuel tank breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 ECS2D002 CAUTION To install the fuel tank check that the breather hose is not folded or pinched by the fuel tank EAS21070 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 15 Fuel tank 3 16 Refer to FUEL TANK on page 7 1 2 Check Crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly ECA13450 CAUTION Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to F
280. n spring force exhaust Spring tilt intake Spring tilt exhaust zu Winding direction intake Winding direction exhaust 40 47 mm 1 59 in 40 53 mm 1 60 in 32 66 mm 1 29 in 33 88 mm 1 33 in 17 53 N mm 100 10 Ib in 1 79 kgf mm 22 86 N mm 130 53 Ib in 2 33 kgf mm 21 52 N mm 122 88 Ib in 2 19 kgf mm 27 99 N mm 159 82 Ib in 2 85 kgf mm 127 40 144 60 28 64 32 51 Ib 12 99 14 74 kgf 133 00 153 00 29 90 34 39 Ib 13 56 15 60 kgf 2 5 1 8 mm 2 5 1 8 mm Clockwise Clockwise Cylinder Bore Taper limit Out of round limit 77 000 77 010 mm 3 0315 3 0319 in 0 050 mm 0 0020 in 0 050 mm 0 0020 in Piston Piston to cylinder clearance Limit Diameter D Height H 2 4 0 010 0 035 mm 0 0004 0 0014 in 0 12 mm 0 0047 in 76 975 76 990 mm 3 0305 3 031 1 in 5 0 mm 0 20 in Offset Offset direction Piston pin bore inside diameter Piston pin outside diameter ENGINE SPECIFICATIONS 0 50 mm 0 0197 in Intake side 17 002 17 013 mm 0 6694 0 6698 16 991 17 000 0 6689 0 6693 Piston ring Top ring Ring type Dimensions B x T End gap installed Ring side clearance 2nd ring Ring type Dimensions B x T Nie End gap installed Ring side clearance Oil ring Dimensions B x T ER End gap installed Barrel 0 90 x 2 75 mm 0 04 x 0 11 in 0 15 0 25 mm 0 0059 0 0098 in 0 030 0 065 m
281. n switch to ON c Measure the turn signal hazard relay input voltage 2 Check signal hazard relay output voltage Out of specification Replace Turn signal hazard relay output voltage DC 12 V ET2D1030 CHECKING THE TURN SIGNAL HAZARD RELAY 1 Check Turn signal hazard relay input voltage Out of specification The wiring circuit from the main switch to the turn signal haz ard relay coupler is faulty and must be repaired Turn signal hazard relay input voltage DC 12V VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt Blue Red 1 Negative tester probe Ground WWWVVVVVVVVVVVVVYVVVYVVYVYVYVYVYVYVYY a Connect the pocket tester DC 20 V to the turn signal hazard relay terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe gt Brown White 1 Negative tester probe gt Ground LU N L R 1 b Turn the main switch to ON c Measure the turn signal hazard relay out put voltage MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D1021 CHECKING THE RELAY UNIT DIODE 1 Check Relay unit diode Out of specification
282. n the key is turned to ON In addition the clock can be displayed for 10 seconds by pushing the SELECT but ton when the main switch is in the OFF or LOCK position To set the clock 1 Turn the key to ON 2 Push the SELECT button and RESET button together for at least two seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the min utes 6 Push the SELECT button and then release it to start the clock Odometer and tripmeter modes Lo c m 25 RESET sELECT 1 Odometer tripmeter fuel reserve tripmeter Push the SELECT button to switch the dis play between the odometer mode ODO and the tripmeter modes TRIP A and TRIP B in the following order TRIP A gt TRIP B gt ODO gt TRIP When the fuel amount in the fuel tank decreases to 3 4 L 0 90 US gal 0 75 Imp gal the left segment of the fuel meter will start flashing and the odometer display will automatically change to the fuel reserve trip meter mode FTRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the dis play between the various tripmeter and odom eter modes in the following order F TRIP TRIP A gt TRIP B gt ODO TRIP To reset a tripm
283. nction is detected in the ECU the fault code number might not appear on the meter DagnosiccodeNo lt o o Symptom Item components and probable cause Malfunction in ECU Check or maintenance job Replace the ECU NOTE Do not perform this procedure with the main switch turned to ON Reinstatement method Turning the main switch to ON 8 72 Diagnostic code Order Item components and probable cause Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Sub wire harness coupler FUEL INJECTION SYSTEM Fault code No Eri Symptom No signals are received from the ECU Check or maintenance job e Check the couplers for any pins that may be pulled out e Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between meter assembly cou pler and ECU coupler Yellow Blue Yellow Blue Malfunction in meter assembly Replace the meter assembly Fault code No Er 2 Symptom DiagnosiccodeNo oO oOo _ Order Malfunction in ECU Item components and probable cause Connections Main wire harness ECU coupler Main wire harness meter assembly coupler Sub wire harness coupler Replace the ECU duration
284. nd washer Clutch thrust plate Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft J Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 Clutch cover crankcase mating surface Yamaha bond No 1215 Generator rotor cover crankcase mating surface Yamaha bond No 1215 2 20 LUBRICATION POINTS AND LUBRICANT TYPES Pickup rotor cover Yamaha bond No 1215 2 21 LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races upper and lower Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Engine mount bolts rear upper and lower Engine mount bolts front left and right Relay arm connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber Seat lock assembly moving parts Sidestand pivoting point and metal to metal moving parts Sidestand switch contact point Sidestand hook and spring contact point Shift shaft jo
285. ne cylinder is defective the display changes every two seconds to show all the detected cyl inder numbers When all cylinder numbers are shown the display repeats Malfunction history code No history 00 History exists Fault codes 11 50 If more than one code number is detected the dis play changes every two seconds to show all the detected code numbers When all code numbers are shown the display repeats Malfunction history code erasure No history 00 e History exists Fault codes 01 28 To erase the history set the e If more than one code engine stop switch to 004 number is detected the dis play alternates every two seconds to show all the detected code numbers When all code numbers are shown the display repeats the same process 8 47 Diag nostic code No Malfunction code reinstate No mulfunction code e Malfunction code exists FUEL INJECTION SYSTEM Meter display 00 Fault code 24 If more than one code number is detected the dis play changes every two seconds to show all the detected code numbers When all code numbers are shown the display repeats Checking method To reinstate set the engine stop switch to 004 Actuator Diag nostic code No Control number operation table Cylinder 1 ignition coil 0 255 Actuation Actuates the cylinder 1 igni tion coil five times at one sec ond inter
286. ng the engine 45 Nm 4 5 m kg 33 ft lb ENGINE REMOVAL YN ATA IES 17 Nm 0 7 m kg 5 1 ft lb Job Parts to remove Right front engine mounting bolt 1 Remarks Left front engine mounting bolt Upper self locking nut Upper engine mounting bolt Lower self locking nut Lower engine mounting bolt Engine mounting adjust bolt Engine For assembly reverse the removal procedure EAS23720 INSTALLING THE ENGINE 1 Install Right front engine mounting bolt 2 1 Refer to CYLINDER HEAD on page 5 19 V ndr 2 Tighten Right front engine mounting bolt 2 a Right front engine mounting bolt 2 50 Nm 5 0 m kg 36 ft Ib 3 Install Engine mounting adjust bolts temporarily tighten Install Engine Install Lower engine mounting bolt 1 Upper engine mounting bolt 2 Self locking nuts NOTE 4 5 Do not fully tighten the bolts and nuts 6 Install Left front engine mounting bolt 1 temporarily tighten Right front engine mounting bolt 1 2 temporarily tighten 5 8 ENGINE REMOVAL 7 Tighten Engine mounting adjust bolts Engine mounting adjust bolt 7 Nm 0 7 m kg 5 1 ft Ib NOTE Use the pivot shaft wrench 1 and pivot shaft wrench adapter
287. ngy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 6 Adjust Brake pedal position Refer to ADJUSTING THE REAR DISC BRAKE on page 3 22 7 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 24 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm 2 6 19 ft lb 5 5182 Nm 3 2 m kg 23415 4 Nm 0 4 m kg 2 9 116 26 Nm 2 6 19 ft lb Job Parts to remove Remarks Front cowling FZ1 S Refer to GENERAL CHASSIS on page 4 1 Rear view mirror FZ1 N Front brake light switch connector Front master cylinder bracket Front brake master cylinder assembly Right handlebar switch Throttle cable housing Throttle cable Grip end Throttle grip Clutch cable Handlebar grip Left handlebar switch Clutch lever holder Upper handlebar holder Disconnect O S S PO Po 4 43 HANDLEBAR Removing the handlebar Job Parts to remove Remarks 15 Handlebar 16 Lower handlebar holder For installation reverse the removal procedure 4 44 EAS22860 REMOVING THE HANDLEBAR 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Handlebar gri
288. ntake valve spring 12 6 Intake valve stem seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve stem seal 8 5 22 VALVES AND VALVE SPRINGS Removing the valves and valve springs Job Parts to remove Remarks Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation reverse the removal procedure 5 23 EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components NOTE Before removing the internal parts of the cylin der head e g valves valve springs valve seats make sure the valves properly seal 1 Remove Valve lifter 1 Valve pad 2 NOTE Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 11172202 2 Check Valve sealing Leakage at the valve seat gt Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS on page 5 26 WWWVVVVVVVVVVYVVVYVVVVVVVVYVYVYVYY a Pour a clean solvent into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 4 A 11171401 AA
289. ntinually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE This Service Manual contains information regarding periodic maintenance to the emission control system Please read this material carefully Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator a bystander or a person checking or repairing the vehicle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy easy to read reference book for the mechanic Comprehensive explanations of all installation removal disassembly assembly repair and check procedures are laid out with the individual steps in sequential order The manual is divided into chapters and each chapter is divided into sections The current section title is shown at the top of each page 1
