Сервисный мануал yamaha fz1

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  2006 FZ1-N(V) FZ1-S(V) SERVICE MANUAL 2D1-28197-E0…
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  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.
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  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.

• Page 4: How To Use This Manual

  EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •…

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  EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6.

• Page 7: Table Of Contents

  EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING…

• Page 9: General Information

  GENERAL INFORMATION IDENTIFICATION………………1-1 VEHICLE IDENTIFICATION NUMBER……….. 1-1 MODEL LABEL………………1-1 FEATURES ………………..1-2 FI SYSTEM ………………..1-3 INSTRUMENT FUNCTIONS……………..1-4 IMPORTANT INFORMATION …………… 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-8 REPLACEMENT PARTS ……………. 1-8 GASKETS, OIL SEALS AND O-RINGS……….1-8 LOCK WASHERS/PLATES AND COTTER PINS ……..1-8 BEARINGS AND OIL SEALS …………..1-9 CIRCLIPS ………………..1-9 CHECKING THE CONNECTIONS ………….1-10…

• Page 10: Identification

  IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

• Page 11: Features

  FEATURES EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

• Page 12: Fi System

  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.

• Page 13: Instrument Functions

  INSTRUMENT FUNCTIONS ET2D1002 kilometers and miles, press the “SELECT” INSTRUMENT FUNCTIONS button for at least one second. Multi-function meter unit Tachometer 1. Coolant temperature display/air intake tem- 1. Tachometer perature display 2. Tachometer red zone 2. Speedometer The electric tachometer allows the rider to 3.

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  “ODO” and off for approximately 3 seconds. If this occurs, the tripmeter modes “TRIP A” and “TRIP B” in have a Yamaha dealer check the electrical cir- the following order: cuit. TRIP A → TRIP B → ODO → TRIP A…
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  • When the key is turned to “ON”, the coolant to a Yamaha dealer and have the standard temperature is automatically displayed, even keys re-registered. if the air intake temperature was displayed If the display indicates any error codes, note prior to turning the key to “OFF”.
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  INSTRUMENT FUNCTIONS 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” button. 3. Turn the key to “ON”, and then release the “SELECT” button after five seconds. 4. Push the “RESET” button to select the desired brightness level. 5.

• Page 17: Important Information

  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…

• Page 18: Bearings And Oil Seals

  IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

• Page 19: Checking The Connections

  CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog Pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •…

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  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.
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-13 90890-01426 YU-38411 Rod holder 4-50, 4-55 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-54 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 4-54 90890-01436 Universal damping rod bleeding tool set…
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-11 90890-03081 Engine compression tester YU-33223 Valve spring compressor 5-23, 5-29 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 5-23, 5-29 90890-04114 Valve spring compressor adapter…
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø4) 5-25 90890-04111 Valve guide remover (4.0 mm) YM-04111 Valve guide remover (ø4.5) 5-25 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø4) 5-25 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide installer (ø4.5) 5-25…

• Page 24: Special Tools

  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No.1215 5-67, 6-12 (Three Bond No.1215®) 90890-85505 Digital circuit tester 7-9, 7-10 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter…

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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum/pressure pump gauge set 90890-06756 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Fuel pressure adapter 90890-03176 YM-03176 Pressure gauge 3-14, 7-8 90890-03153 YU-03153 Camshaft wrench 5-11, 5-16 90890-04143 YM-04143 1-16…
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  SPECIAL TOOLS 1-17…

• Page 27: Specifications

  SPECIFICATIONS GENERAL SPECIFICATIONS…………..2-1 ENGINE SPECIFICATIONS…………….2-1 CHASSIS SPECIFICATIONS …………… 2-8 ELECTRICAL SPECIFICATIONS……………2-10 TIGHTENING TORQUES…………….2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS…….2-12 ENGINE TIGHTENING TORQUES …………2-13 CHASSIS TIGHTENING TORQUES …………2-17 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-20 ENGINE ………………..2-20 CHASSIS ………………..2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS ………2-23 ENGINE OIL LUBRICATION CHART ………..2-23 LUBRICATION DIAGRAMS …………..

• Page 28: General Specifications

  3C39 (AUS) Dimensions Overall length 2140 mm (84.3 in) Overall width 770 mm (30.3 in) Overall height 1060 mm (41.7 in) (FZ1-N) 1205 mm (47.4 in) (FZ1-S) Seat height 815 mm (32.1 in) Wheelbase 1460 mm (57.5 in) Ground clearance 135 mm (5.31 in)

• Page 29: Engine Specifications

  ENGINE SPECIFICATIONS Inner-rotor-to-outer-rotor-tip clearance 0.010–0.100 mm (0.0004–0.0039 in) Limit 0.18 mm (0.0071 in) Outer-rotor-to-oil-pump-housing clearance 0.090–0.150 mm (0.0035–0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.06–0.13 mm (0.0024–0.0051 in) Limit 0.20 mm (0.0079 in) Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) Relief valve operating pressure 600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80…

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  ENGINE SPECIFICATIONS Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links RH2020/122 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.21–0.25 mm (0.0083–0.0098 in) Valve dimensions Valve head diameter A (intake) 23.40–23.60 mm (0.9213–0.9291 in) Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in)
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  ENGINE SPECIFICATIONS Limit 4.425 mm (0.1742 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in) Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.550 mm (0.1791 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust)
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  ENGINE SPECIFICATIONS Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in) Piston ring Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Ring side clearance…
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  ENGINE SPECIFICATIONS Journal oil clearance (using plastigauge®) 0.014–0.037 mm (0.0006–0.0015 in) Bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green Clutch Clutch type Wet, multiple-disc Clutch release method Outer pull, rack and pinion pull Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit…
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  ENGINE SPECIFICATIONS Idling condition Engine idling speed 1100–1300 r/min Intake vacuum 30.0 kPa (8.9 inHg) (225 mmHg) 95.0–105.0 °C (203.00–221.00 °F) Water temperature 80.0–90.0 °C (176.00–194.00 °F) Oil temperature Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)

• Page 35: Chassis Specifications

  Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) Loading condition 90–196 kg (198–432 lb) (FZ1-N) 90–190 kg (198–419 lb) (FZ1-S) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)

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  CHASSIS SPECIFICATIONS Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.20 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal free play 4.3–9.3 mm (0.17–0.37 in) Rear disc brake…

• Page 37: Electrical Specifications

  1.12 A Headlight Bulb type Halogen bulb Bulb voltage, wattage × quantity 12 V, 60 W/55.0 W × 1 (FZ1-N) Headlight 12 V, 60 W/55.0 W × 2 (FZ1-S) 12 V, 5.0 W × 2 Auxiliary light 12 V, 5.0 W/21.0 W × 1 Tail/brake light 12 V, 10.0 W ×…

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  Model/manufacturer 5VY/SOMIC ISHIKAWA Servo motor Model/manufacturer 2D1/YAMAHA Fuses Main fuse 50.0 A Headlight fuse 15.0 A (FZ1-N) 25.0 A (FZ1-S) Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A 10.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A…

• Page 39: Tightening Torques

  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 until the specified tightening torque is reached.

• Page 40: Engine Tightening Torques

  TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) 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 12 Nm (1.2 m·kg, 8.7 ft·lb) Cylinder head stud bolt (exhaust…

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  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head and exhaust pipe 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and muffler bolt 20 Nm (2.0 m·kg, 14 ft·lb) EXUP pulley and shaft arm nut 7 Nm (0.7 m·kg, 5.1 ft·lb) EXUP valve pulley cover bolt 14 Nm (1.4 m·kg, 10 ft·lb) EXUP cable nut…
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  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch spring bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Use a lock washer 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…
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  TIGHTENING TORQUES 2-16…

• Page 44: Chassis Tightening Torques

  TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut 113 Nm (11.3 m·kg, 82 ft·lb) Upper handlebar holder bolt 24 Nm (2.4 m·kg, 17 ft·lb) Lower handlebar holder nut 32 Nm (3.2 m·kg, 23 ft·lb) Lower bracket pinch bolt…

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  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake hose holder screw 7 Nm (0.7 m·kg, 5.1 ft·lb) 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 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank cap bolt…
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  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Clutch cable adjust nut 7 Nm (0.7 m·kg, 5.1 ft·lb) NOTE: 1 First, tighten the ring nut to approximately 52 Nm (5.2 m•kg, 38 ft•lb) with a torque wrench, then loosen the lower ring nut completely. 2 Retighten the lower ring nut 18 Nm (1.8 m•kg, 13 ft•lb).

• Page 47: Lubrication Points And Lubricant Types

  Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft 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.

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  LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Pickup rotor cover Yamaha bond No. 1215 2-21…

• Page 49: Chassis

  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…

• Page 50: Lubrication System Chart And Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23…

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  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8. Shift fork (upper) 9. Main axle 10.Mission shower 11.Drive axle 12.AC magneto axle 13.Piston cooler 14.Chain tensioner…

• Page 52: Lubrication Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25…

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  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-26…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump 2-28…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler 2-30…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-32…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33…
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  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-34…

• Page 62: Cooling System Diagrams

  COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35…

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  COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-36…
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  COOLING SYSTEM DIAGRAMS 2-37…
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  COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-38…