290. o exposure of bare con ductors due to the misalignment of tubes Route the AC magneto lead by the inside of vehicle away from the water hose Clamp the clutch cable radiator fan motor lead left and water pump breather hose Point the clamp head to the upper side of the vehicle and fit it so that the band tip is positioned inside For the band position install the band using the engine position as a guide as shown in the illustration Insert the clamp to the frame and clamp the clutch cable For the clamping position place the clamp so that the caulking attachment on the clutch cable side is posi tioned at the vehicle front side where the clamp is located Clamp opening should be positioned at the outside of the vehicle The inserting direction of the onion head of the horn lead shall be as shown in the illus tration The front side of the vehicle The outside of the vehicle The upper side of the vehicle The inside of the vehicle Route the clutch cable under the convexity sections of the throttle bodies Route the radiator fan motor lead left between the convexity sections of the throt tle bodies Route the wire harness between the con vexity sections of the throttle bodies Innermost section of the vehicle Can be routed in any order AA Route the water pump breather hose finally in the guide after passing other hoses so that it can be positioned on the outside of the v
291. ode indication 1 Check the wire harness and con nector 2 Replace the immobilizer unit 3 Replace the ECU 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 8 86 IMMOBILIZER SYSTEM a b 2 1 1 15 1 z k 3 a Light on b Light off 8 87 IMMOBILIZER SYSTEM 8 88 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8 89 ONDARON Main switch immobilizer unit Front brake light switch Starter relay Battery Fuse box Rear brake light switch Neutral switch Sidestand switch 9 Oil level switch 10 Radiator fan motor 11 Horn 12 19 coil 8 90 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 8 91 ONOORWOND Coolant temperature sensor Intake air temperature sensor Intake air pressure sensor Fuel pump ECU Lean angle sensor Starting circuit cut off relay Headlight relay on off 9 Radiator fan motor relay 10 Turn signal relay 11 Recifier regulator 12 Throttle position sensor 13 Sub throttle position sensor 8 92 ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES pa ei ua ot au oz v a 912 bo are em mA Es ee Er m ce m d
292. of specification Replace Minimum ignition spark gap 6 0 mm 0 24 in VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Disconnect the spark plug cap from the spark plug b Connect the ignition checker dynamic spark tester 2 as shown Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 18110202 1 Spark plug cap Set main switch to ON d Measure the ignition spark gap e Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor Crankshaft position sensor resistance 336 504 at 20 C 68 F WWWVVVVVVVVVVVVVYVVVYVVYVYVVYVYVYVYYY 8 104 a Connect the pocket tester Q x 100 to the crankshaft position sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Gray 1 Negative tester probe Black 2 A Gy 2 1 b Measure the crankshaft position sensor resistance MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor 2 Check Lean angle sensor out put voltage Out of specification Repla
293. on coil Execute the diagnostic mode Code No 33 Test the primary and secondary coils for continuity Replace if defective Refer to CHECKING THE IGNITION COILS on page 8 103 8 63 Reinstatement method Starting the engine and operating it at idle FUEL INJECTION SYSTEM Fault code 39 Symptom Open circuit detected in a injector J 36 Injector 1 Diagnostic code No injector we Item components and probable cause Connections Injector coupler Main wire harness ECU coupler Sub wire harness coupler Injector 3 Injector 4 Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers f there is a malfunction repair it and connect the copler securely Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between primary injector cou pler and ECU coupler Red Blue Red Blue 1 Red Black Red Black 2 Green Black Green Black 3 Blue Black Blue Black 4 Orange Black Orange Black Defective primary injector Execute the diagnostic mode Code Nos 36 37 38 39 Replace if defective Refer to CHECKING THE INJECTORS on page 7 8 8 64 Reinstatement method Start the engine and operating it at idle FUEL INJECTION SYSTEM Fault code No 41 Symptom Lean angle sensor o
294. option of the FI system has resulted in a highly precise fuel supply improved engine response better fuel economy and reduced exhaust emissions 2017 982375 6 16 18 19 21 15 1 1413 1210 4 23 1 Ignition coil 14 Spark plug 2 Air filter case 15 Cylinder identification sensor 3 Intake air temperature sensor 16 Battery 4 Fuel delivery hose 17 ECU 5 Fuel tank 18 Atomospheric pressure sensor 6 Fuel pump 19 Relay unit fuel pump relay 7 Intake air pressure sensor 20 Engine trouble warning light 8 Throttle position sensor 21 Lean angle sensor 9 Sub throttle position sensor 22 Air cut off valve 10 Fuel injector 23 0 sensor 11 Catalytic converter 12 Crankshaft position sensor 13 Coolant temperature sensor FI SYSTEM ET2D1001 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa 3 24 kg cm 46 1 psi Accordingly when the energizing signal from the ECU energizes the fuel injector the fuel passage opens caus ing the fuel to be injected into the intake manifold only during the time the passage remain open Therefore the longer the length of time the fuel injector is energized injection duration the greater the volume of fuel that is supplied Conversely the shorter the length of time the fuel injector is ener gized injection duration the lesser the volume of fuel that
295. or 2 Outer rotor 3 Oil pump housing 4 NOTE When installing the inner rotor align the pin 1 in the oil pump shaft with the groove in the inner rotor 2 3 Install Oil water pump driven sprocket 1 Oil water pump driven sprocket bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITE NOTE 5VY mark of the oil water pump driven gear is installed at oil pump side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 62 EAS25030 INSTALLING THE OIL WATER PUMP ASSEMBLY 1 Install Oil ring MI Oil water pump assembly 1 Dowel pin Bolts 2 Oil water pump assembly bolt 12 Nm 1 2 m kg 8 7 ft Ib LOCTITEG OIL PUMP 2 Install Washer Oil water pump assembly drive chain 1 Oil water pump assembly drive sprocket 2 Collar NOTE Install the oil water pump assembly drive chain 1 onto the oil water pump assembly drive sprocket 2 EC2D1008 CAUTION After installing the oil water pump assem bly drive chain and drive sprocket make sure the oil water pump turns smoothly 3 Install Oil water pump assembly drive chain guide 4 Oil water pump assembly drive chain guide bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITE NOTE UP mark of the oil water pump assembly drive chain guide is upward 5 64 OIL PUMP EAS25050 4 Install INSTALLING THE OIL
296. or fan motor Reserve Reserve FZ1 N Reserve FZ1 S EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Rider and passenger seat EAS28030 CHECKING AND CHARGING THE BATTERY EWA13290 Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid Therefore always follow these preventive measures Wear protective eye gear when handling or working near batteries Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO NOT SMOKE when charging or dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate
297. orm this measurement at two or three dif ferent places 12345 67 8 910111213141516 CHAIN DRIVE 8 910111213141516 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain VVVVVVVVVVVVVVVVVVVVVVVVVVVVYVY a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it ECA14290 CAUTION 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 dirt or water into the drive chain s internals and solvents will deteriorate the O rings A coarse brush can also damage the O rings Therefore use only kerosene to clean the drive chain Do not soak the drive chain in kerosene for more than ten minutes otherwise the O rings can be damaged 4 70 12510201 4 Check O rings 1 Damage Replace the drive chain Drive chain rollers 2 Dama
298. ose connector cover Fuel hose Fuel sender coupler Fuel pump coupler Fuel tank breather hose Fuel tank drain hose EC2D1009 CAUTION Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses since there may be fuel remaining in it NOTE To remove the fuel hose from the fuel injec tion pipe slide the cover a on the end of the hose in the direction of the arrow shown and then remove the hose Before removing the hoses place a few rags in the area under where it will be removed t a 3 Remove Fuel tank NOTE Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump FUEL TANK ECA14720 CAUTION Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKING THE FUEL PUMP BODY 1 Check Fuel pump body Obstruction Clean Cracks damage Replace fuel pump assembly 2 Check Diaphragms and gaskets Turn fatigue cracks Replace fuel pump assembly 3 Check Valves Cracks damage Replace fuel pump assembly EAS26690 CHECKING THE FUEL PUMP OPERATION 1 Check Fuel pump
299. ose direction MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAT2D1004 CHECKING THE THERMO WAX 1 Check Thermo wax 1 Damage Replace the thermo wax assembly ET2D1025 ADJUSTING THE THERMO WAX 1 Adjust Thermo wax the end face distance a VVVVVVVVVVVVVVVVVVVVVVVVVVVVVYV THROTTLE BODIES a Before adjusting the distance push the rod b in order to be fitted in several times by hand b Measure the outside air temperature and adjust the distance a by turning the adjusting screw 2 Refer to the thermo wax tolerance table based on the mea sured outside air temperature for correct adjustment 17 2 0 677 17 0 669 16 8 0 661 16 6 0 654 16 4 0 646 16 2 0 638 16 0 630 15 8 0 622 mmi in 2 lt C F MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA NOTE Setup tolerance of the longitudinal axis should be 0 2 mm 0 008 in After adjusting the thermo wax check that the first idling is released at the coolant tem perature around 60 C 140 F by idling If the first idling is not released around 60 C 140 F make sure to set it again When the coolant temperature is low adjust the dis tance between the end faces longer or adj
300. ottle body synchronization VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a With throttle body 3 as standard adjust throttle bodies 1 2 and 4 using the air screw 1 NOTE After each step rev the engine two or three times each time for less than a second and check the synchronization again f the air screw is removed turn the screw 3 4 turn in and be sure to synchronize the throttle body EC2D1080 CAUTION Do not use the throttle valve adjusting screws to adjust the throttle body synchro nization Vacuum pressure at engine idling speed 30 kPa 225 mmHg 8 9 inHg NOTE The difference in vacuum pressure between two throttle bodies should not exceed 1 33 kPa 10mmHg 0 39 inHg 9 Measure Engine idling speed Out of specification Adjust Make sure that the vacuum pressure is within specification 10 Stop the engine and remove the measuring equipment 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 9 Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 12 0 20 12 Install Synchronizing hoses Fuel tank Refer to FUEL TANK on page 7 1 Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 EAS20600 ADJUSTING THE EX
301. p 1 NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar 3 Remove Throttle cable housing 1 Throttle grip 2 NOTE While removing the throttle cable housing pull back the rubber cover 3 EAS22880 CHECKING THE HANDLEBAR 1 Check Handlebar Bends cracks damage gt Replace 13690 Do not attempt to straighten bent handle bar as this may dangerously weaken it HANDLEBAR EAS22930 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holders 1 NOTE Temporarily tighten the nuts 2 3 Install Handlebar 1 Upper handlebar holder 2 Upper handlebar holder bolt 24 Nm 2 4 m kg 17 ft Ib ECA14250 CAUTION First tighten the bolts on the front side of the handlebar holder and then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position NOTE The upper handlebar holder should be installed with the punch mark facing for ward Align the match marks b on the handlebar with the upper surface of the lower handlebar holders 4 Tighten Lower handlebar holder nuts Lo
302. pen or short circuit detected Diagnostic code No 08 7 Leananglsenso C Order Item components and probable cause Connections Lean angle sensor coupler Main wire harness ECU coupler Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in lead Repair or replace if there is an open or short circuit Between lean angle sensor coupler and ECU coupler Blue Blue Yellow Green Yellow Green Black Blue Black Blue Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 105 8 65 Reinstatement method Turning the main switch to ON Fault code No n Diagnostic code No Order Symptom Item components and probable cause Installed state of speed sensor FUEL INJECTION SYSTEM sor Check or maintenance job Check for looseness or pinch ing Connections Speed sensor coupler Main wire harness ECU coupler e Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in lead Repair or replace if there is an open or s
303. pres sure in the fuel lines could cause fuel to spurt out when removing the hoses 7 8 THROTTLE BODIES c Connect the pressure gauge 2 and adapter 3 to the fuel hose fuel tank to pri mary injector fuel rail Vacuum pressure pump gauge set 90890 06756 Pressure gauge 90890 03153 YU 03153 Fuel pressure adapter 90890 03176 YM 03176 d Start the engine e Measure the fuel pressure Fuel pressure 324 kPa 46 1 psi 3 24 kg cm Faulty Replace the fuel pump MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS27020 ADJUSTING THE THROTTLE POSITION SENSOR NOTE Before adjusting the throttle position sensor the engine idling speed should be properly adjusted 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE POSITION SENSOR on page 8 109 2 Adjust Throttle position sensor angle WWWWVVVVVVVVVVVVVYYVVYVVVYVYVVYVVYYY a Connect the throttle position sensor cou pler to the wire harness b Connect the digital circuit tester to the throttle position sensor Positive tester probe yellow terminal 1 Negative tester probe black blue terminal 2 Digital circuit tester 2 90890 03174 2 1 Measure the throttle position sensor volt age d Adjust the throttle position sensor angle so the measured voltage is within the speci fied range Throttle position sensor voltage 0 63 0 73 V e After adjusting the thrott
304. procedure applies to all of the brake pads 1 Operate the brake 2 Check Rear brake pad Wear indicators b almost touch the brake disc Replace the brake pads as a set Refer to REAR BRAKE on page 4 32 b 3 23 EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Brake hose 1 Cracks damage wear Replace O 30 2 Brake hose clamp 2 Loose Tighten the clamp bolt LJ 00 N 3 Hold the vehicle upright and apply the front brake several times 4 Check Brake hose Brake fluid leakage Replace the dam aged hose Refer to FRONT BRAKE on page 4 20 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace CHASSIS 2 Check 3 24 Brake hose clamp 2 Loose Connection Tighten the clamp bolt P o 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 32 EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Ch
305. ption of the mal function The warning light flashes when any one of the conditions listed below is present and the start switch is pushed 11 Cylinder identification sensor 30 Lean angle sensor latch up detected 12 Crankshaft position sensor 41 Lean angle sensor open or short circuit 19 Sidestand switch 50 ECU internal malfunction open circuit in the wire to the ECU faulty ECU memory Checking the engine trouble warning light The engine trouble warning light comes on for 1 4 seconds after the main switch has been turned to ON and it comes on while the start switch is being pushed If the warning light does not come on under these conditions the warning light LED may be defective 8 37 FUEL INJECTION SYSTEM Main switch OFF Main switch ON Engine trouble warning light off Engine trouble warning light on for 1 4 sec onds ooomp ET2D1027 SELF DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illu minates the engine trouble warning light and provides the engine with alternate operating instruc tions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operatin
306. pump seal 1 DM ECA14080 CAUTION Never lubricate the water pump seal sur face with oil or grease 4 Measure NOTE Impeller shaft tilt Install the water pump seal with the special Out of specification Repeat steps 3 tools and 4 Bef 14090 efore installing the water pump seal apply CAUTION Yamaha bond No 1215 Three Bond No 1215 2 to the water pump housing Make sure the rubber damper and rubber 3 damper holder are flush with the impeller Mechanical seal installer 4 Y lt Impeller shaft tilt limit 90890 04078 0 15 mm 0 006 in Water pump seal installer YM 33221 A Middle driven shaft bearing driver 5 90890 04058 Bearing driver 40 mm YM 04058 Yamaha bond No 1215 Three Bond No 1215 2 90890 85505 1 Straightedge 2 Impeller 14150501 A Push down 3 Install Rubber damper holder 1 JEW Rubber damper 2 6 12 WATER PUMP FUEL SYSTEM FUEL TANK RR DOREM A eM 7 1 REMOVING THE FUEL TANK 7 2 REMOVING THE FUEL PUMP rt etre 7 2 CHECKING THE FUEL PUMP 0 7 2 CHECKING THE FUEL PUMP OPERATION 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL 7 3 THROTTLE BODIES eave
307. r oil ring rail Upper oil ring rail 2nd ring Oil ring expander Lubricate e Crankshaft pins Big end bearings Connecting rod big end inner surface with the recommended lubricant Recommended lubricant Engine oil 6 Check Cylinder stud bolts 1 NS Cylinder stud bolt 8 Nm 0 8 m kg 5 8 ft lb 7 Install Cylinder gasket 2 WM 8 Install Big end bearings onto the connecting rods and connecting rod caps NOTE Align the projections on the big end bear ings with the notches b in the connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure that the characters on both the connecting rod and connecting rod cap are aligned 11630301 9 Tighten Connecting rod bolts Connecting rod bolt 29 4 Nm 3 0 m kg 21 ft lb CRANKSHAFT NOTE Install by carrying out the following proce dures in order to assemble in the most suit able condition First tighten the bolts to 15 Nm 1 5 m kg 11 ft lb e Retighten the bolts to 29 4 Nm 3 0 m kg 21 ft lb VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Replace the connecting rod bolts with new ones b Clean the connecting rod bolts c After installing the big end bearing assem ble the connecting rod and connecting rod cap once using a single unit of the connect ing rod d Tig
308. r retainer bolt 10 Nm 1 0 m kg 7 2 ft Ib LOCTITEG NOTE Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Make sure that the drive axle bearing circlip is inserted into the grooves in the upper crankcase ele CO 200 I EU rcu i T f Ul TRANSMISSION 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly 5 93 COOLING SYSTEM exte tu en Iuda 6 1 m poete etre ee das 6 3 INSTALLING THE BADIATORH idet toi o er ttm b ep ense ie 6 3 OIL GOQUER EE 6 4 CHECKING THE OIL COOLER ehem ete tete een 6 5 INSTALLING THE OIL COOLEL aia Aenea 6 5 THERMOSTAT 6 6 CHECKING THE THERMOS AT Daten a 6 8 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP nori 6 10 DISASSEMBLING THE WATER 6 11 CHECKING THE WATER
309. r short circuit in wire harness Repair or replace if there is an open or short circuit Between sub throttle position sensor coupler and ECU cou pler Black Blue Black Blue Green Yellow Green Yellow Blue Blue Defective sub throttle position sensor Execute the diagnostic mode Code No 56 3 Replace if defective Refer to CHECKING THE SUB THROTTLE POSITION SENSOR on page 8 110 8 71 Diagnostic code 56 Order Item components and probable cause Connections e Sub throttle servo motor coupler Main wire harness ECU coupler FUEL INJECTION SYSTEM Fault code No 48 Symptom Subthrotile servo motorstuck Check or maintenance job Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sub throttle servo motor coupler and ECU coupler Yellow Red Yellow Red Yellow White Yellow White Fault code No Order Defective sub throttle servo motor Execute the diagnostic mode Code No 56 Replace if defective Refer to CHECKING THE SUB THROTTLE SERVO on page 7 10 Sub throttle servo motor Reinstatement method Turning the main switch to ON Faulty ECU memory When this malfu
310. r switch Replace the neutral switch Replace the sidestand switch Replace the clutch switch Replace the right handlebar switch Properly connect or repair the starting system s wiring CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM NOW Rectifier regulator A C magneto Fuse main Battery CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged NOTE Before troubleshooting remove the following part s CHARGING SYSTEM 1 Rider and passenger seat 1 Check the fuse Main Refer to CHECKING THE FUSES on page 8 97 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 106 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 106 Check the entire charging system s wiring Refer to CIRCUIT DIAGRAM on page 8 11 This circuit is OK NG NG gt NG gt NG 8 13 Replace the fuse Clean the battery terminals Recharge or replace the battery Replace the startor assembly Replace the rectifier regulator Properly connect or repair the charg ing system s wiring CHARGING S
311. rake hose 3 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22360 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Remove Brake caliper pistons 1 Brake caliper piston seals 2 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Secure the brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper EWA13570 Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 58 SOT de SEES c Remove the brake Le piston seals d Repeat the previous steps to force out the right side pistons from the brake caliper MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS22390 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replace ment schedule Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks damage Replace the brake cali per assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA1
312. rankshaft clockwise several full turns to seat the parts h Measure the valve clearance again i If the valve clearance is still out of specifi cation repeat all of the valve clearance adjustment steps until the specified clear ance is obtained 7 Install All removed parts NOTE For installation reverse the removal proce dure EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand 2 Remove Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Synchronizing hoses 1 4 Install Vacuum gauge 1 onto the synchronizing hose Digital tachometer near the spark plug Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 5 Install Fuel tank Refer to FUEL TANK on page 7 1 6 Start the engine and let it warm up for sev eral minutes 7 Check Engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 9 tes Engine idling speed 1 100 1 300 r min 8 Adjust ENGINE Thr
313. rcuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the battery AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 6 Install Battery 7 Connect Battery leads to the battery terminals ECA13630 CAUTION ee 2 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt gt Clean with a wire brush Loose connection Connect properly 9 Lubricate Battery terminals Recommended lubricant Dielectric grease 10 Install Rider and passenger seat ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the continuity reading is incor rect replace the relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Disconnect the relay from the wire harness 2 Connect the pocket tester O x 1 and bat tery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Positive battery terminal Negative battery terminal Positive tester probe Negative tester probe Amo Relay operation Continuity No continuity between 3 to 4 FZ1 N 1 Positive battery terminal 8 100 ELECTRICAL COMPONENTS 2 Negative battery terminal 4 Negative
314. re hose Disconnect Intake air pressure sensor 12 Fuel distributor Aj 13 Injector 14 Spring 1 Link cover N 15 Thermo wax assembly 16 Idle adjust screw wire 7 Loosen 18 Cotter pin 7 6 THROTTLE BODIES Removing the injectors Remarks reverse the removal For installation procedure Job Parts to remove Sub throttle servo motor assembly Throttle position sensor Throttle body assembly 21 22 23 7 7 EAS26980 CHECKING THE INJECTORS 1 Check Injectors Damage gt Replace EAS26990 CHECKING THE THROTTLE BODIES 1 Check Throttle bodies Cracks damage Replace the throttle bodies as a set 2 Check Fuel passages Obstructions Clean WWWVVVVVVVVVVYVYVVYVYVVYVVVVVVVYVYVYY a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution Blow out all of the passages with com pressed air MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D1033 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Remove the rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 Disconnect the fuel hose fuel tank to pri mary injector fuel rail 1 from the primary injector fuel rail EW2C01008 Cover fuel hose connections with a cloth when disconnecting them Residual
315. rk plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve 2 Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston 3 Air filter Improperly installed air filter Clogged air filter element 4 Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft Fuel system 1 Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel strainer Clogged fuel tank drain hose Clogged rollover valve hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel 9 1 TROUBLESHOOTING Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or secondary coils 5 Ignition system Faulty ECU Faulty crankshaft position sensor Switches and wiring Fault
316. rocedure 4 58 EAS23110 REMOVING THE LOWER BRACKET 1 Stand the vehicle on a level surface EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Remove Upper ring nut 1 Rubber washer Lower ring nut 2 Lower bracket NOTE Hold the lower ring nut with the ring nut wrench 3 and then remove the upper ring nut with the steering nut wrench 4 Ring nut wrench 90890 01268 Spanner wrench YU 01268 Steering nut wrench 90890 01403 Spanner wrench YU 33975 EWA13730 Securely support the lower bracket so that there is no danger of it falling EAS23120 CHECKING THE STEERING HEAD 1 Wash Bearings Bearing races Recommended cleaning solvent Kerosene 2 Check Bearings 1 Bearing races 2 STEERING HEAD Damage pitting Replace S S amp S Bap e gt 3 Replace Bearings Bearing races a Remove the bearing races from the steer ing head pipe with a long rod 1 and ham mer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber seal and new bearing races ECA14270 CAUTION If the bearing race is not installed properly the steering head pipe could be damaged NOTE Always replace the bearings and bearing races as a Set When
317. roper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 a 26 7 Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM page 3 25 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Union bolt 1 Copper washers 2 Brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 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 Replace 4 41 REAR BRAKE 3 Check Brake fluid reservoir Cracks damage Replace Brake fluid reservoir diaphragm Cracks damage Replace 4 Check Brake hose Cracks damage wear Replace EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components Recommended fluid DOT4 ET2D1022 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install Copper washers NM Brake hose 1 Union bolt 2 EW2D10
318. roximately 19 Nm 1 9 14 6 with a torque wrench following the tightening order 2 Retighten the bolts 67 Nm 6 7 48 ftelb with a torque wrench Connecting rod cap bolt 1 Tighten the connecting rod bolts to 20 Nm 2 0 14 ftelb and then tighten them further to reach the specified angle 150 e Crankcase bolt main journal 1 First tighten the bolts to approximately 20 Nm 2 0 14 ftelb with a torque wrench following the tightening order 2 Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm 2 0 mekg 14 ftelb again 3 Retighten the bolts further to reach the specified angle 60 2 15 TIGHTENING TORQUES Cylinder head tightening sequence 2 16 EAS20350 CHASSIS TIGHTENING TORQUES Item Upper bracket pinch bolt Thread size M8 TIGHTENING TORQUES Tightening torque 26 Nm 2 6 m kg 19 ft lb Remarks Steering stem nu
319. rt circuit sub wire harness Open or short circuit in wire harness Improperly installed injector Defective injector Lean angle sensor open or short circuit detected Open or short circuit in wire harness Defective lean angle sensor Malfunction in ECU No normal signals are recieved from the speed sensor Open or short circuit in wire harness Malfunction in speed sensor Malfunction in ECU Neutral switch open or short circuit detected Open or short circuit in wire haraness Malfunction in neutral switch Malfunction in ECU Power supply to the injec tors and the fuel pump is not normal Open circuit in wire harness Malfunction in ECU An error is detected while reading or writing on EEPROM CO adjustment value Malfunction in ECU The CO adjustment value is not properly written on or read from the internal memory Power supply to the fuel injection system relay is not normal Malfunction in the charging system Refer to CHARGING SYSTEM on page 8 11 Sub throttle servo motor potention circuit open or short circuit detected Open or short circuit in wire harness Detective Sub throttle servo motor poten tion circuit Sub throttle servo motor is stuck Open or short circuit in wire harness Stuck Sub throttle servo motor mecha nism e Stuck Sub throttle servo motor motor Faulty ECU memory Whe
320. s When the sub throttle position sensor output voltage is 0 4 V or more check that the sub throttle position sensor output voltage is 4 6 V or less with the nut of worm shaft turned to the full open side until it stops 5 Connect Sub throttle motor assembly coupler EAS2D1011 CHECKING THE SUB THROTTLE SERVO MOTOR 1 Check Sub throttle servo motor operation Out of specification Replace WWWVVVVVVVVVVVVVYVYVVYVVYVYVVYVYVYVYY a Check whether or not the sub throttle valve is seized 1 Turn the nut of worm shaft of the sub throt tle servo motor by hand to check that the sub throttle valve is moved smoothly by hand 2 If itis not moved smoothly disconnect the link between the sub throttle servo motor and sub throttle valve and then check whether or not the sub throttle valve is moved smoothly by hand Refer to THROTTLE BODIES on page 7 4 3 When the sub throttle valve is not moved smoothly repair or replace it since the cause is the seizure of sub throttle valve body itself When it moved smoothly at Step 1 and 2 replace the sub throttle servo motor b Perform the self diagnosis mode and check the operation of sub throttle valve by visual inspection Code No 56 The operation should be carried out as 5 second drive in the full open direction 2 second stop and 5 second drive in the full cl
321. s 5 81 CRANKSHAFT ET2D1020 CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crank shaft journal bearing clearance 0 014 0 037 mm 0 0006 0 0015 in Limit 0 10 mm 0 0039 in EC2D1008 CAUTION Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent engine damage the crankshaft journal bearings must be installed in their original positions WWWWVVVVVVVVVVYVVVYYVVYYVYVVVVYVYVYY a Clean the crankshaft journal bearings cranshaft journals and bearing portions of the crankcase b Place the upper crankcase upside down on a bench c Install the crankshaft journal upper bear ings 1 and the crankshaft into the upper crankcase NOTE Align the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase b 52 Puta piece of Plastigauge 2 each crankshaft journal NOTE Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bear ings 1 into the lower crankcase and assemble the crankcase halves NOTE Align the projections of the crankshaf
322. s an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler Gray Gray Black Blue Black Blue Defective crankshaft position sensor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 104 8 51 Reinstatement method Cranking the engine FUEL INJECTION SYSTEM Fault code No 13 Symptom Intake air pressure sensor open or short circuit detected Diagnostic code 03 Intake air pressure sensor Orde r Item components and probable cause Connections ntake air pressure sensor coupler Main wire harness ECU coupler Sub wire harness coupler Check or maintenance job Check the couplers for any pins that may have pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness and or sub wire harness Repair or replace if there is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler Black Blue Black Blue Pink White Pink White Blue Blue Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SEN SOR on page 8 112 Reinstatement method Turn the main switch to ON Intake air pressure sensor faulty intake air pressure sen
323. s detected Open circuit in wire harness ECU Coupler the input line of ECU No 24 Malfunction in ECU terminal is detected when the start switch is pressed 8 43 Symptom When the main switch is turned to ON the atmo spheric pressure sensor voltage and intake air pres sure sensor voltage differ greatly FUEL INJECTION SYSTEM Probable cause of malfunction Atmospheric pressure sensor hose is clogged Intake air pressure sensor hose is clogged kinked or pinched Malfunction of the atmospheric pressure sensor in the intermediate electrical poten tial Malfunction of the intake air pressure sen sor in the intermediate electrical potential Malfunction in ECU Diagnostic code No Coolant temperature sen Sor open or short circuit detected Open or short circuit in wire harness Defective coolant temperature sensor Improperly installed coolant temperature sensor Malfunction in ECU Intake air temperature sen Sor open or short circuit detected Open or short circuit in wire harness Defective intake air temperature sensor Improperly installed intake air temperature sensor Malfunction in ECU Atmospheric pressure sen Sor open or short circuit detected Open or short circuit in sub wire harness Defective atmospheric pressure sensor Improperly installed atmospheric pressure sensor Malfunction in ECU No normal signal is
324. s the front wheel s heavy spot X AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Adjust Front wheel static balance VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE Start with the lightest weight 12010105 b Turn the front wheel 90 so that the heavy spot is positioned as shown M 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 12010105 4 Check Front wheel static balance WWWVVVVVVVVVVYVVVYVVVVVVVVVVYVYY a Turn the front wheel and make sure it stays at each position shown D 12010106 b If the front wheel does not remain station ary at all of the positions rebalance it MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL DISC The following procedure applies to both of the brake discs 1 Lubricate Wheel axle Oil seal lips Recommended lubricant Lithium soap based grease 2 Lift the wheel up between the fork legs 3 Insert the wheel axle NOTE Install the tire and wheel with the mark 1 pointing in the direction of wheel rotation gE la 4 Lower the front wheel so that it is on the ground 5 Tighten Wheel axle Wheel axle nut 72 Nm 7 2 m kg 52 ft
325. s the turn signal light lead left the route between the ribs of the battery box and tail brake light lead F Clamp each lead at the positioning taping section and then insert it to the cover In random order Positioning tape is only used for the right handlebar switch Fit other leads so that they are not slack G Clamp each lead at the positioning taping section and then insert it to the cover In random order Route the rear side of the vehicle to the wire harness ANOaRWON 2 52 CABLE ROUTING CABLE ROUTING 7 i E 2 4 6 4 7 ML Ry 2 53 ONOnROND 9 Fuel tank Fuel tank drain hose Fuel tank breather hose Clip Air filter bracket 3 way connector Hose Fuel hose Damper 10 Collar 11 Fuel tank bracket 12 0 ring 13 Fuel pump A B C D m ZTA Hook the cover pawl to the fuel tank bracket The knob of the clip can be positioned in any direction Assemble the two folding sections of the collar flange as shown in the illustration Fit the knob of the clip
326. s used Noise interference or dis connected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnection of the communication harness 3 Immobilizer unit failure 4 ECU failure Measures 1 Place the immobi lizer unit away more than 50 mm from the transpon der of other vehi cle 2 Register the stan dard key 1 Check the wire harness and con nector 2 Replace the immobilizer unit 3 Replace the ECU IMMOBILIZER UNIT Codes do not match between ECU and immobilizer unit Noise interference or dis connected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnection of the communication harness 3 Immobilizer unit failure 4 ECU failure When the used parts form other vehicles are used the code re reg istering key ID is not registered to the ECU 1 Register the code re registering key ID 2 Check the wire harness and con nector 3 Replace the immobilizer unit 4 Replace the ECU IMMOBILIZER UNIT Key code registra tion error Same standard key was attempted to continu ously two times register Prepare the new standard key and register it ECU Undefinition code is received Noise interference or dis connected lead cable 1 Obstruction due to radio wave noise 2 Error by disconnection of the communication harness 3 Immobilizer unit failure 4 ECU failure Immobilizer system indicator light error c
327. s wiring page 8 21 OK This circuit is OK The turn signal light turn signal indicator light or both fail to blink 1 Check the turn signal bulb NG gt Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 96 Replace the turn signal bulb 2 Check the turn signal switch Refer to CHECKING THE Replace the left handlebar switch SWITCHES on page 8 93 8 24 3 Check the hazard switch Refer to CHECKING THE SWITCHES page 8 93 4 Check the turn signal hazard relay Refer to CHECKING THE RELAYS on page 8 100 5 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is OK 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 93 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is OK 1 Check the oil level switch Refer to CHECKING THE SWITCHES on page 8 93 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 21 This circuit is OK The fuel level warning light fails to come on The neutral indicator light fails to come on The oil level warning light fails to come on NG NG NG
328. sary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 4 39 per assembly Brake caliper body 3 Cracks damage Replace the brake cali per assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air EWA13610 Whenever a brake caliper is disassembled replace the brake caliper piston seals 2 Check Brake caliper bracket 1 Cracks damage gt Replace EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA13620 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid e Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals NY Recommended fluid DOT4 EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Install Brake caliper 1 temporarily Copper washers 2 Brake hose 3 Union bolt 4 EN Brake hose union bolt 30 Nm 3 0 m kg 22 ft lb EWA13530 Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING on page 2 39 EC2D1010 CAUTION
329. sensor Defective cylinder identification sensor when the engine is Improperly installed sensor started or while the vehi Malfunction in ECU cle is being driven No normal signals are Open or short circuit in wire harness received from the crank Defective crankshaft position sensor shaft position sensor Malfunction in pickup rotor Improperly installed sensor Malfunction in ECU Intake air pressure sensor Open or short circuit in wire harness open or short circuit Open or short circuit in sub wire harness detected Defective intake air pressure sensor Malfunction in ECU Intake air pressure sensor Intake air pressure sensor hose is faulty intake air pressure detached clogged kinked or pinched sensor system Malfunction in ECU Throttle position sensor Open or short circuit in wire harness open or short circuit Open or short circuit in sub wire harness detected Defective throttle position sensor Improperly installed throttle position sensor Malfunction in ECU Throttle position sensor Stuck throttle position sensor stuck Malfunction in ECU EXUP servo motor poten Open or short circuit in sub wire harness tion circuit open or short Detective EXUP servo motor potention cir circuit detected cuit EXUP servo motor is stuck Open or short circuit in sub wire harness e Stuck EXUP servo motor mechanism Stuck EXUP servo motor motor Open circuit i
330. skirt diameter P with the micrometer CRANKSHAFT 4 mm 0 16 in from the bottom edge of the piston Piston size P 76 975 76 990 mm 3 0305 3 0311 in d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Piston to cylinder clearance Cylinder bore Piston skirt diameter P Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 120 mm 0 0047 in f If out of specification replace the cylinder and the piston and piston rings as a set MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ET2D1015 CHECKING THE PISTON RINGS 1 Measure Piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings 5 73 Li Li Li A Piston ring side clearance e Top ring 0 030 0 065 mm 0 0012 0 0026 in Limit 0 115 mm 0 0045 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in Limit 0 115 mm 0 0045 in 11221402 2 Install Piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown 5 mm 0 20 in a 11221401 3 Measure Piston ring end gap Out of specification Replace the piston ring NOTE CRANKSHAFT
331. spring seat 2 ET2D1010 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates CLUTCH 1 Check Friction plate Damage wear Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 8 mm 0 110 in 1411101 EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 4 Out of specification gt Replace the clutch plates as a set GY Clutch plate warpage limit 2 0 1 mm 0 0039 EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure e Clutch spring free length Out of specification gt Replace the clutch springs as a set Clutch spring free length 52 5 mm 2 07 in Limit 49 9 mm 1 96 in EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing NOTE Pitting on the clutch hous
332. ssed Plastigauge width c on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specifica tion select replacement crankshaft journal bearings 2 Crankshaft journal bearings J1 J5 NOTE The numbers A stamped into the crank shaft web and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes e J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings f the size is the same for all J4 to J5 one digit for that size is indicated Crankcase side only For example if the crankcase J4 and crankshaft web J numbers are 6 and 2 respectively then the bearing size for J4 is J4 crankcase J crankshaft web 1 6 2 1 3 brown CRANKSHAFT JOURNAL BEARING COLOR CODE White Blue Black Brown Green CRANKSHAFT 1 Jt J2 Js Ja ds ET2D1021 INSTALLING THE CRANKSHAFT 1 Install Crankshaft journal upper bearings 1 into the upper crankcase NU ed 2 Lubricate Crankshaft journal upper bearings with the recommended lubricant Recommended lubricant Engin
333. stem fails to operate no spark or intermittent spark NOTE Before troubleshooting remove the following part s 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses NG5 Main backup fuel injection and ignition Replace the fuse s Refer to CHECKING THE FUSES on page 8 97 2 Check the battery Refer to CHECKING AND Clean the battery terminals CHARGING THE BATTERY on Recharge or replace the battery page 8 97 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS page 3 10 Re gap or replace the spark plugs 4 Check the ignition coils Refer to CHECKING THE IGNI Replace the ignition coils TION COILS on page 8 103 5 Check the crankshaft position sen sor Refer to CHECKING THE CRANKSHAFT POSITION SEN SOR on page 8 104 Replace the crankshaft position sen sor 6 Check the relay unit fuel pump Refer to CHECKING THE RELAYS on page 8 100 Replace the relay unit 7 Check the fuel pump Refer to CHECKING THE Replace the fuel pump SWITCHES on page 8 93 8 33 8 Check the main switch Refer to CHECKING THE SWITCHES on page 8 93 9 Check the engine stop switch Refer to CHECKING THE SWITCHE
334. stem must be disassembled drained cleaned properly filled and bled after reassembly Never use solvents on internal brake components Use only clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS22570 CHECKING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 14 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 Brake disc deflection limit 0 15 mm 0 0059 in 4 Measure Brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 REAR BRAKE Brake disc thickness limit 4 5 mm 0 18 in 5 Adjust Brake disc deflection Refer to CHECKING THE FRONT BRAKE DISCS on page 4 25 Brake disc bolt 30 Nm 3 0 m kg 22 ft Ib LOCTITEG 6 Install Rear wheel Refer to HEAR WHEEL on page 4 14 EAS22580 REPLACING THE REAR BRAKE PADS NOTE
335. sure 93 3 122 7 kPa 0 93 1 23 kg cm 0 9 1 2 bar 13 5 17 8 psi VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Install the radiator cap tester 1 and radia tor cap tester adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 RADIATOR 14110202 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to RADIATOR on page 6 1 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 19 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm 1 0 m kg 7 2 ft lb Job Parts to remove Remarks Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 12 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 3 Washer 1 4 Oil cooler 1 5 O ring 1 6 Water pump outlet pipe
336. t 50 Turn signal indicator light left 51 Turn signal indicator light right 52 Meter light 53 Oil level switch 54 Right handlebar switch 55 Front brake light switch 56 Engine stop switch 57 Start switch 58 Rear brake light switch 59 Left handlebar switch 60 Clutch switch 61 Pass switch 62 Dimmer switch 63 Hazard switch 64 Turn signal switch 65 Horn switch 66 Horn 67 Turn signal relay 68 Front turn signal light left 69 Front turn signal light right 70 Rear turn signal light left 71 Rear turn signal light right 72 Auxiliary light 73 Headlight 74 License plate light 75 Tail brake light 76 Headlight relay on off 77 Headlight relay dimmer 78 Fuse tail light 79 Fuse ingition 80 Anti safety alarm option 81 Fuse signal 82 Fuse headlight 83 Radiator fan motor relay 84 Fuse radiator fan motor left 85 Fuse radiator fan motor right 86 Radiator fan motor left 87 Radiator fan motor right 88 Ground EAS28750 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue Lg Light green Pink R Red Sb Sky blue W White Y Yellow B G Black Green B L Black Blue B R Black Red B W Black White B Y Black Yellow Br G Brown Green Br L Brown Blue Br R Brown Red BrAN Brown White Br Y Brown Yellow G B G R G W G Y Gy G Gy R L B L R L W L Y O B O G O Y P B P W R B R G R L R W
337. t Upper handlebar holder bolt M28 113 Nm 11 3 m kg 82 16 Lower handlebar holder nut 32 Nm 3 2 m kg 23 ft lb Lower bracket pinch bolt 24 Nm 2 4 m kg 17 ft lb 23 Nm 2 3 m kg 17 ft lb Lower ring nut SEE NOTE Cap bolt 23 Nm 2 3 m kg 17 ft lb Damper rod assembly bolt 23 Nm 2 3 m kg 17 ft lb Brake master cylinder bracket bolt 10 Nm 1 0 m kg 7 2 ft lb Brake master cylinder reservoir cap screw NO Po PO 5 PO 2 Nm 0 2 m kg 1 4 10 Front brake hose union bolt 30 Nm 3 0 m kg 22 ft lb Front brake hose holder bolt 7 Nm 0 7 m kg 5 1 ft lb Cowling stay bolt FZ1 S 33 Nm 3 3 m kg 24 ft lb Cowling bracket bolt FZ1 S 7 Nm 0 7 m kg 5 1 ft lb Front fender bolt 6 Nm 0 6 m kg 4 3 ft lb Clutch lever holder pinch bolt 11 Nm 1 1 m kg 8 0 ft lb Right front engine mounting bolt 1 45 Nm 4 5 m kg 33 ft lb Right front engine mounting bolt 2 Nm 5 0 m kg 36 ft lb Left front engine mounting bolt 45 Nm 4 5 m kg 33 ft lb Upper self locking nut Lower self locking nut 51 Nm 5 1 m kg 37 ft lb 51 Nm 5 1 m kg 37 ft lb Engine mounting adjust bolt upper 5 PO PO 7 Nm 0 7 m kg 5 1 ft lb Engine mounting adjust bolt lower 7 Nm 0 7 m kg 5 1 ft Ib Pivot shaft nut 105 Nm
338. t code Refer to Self Diagnostic Function table c Identify the probable cause of malfunction Refer to Diagnostic code table 2 Checking and repair the probable cause of malfunction Fault code No Fault code No ECU internal malfunc Non registered data has been received tion from the meter Check and repair Refer to TROUBLE SHOOTING Check and repair Refer to Self Diag nostic Function table DETAILS on page 8 50 Monitor the operation of the sensors and actuators in the diag nostic mode Refer to Sensor operation table and Actuator operation table 3 Perform ECU reinstatement action Refer to Reinstatement method of table in TROUBLESHOOTING DETAILS 4 Turn the main switch to OFF and back to ON then check that no fault code number is displayed Unable Unable NOTE If fault codes are displayed repeat steps 1 to 4 until no fault code number is displayed 5 Erase the malfunction history in the diag nostic mode Refer to Sensor operation table Diagnostic code No 62 NOTE Turning the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Re
339. t journal lower bearings with the notches in the lower crankcase Do not move the crankshaft until the clear ance measurement has been completed 2 f Tighten the bolts to specification the tightening sequence cast on the crankcase CRANKSHAFT Crankcase bolt Bolt 1 10 1st 20 Nm 2 0 m kg 14 ft lb 2nd 20 Nm 2 0 m kg 14 ft lb 3rd 60 Bolt 117 416 24 Nm 2 4m kg 17 ft lb Bolt 17 26 12 Nm 1 2m kg 8 7 ft lb M9 x 105 mm 4 1 in bolts 1 10 M8 x 60 mm 2 4 in bolt 11 LOCTITE M8 x 60 mm 2 4 in bolts 12 16 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 65 mm 2 5 in bolts 17 18 M6 x 60 mm 2 4 in bolt and washer 22 M6 x 60 mm 2 4 in bolts 24 25 M6 x 50 mm 2 0 in bolts 20 26 M8 x 50 mm 2 0 in bolts 13 15 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque NOTE Lubricate the crankcase bolt threads with engine oil Refer to CRANKCASE on page 5 66 T 0475595 EUN g Remove the lower crankcase and the crankshaft journal lower bearings h Measure the compre
340. tart the engine warm it up for several minutes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter wrench 90890 01426 YU 38411 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil ECA13390 CAUTION Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter car tridge 11730302 c Tighten the new oil filter cartridge to speci fication with an oil filter wrench EN Cil filter cartridge 17 Nm 1 7 m kg 12 16 6 Replace Engine oil drain bolt gasket 7 Install Engine oil drain bolt along with the new gasket Engine oil drain bolt 43 Nm 4 3 m kg 31 ft Ib ENGINE 8 Fill Crankcase with the specified amount of the recom mended engine oil Quantity Total amount 3 8 L 3 34 Imp qt 4 02 US qt Without oil filter cartridge replacement 2 9 L 2 55 Imp qt 3 07 US qt With oil filter cartridge replace ment 3 1 L 2 73
341. tat assembly Job Parts to remove Rider and passenger seat THERMOSTAT Remarks Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOL ANT on page 3 19 Thermostat assembly outlet hose Thermostat assembly Thermostat assembly inlet hose Band 6 6 For installation reverse the removal procedure THERMOSTAT Disassembling the thermostat assembly 110 Nm 1 0 m kg 7 2 1 10 Job Parts to remove Remarks Thermostat housing cover Thermostat Thermostat housing O ring For assembly reverse the disassem bly procedure EAS26450 CHECKING THE THERMOSTAT 1 Check Thermostat Does not open at 71 85 C 160 185 F Replace 14250202 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Suspend the thermostat 3 in a container 4 filled with water b Slowly heat the water 2 c Place a thermometer 1 in the water d While stirring the water observe the ther mostat and thermometer s indicated tem perature 14250201 T amp o L 71 C 160 F 85 185 Temperature A Fully closed B Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcool
342. te First standard key a Main switch ON h Second standard key b Main switch OFF i Registration mode c LED on A Registration of the second standard key is d LED off complete e Less than 5 05 B Immobilizer system indicator light stops f 9 Voiding the standard key code If a standard key has been lost it is possible to disable its use by re registering the remaining stan dard key Standard key registration erases the stored standard key code from the memory thus dis abling the lost standard key To re register refer to Standard key registration Standard key code voiding method o a Main switch ON f Code re registering key b Main switch OFF g Remaining standard key c LED on h Registration mode d LED off A If the immobilizer system indicator light e Less than 5 0 5 stops flashing 5 seconds after the first stan dard key is registered the second standard key cannnot be registered 8 84 IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turn the indicator light does not come on or flashing 1 Check the fuses NG gt Main ignition and backup Refer to CHECKING THE FUSES on page 8 97 Replace the fuse s 2 Check the battery Refer to CHECKING AND Clean the battery terminals CHARGING THE BATTERY on Recharge or replace the battery page 8 97
343. tes 5 81 CHECKING THE CRANKSHAFT DRIVE SPROCKET 5 81 CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5 81 INSTALLING THE 5 83 TRANSMISSION bated eed Race ene 5 85 REMOVING THE 040 5 90 CHECKING THE SHIFT FOROS 5 90 CHECKING THE SHIFT DRUM 5 91 CHECKING THE TRANSMISSION INSTALLING THE TRANSMISSION EAS23710 ENGINE REMOVAL Removing the drive sprocket 10 Nm 1 0 m kg 7 2 ft lb Job Parts to remove Locknut ENGINE REMOVAL Remarks Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Plate Po For installation reverse the removal procedure ENGINE REMOVAL Removing the exhaust pipe w 16 5 Nm 0 65 4 7 ft lb 20 Nm 2 0 m kg 14 ft lb 20 Nm 2 0 m kg 14 ft lb 145 5 Nm 4 55 m kg 33 ft Ib Job Parts to remove Remarks Rider and passenger seat Refer to GENERAL CHASSIS on page 4 1 EXUP pulley cover EXUP servo motor cover EXUP cables EXUP servo motor sensor Exhaust pipe assembly Exhaust pipe gasket Muffler Muffler gasket Muffler cover Muffler end cover CO N
344. the Main wire harness ECU coupler that may be pulled out engine and Check the locking condition of operating it at the coupler idle If there is a malfunction repair it and connect the coupler securely Faulty battery Replace or change the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 8 11 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch Red Red Between main switch and igni tion fuse Brown Blue Brown Blue Between ignition fuse and ECU Red White Red White 8 70 FUEL INJECTION SYSTEM Fault code No 47 Symptom Sub throttle position sensor open or short circuit detected Diagnostic monitor Order Item components and probable Check or maintenance job Reinstatement cause method Installed state of sub throttle position Check for looseness or pinch Turning the sensor ing main switch to 1 Check that the sensor is ON installed in the specified posi tion Connections Check the couplers for any pins Sub throttle position sensor coupler that may be pulled out Main wire harness ECU coupler Check the locking condition of 2 Sub wire harness coupler the couplers If there is a malfunction repair it and connect the coupler securely Open o
345. the atmospheric pressure sensor voltage and intake air pressure sensor voltage dif fer greatly 8 38 Fault code No Coolant temperature sensor open or short circuit FUEL INJECTION SYSTEM Symptom Coolant temperature sensor open or short circuit detected Able unable to start Able unable to drive Intake air temperature sensor open or short circuit Intake air temperature sensor open or short circuit detected Atmospheric pressure sensor open or short circuit Atmospheric pressure sensor open or short circuit detected Able Able sensor No normal signal is received from the sensor Able Able Lean angle sensor latch up detected No normal signal is received from the lean angle sensor Unable Unable Cylinder 1 ignition open circuit Primary lead of the cylinder 1 ignition coil open circuit detected Able depend ing on the num ber of faulty cylin ders Able ing on the num ber of faulty cylin ders Cylinder 2 ignition coil open circuit Primary lead of the cylinder 2 ignition coil open circuit detected Able depend ing on the num ber of faulty cylin ders Able depend ing on the num ber of faulty cylin ders Cylinder 3 ignition coil open circuit Primary lead of the cylinder 3 ignition coil open circuit detected Able depend ing
346. the connecting rod bolts NOTE Install by carrying out the following procedures in order to assemble in the most suitable con dition Connecting rod bolt SN 29 4 Nm 3 0 m kg 21 ft lb NOTE First tighten the bolts to 15 Nm 1 5 m kg 11 ft lb Retighten the bolts to 29 4 Nm 3 0 m kg 21 ft lb f Replace the connecting rod bolts with new ones g Clean the connecting rod bolts h After installing big end bearing assemble the connecting rod and connecting rod cap once using a single unit of the connecting rod i Tighten the connecting rod bolt while checking that the sections shown and b are flush with each other by touching the surface Side machined face a Thrusting faces 4 places at front and rear To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment CRANKSHAFT 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 k Tighten the connecting rod bolts Connecting rod bolt 20 Nm 2 0 m kg 14 ft Ib 150 EC2D1014 CAUTION Tighten the connecting rod bolts using the plastic region tightening angle method Clean the connecting rod bolts m Tighten the connecting rod bolts n Puta mark 1 on the
347. the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between sensor coupler and ECU coupler Gray Green Gray Green Black Blue Black Blue Pink Black Pink Black Red White Red White Check fuel pressure Refer to THROTTLE BODIES on page 7 4 Defective sensor Replace if defective Reinstatement method Start and warm up the engine until the cool ant tempera ture rises over 60 C when accelerat ing the throttle the waring light is turned off or itis reset by the diagnostic mode Code No 63 Fault code No 30 Symptom No normal signal is received from the lean angle sensor Diagnostic code No 08 77 Leananglesensor Order Item components and probable cause The vehicle has overturned Check or maintenance job Raise the vehicle upright Installed state of the lean angle sen Sor Check the installed direction and condition of the sensor Connections Lean angle sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 105 8 59
348. thout the dowel pins and camshaft caps b Position strip of Plastigauge 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clear ance with the Plastigauge Camshaft cap bolt SN 10 Nm 1 0 m kg 7 2 ft lb d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 5 Camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylinder head and the camshaft caps as a set Camshaft journal diameter 22 459 22 472 mm 0 8842 0 8847 11151003 EAS23870 CHECKING THE TIMING CHAIN AND CAM SHAFT SPROCKET 1 Check Timing chain 1 Damage stiffness Replace the timing chain and camshaft and camshaft sprocket as a set CAMSHAFTS 2 Check e Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing
349. tor coil resistance STATOR F074T85073 MITSUBISHI 14 0 V40 0 A6500 r min 0 14 0 18 0 at 20 C 68 F Voltage regulator Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer FHO12AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ14S Voltage capacity 12 V 11 2 Ah Specific gravity 1 310 Manufacturer GYM Ten hour rate amperage 1 12A Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W x 1 FZ1 N 12 V 60 W 55 0 W x 2 FZ1 S Auxiliary light 12V 5 0W x2 Tail brake light 12 V 5 0 W 21 0 W x 1 Front turn signal light 12 V 10 0W x2 Rear turn signal light 12 V 10 0W x2 License plate light 12 V 5 0 W x 1 Meter lighting LED Indicator light Neutral indicator light LED Turn signal indicator light LED Oil level warning light LED High beam indicator light LED 2 10 Coolant temperature warning light Engine trouble warning light Immobilizer system indicator light ELECTRICAL SPECIFICATIONS LED LED LED Electric starting system System type Constant mesh Starter motor Model manufacturer Power output Armature coil resistance Brush overall length Limit Brush spring force Commutator diameter Limit Mica undercut depth SM13 MITSUBA 0 80 kW 0 0250 0 0350 12 5 mm 0 49 in 5 00 mm 0 20 in 7 65 10 01 N 27 54 36 03 oz 780 1021 gf 28 0 mm
350. tween coolant temperature sensor coupler and ECU cou pler Green White Green White Black Blue Black Blue Defective coolant temperature sensor Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 108 8 56 Reinstatement method Turning the main switch to ON FUEL INJECTION SYSTEM Fault code No Symptom Intake air temperature sensor open or short circuit detected Diagnostic code 05 Intake air temperature sensor Item components and probable Check or maintenance job Reinstatement Order cause method Connections Check the couplers for any pins Turning the ntake air temperature sensor cou that may be pulled out main switch to pler e Check the locking condition of ON Main wire harness ECU coupler the couplers Sub wire harness coupler If there is a malfunction repair it and connect the coupler securely Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU cou pler Brown White Brown White Black Blue Black Blue Defective intake air temperature sen Execute the diagnostic mode SOr Code No 05 Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERATURE SENSOR on page 8 112 8 57 FUEL INJECTION SYSTEM Fault code No Symptom Atmospheric
351. uildup 2 Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality Cooling system 1 Coolant Low coolant level 2 Radiator Damaged or leaking radiator Faulty radiator Bent or damaged radiator fin 3 Water pump Damaged or faulty water pump Thermostat Thermostat stays closed Oil cooler Clogged or damaged oil cooler Hose s pipe s Damaged hose Improperly connected hose Damaged pipe Improperly connected pipe Fuel system 1 Throttle body ies Damaged or loose throttle body joint 2 Air filter Clogged air filter element Chassis 1 Brake s Dragging brake Electrical system 1 Spark plug s Incorrect spark plug Incorrect spark plug heat range 2 Ignition system Faulty ECU EAS28610 OVERCOOLING Cooling system 1 Thermostat Thermostat stays open EAS28620 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit TROUBLESHOOTING Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS28660 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal
352. um soap based grease 2 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 p A Drive chain slack 2 25 35 mm 0 98 1 38 3 Tighten Wheel axle nut Brake caliper bolts Wheel axle nut 150 Nm 15 m kg 108 ft lb Brake caliper bolt front 27 Nm 2 7 m kg 20 ft Ib Brake caliper bolt rear 22 Nm 2 2 m kg 16 ft Ib 4 18 REAR WHEEL EWA13500 Make sure the brake hose is routed prop erly 4 19 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 15 Nm 0 5 m kg 3 6 ft lb Job Parts to remove Remarks Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw For installation reverse the removal procedure 4 20 FRONT BRAKE Removing the front brake master cylinder 2 Nm 0 2 1 4 ft lb 30 Nm 3 0 m kg 22 ft lb Job Parts to remove Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAU LIC BRAKE SYSTEM page 3 25 Right rearview mirror FZ1 N Brake master cylinder reservoir cap Brake master cylinder reservoir dia phragm holder Brake master cylinder diaphragm Brake lever Front brake light switch lead coupler Front brake light switch Union bolt Copper washer Master cylinder bracket Master cylinder assembly N wo Disconnect
353. ump inlet pipe and outlet pipe 8 Check Copper washers 1 EY 9 Install Coolant drain bolts 2 Coolant drain bolt 10 Nm 1 0 m Kg 7 2 ft Ib 1 10 Install Coolant reservoir tank 11 Connect Coolant reservoir hose 12 Fill Cooling system with the specified amount of the recom mended coolant Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 2 25 L 1 98 Imp qt 2 38 US qt Coolant reservoir capacity 0 25 L 0 22 Imp qt 0 26 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care EWA13040 If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention ECA13480 CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant 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
354. ump relay Code No 09 Replace if defective If there is no malfunction with the fuel pump relay replace the ECU 8 68 FUEL INJECTION SYSTEM Fault code No An error is detected while reading or writing on EEPROM ymp CO adjustment value Diagnostic code 60 EEPROM fault cylinder No Orde Item components and probable Reinstatement r cause method Malfunction in ECU Set the faulty cylinder s exhaust Turning the gas volume main switch to 1 Execute the diagnostic mode ON Code No 60 to check the Readjust the faulty cylinder number If mul exhaust gas vol tiple cylinders are defective ume after it is the numbers of the faulty cyl reinstated inders are displayed alter nately at 2 second intervals 2 Execute the CO adjustment mode and set the exhaust gas volume of the faulty cylinder to If O is displayed set the numerical value other than 0 When the malfunction 15 recovered reset 0 Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 8 Replace ECU if it does not recover from the malfunction Check or maintenance job 8 69 FUEL INJECTION SYSTEM code Ne Symptom Power supply to the fuel ieee system relay is not nor Diagnos ccodeNo lt o Order Item components and probable Check or maintenance job Reinstatement cause method Connections Check the coupler for any pins Starting
355. ust THROTTLE BODIES it shorter when the coolant temperature is high In case of turning the adjusting bolt two third turn the temperature varies about 10 C 50 F 7 12 AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM Removing the air cut off valve assembly and hoses Job Parts to remove 4 Remarks Air cut off valve coupler Disconnect Air cut off valve hose 1 Disconnect Air cut off valve hose 2 Disconnect Air cut off valve hose 3 Disconnect Air cut off valve Reed valve cap Reed valve assembly Plate AININ For assembly reverse the removal procedure 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 reed valve opens allowing secondary air to flow into the exhaust port The required temperature for burning the unburned exhaust gases is approximately 600 to 700 C Air cut off valve The air cut off valve is controlled by the signals from the ECU in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve r
356. vals the engine trou ble warning light Checking method Check the spark five times e Connect an ignition checker Cylinder 2 ignition coil Actuates the cylinder 2 igni tion coil five times at one sec ond intervals the engine trou ble warning light Check the spark five times e Connect an ignition checker Cylinder 3 ignition coil Actuates the cylinder 3 igni tion coil five times at one sec ond intervals the engine trou ble warning light Check the spark five times e Connect an ignition checker Cylinder 4 ignition coil Actuates the cylinder 4 igni tion coil five times at one sec ond intervals the engine trou ble warning light Check the spark five times e Connect an ignition checker Injector 1 Actuates the injector 1 five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of the injector 1 five times Injector 2 Actuates the injector 2 five times at one second inter vals Illuminates the engine trou ble warning light 8 48 Check the operating sound of the injector 2 five times FUEL INJECTION SYSTEM Diag nostic code No Actuation Checking method Injector 3 Actuates the injector 3 five Check the operating sound times at one second inter of the injector 3 five times va
357. ve Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS25980 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove Crankshaft assembly Crankshaft journal upper bearings from the upper crankcase Refer to CRANKSHAFT on page 5 70 5 72 NOTE Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place ET2D1032 3 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and the piston and piston rings as a set 2 Measure Piston to cylinder clearance VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Measure cylinder bore with the cylinder bore gauge NOTE Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the mea surements 77 00 77 01 mm 8 0315 3 0319 in 77 06 mm 3 03 in 0 005 mm 0 0002 in 0 005 mm 0 0002 in Cylinder bore Wear limit Taper limit Out of round R C maximum of D Dg maximum of D or Do maximum of Ds or Dg maximum of D Dg or D5 minimum of Do Dy Dg b If out of specification replace the cylinder and the pistons and piston rings as a set c Measure piston
358. wer handlebar holder nut 32 Nm 3 2 m kg 23 ft lb 5 Install Clutch lever holder 1 Clutch cable NOTE Align the slit in the clutch lever holder with the punch mark a in the handlebar 6 Install Left handlebar switch NOTE Align the projections a on the left handlebar switch with the hole b in the handlebar 7 Install Handlebar grip 1 Grip end 2 HANDLEBAR Grip end 26 Nm 2 6 m kg 19 ft Ib VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Apply a thin coat of rubber adhesive onto the left end of the handlebar b Side the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag EW2D1007 Do not touch the handlebar grip until the rubber adhesive has fully dried NOTE There should be 1 3 mm 0 04 0 12 in of clearance a between the handlebar grip and the grip end 8 Install Throttle grip 1 Throttle cable hoousing 2 Throttle cables Grip end 3 NOTE Align the projections a on the throttle cable housing with the hole b in the handlebar 9 Install Right handlebar switch 4 46 NOTE Align the projections a on the handlebar switch with the holes b in the handlebar Threre should be 1 3 mm 0 04 0 12 in of cl
359. when neither of these con ditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEU TRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR Battery Main fuse Main switch Ignition fuse Engine stop switch Starting circuit cut off relay Diode Clutch switch 9 Sidestand switch 10 Neutral switch 11 Start switch 12 Starter relay 13 Starter motor ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn NOTE ELECTRIC STARTING SYSTEM Before troubleshooting remove the following part s 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses Main and ignition Refer to CHECKING THE FUSES on page 8 97 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 97 3 Check the starter motor operation Refer to CHECKING THE STAR TOR MOTOR OPERATION on page 8 105 4 Check the starter motor Refer to CHECKING THE STARTER on page 5 42 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RELAYS
360. with engine oil Install a washer on bolts 1 10 and 22 Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase M9 x 105 mm 4 1 in bolts 1 10 M8 x 60 mm 2 4 in bolt 11 LOCTITE M8 x 60 mm 2 4 in bolts 12 16 M6 x 70 mm 2 8 in bolts 19 21 23 M6 x 65 mm 2 5 in bolts 17 18 M6 x 60 mm 2 4 in bolt and washer 22 M6 x 60 mm 2 4 in bolts 24 25 M6 x 50 mm 2 0 in bolts 20 26 M8 x 50 mm 2 0 in bolts 13 15 CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons Job Parts to remove Remarks Lower crankcase Refer to CRANKCASE on page 5 66 Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring Cylinder Cylinder gasket BR AIA 5 5 For installation reverse the removal procedure 5 70 CRANKSHAFT Removing the crankshaft 60 6 0 43 ft lb SS SS Job Parts to remove Crankcase gt Remarks Separate Refer to CRANKCASE on page 5 66 Connecting rod and connecting rod caps Refer to REMOVING THE CON NECTING RODS AND PISTONS on page
361. y FUEL SYSTEM QO ELECTRICAL SYSTEM TROUBLESHOOTING GENERAL INFORMATION eei Union bat ec E ee t hrec eee 1 1 VEHICLE IDENTIFICATION NUMBER eee 1 1 MODEL LABEL iere eire Ok el beo uel nr a en ene tan 1 1 Ao 1 2 FILSYSTEM Mee 1 3 INSTRUMENT 8 2 22 4 2 1 1 4 IMPORTANT INFORMATION 2 21241 1 8 PREPARATION FOR REMOVAL AND 5 1 8 REPLACEMENT PARTS e ttu dc ac Enter tera deren 1 8 GASKETS OIL SEALS AND O RINGS se 1 8 LOCK WASHERS PLATES AND COTTER 5 1 8 BEARINGS AND OIL SEALS eee 1 9 GCIRGEIPS ct cie cete ub bet 1 9 CHECKING THE CONNECTIONS 2 2 2 1 10 SPECIAL TOOLS on tup eee 1 11 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe D 0 EAS20150 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ja i 1 1 IDENTIFICATION FEATURES EAS2017
362. y a Out of specification Adjust Throttle cable free play at the flange of the throttle grip 3 0 5 0 mm 0 12 0 20 2 Adjust Throttle cable free play VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained Direction a Throttle cable free play is increased Direction b Throttle cable free play is decreased c Tighten the locknut EW2D1001 After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove Radiator upper bolts Radiator lower bolt Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs ECA13320 CAUTION Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 3 Check Spark plug type Incorrect Change ENGINE 6 Measure Spark plug gap with a wire thickness gauge Out of specification Regap Spark plug gap 0 6 0 7 mm 0 0236 0 0276 in 7 Install Spark plugs
363. y differ slightly from those specified Throttle position sensor resis tance 0 6 KQ at 20 C 68 F 3 Install Sub throttle position sensor NOTE When installing the throttle position sensor adjust its angle properly Refer to CHECKING THE SUB THROTTLE POSITION SENSOR on page 8 110 EA2D1012 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace 8 110 Air induction system solenoid resistance 18 22 Q at 20 C 68 F VVVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Remove the Air induction system solenoid coupler from the wire harness b Connect the pocket tester Q x 1 to the Air induction system solenoid terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Brown 1 Negative tester probe Brown Red 2 c Measure the Air induction system solenoid resistance MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EAS28380 CHECKING THE ATMOSPHERIC PRES SURE SENSOR 1 Check Atmospheric pressure sensor output volt age Out of specification Replace Atmospheric pressure sensor output voltage 3 75 4 25 V WWWVVVVVVVVVVVVVYVYVYVYVVVYVVYVYVYYY a Connect the pocket tester DC 20 V to the atmospheric pressure sensor coupler wire harness side as shown ELECTRICAL
364. y main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch N EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1 Cylinder s and cylinder head s Incorrect valve clearance Damaged valve train components 2 Air filter Clogged air filter element Fuel system 1 Throttle body ies Damaged or loose throttle body joint Improperly synchronized throttle bodies Improperly adjusted engine idling speed idle adjusting screw 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 electrode Worn or damaged insulator 3 Ignition coil s Broken or shorted primary or secondary coils Cracked or broken ignition coil 4 Ignition system Faulty ECU Faulty crankshaft position sensor EAS28510 POOR MEDIUM AND HIGH SPEED PER FORMANCE Refer to STARTING FAILURES on page 9 1 Engine 1 Air filter Clogged air filter element Fuel system 1 Fuel pump Faulty fuel pump EAS

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