• Page 66: Cable Routing

  CABLE ROUTING EAS20430 CABLE ROUTING 2-39…

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  CABLE ROUTING 1. Clutch cable 2. Left handlebar switch lead 3. Main switch lead 4. Immobilizer lead 5. Horn lead 6. Horn stay assembly 7. Throttle cable (pull side) 8. Throttle cable (return side) 9. Wire harness 10.Brake hose 11.Throttle cables 12.Right handlebar switch lead A.
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  CABLE ROUTING 2-41…
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  CABLE ROUTING M. Pass the radiator fan motor lead (right) 1. Wire harness above the coolant reservoir hose and route 2. Right handlebar switch lead it to the inside of the frame. 3. Throttle cable N. Pass the coolant reservoir hose to the vehi- 4.
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  CABLE ROUTING 2-43…
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  CABLE ROUTING H. Route the hose assembly 1 by the vehicle 1. Clutch cable front side where the water pump inlet pipe 2. Water pump breather hose is routed. For the hose tip position, route 3. Oil level switch lead the hose so that 10 mm (0.39 in) or more 4.
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  CABLE ROUTING 2-45…
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  CABLE ROUTING 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…
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  CABLE ROUTING 2-47…
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  CABLE ROUTING 53.Direct ignition coil lead 1. Throttle cables 54.Speed sensor lead 2. Right handlebar switch lead 55.Lean angle sensor lead 3. Wire harness 56.Battery box 4. Throttle cable (pull side) 57.Turn signal light relay lead 5. Throttle cable (return side) 58.Rear frame 6.
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  CABLE ROUTING 2-49…
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  CABLE ROUTING AJ.Clamp each lead at the positioning taping Q. Pass the turn signal light lead (right) and section (white) and then insert it to the license plate light lead under the rear cover. (In random order) fender bracket and route between the ribs of the battery box.
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  CABLE ROUTING 2-51…
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  CABLE ROUTING FZ1-S 1. Clutch cable 2. Left handlebar switch lead 3. Immobilizer lead 4. Main switch lead 5. Protector 6. Throttle cables 7. Right handlebar switch lead 8. Throttle cable (pull side) 9. Throttle cable (return side) 10.Bracket 11.Wire harness 12.Turn signal light lead 13.Seat lock cable 14.Tail/brake light lead…
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  CABLE ROUTING 2-53…
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  CABLE ROUTING 1. Fuel tank 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Clip 5. Air filter bracket 6. 3 way connector 7. Hose 8. Fuel hose 9. Damper 10.Collar 11.Fuel tank bracket 12.O-ring 13.Fuel pump A. Hook the cover pawl to the fuel tank bracket.
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  CABLE ROUTING 2-55…

• Page 83: Periodic Checks And Adjustments

  PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ……………..3-1 INTRODUCTION ………………3-1 ENGINE………………….3-4 ADJUSTING THE VALVE CLEARANCE ……….3-4 SYNCHRONIZING THE THROTTLE BODIES ……..3-6 ADJUSTING THE EXHAUST GAS VOLUME………3-8 ADJUSTING THE ENGINE IDLING SPEED ……….3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ……3-9 CHECKING THE SPARK PLUGS…………

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  LUBRICATING THE CENTERSTAND (FZ1-S) ……..3-34 LUBRICATING THE REAR SUSPENSION ……….3-34 ELECTRICAL SYSTEM…………….3-35 CHECKING AND CHARGING THE BATTERY……..3-35 CHECKING THE FUSES…………..3-35 REPLACING THE HEADLIGHT BULBS……….3-35 ADJUSTING THE HEADLIGHT BEAM ……….3-36…

• Page 86: Periodic Maintenance

  • 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 technical skills. ODOMETER READ-…

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  PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 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…
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  PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 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.

• Page 89: Engine

  ENGINE EAS20470 • Valve clearance ENGINE Out of specification → Adjust. Valve clearance (cold) EAS20490 ADJUSTING THE VALVE CLEARANCE Intake valve The following procedure applies to all of the 0.11–0.20 mm (0.0043–0.0079 valves. Exhaust valve NOTE: • Valve clearance adjustment should be made 0.21–0.25 mm (0.0083–0.0098 on a cold engine, at room temperature.

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  ENGINE 6. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. Valve lapper 90890-04101 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.

• Page 91: Synchronizing The Throttle Bodies

  ENGINE If the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062in) g. Install the exhaust and intake camshafts, d. Calculate the sum of the values obtained in timing chain and camshaft caps. steps (b) and (c) to determine the required valve pad thickness and the valve pad Camshaft cap bolt number.

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  ENGINE Refer to «GENERAL CHASSIS» on page 4- • Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel tank a. With throttle body #3 as standard, adjust Refer to «FUEL TANK» on page 7-1. throttle bodies #1, #2, and #4 using the air 3.

• Page 93: Adjusting The Exhaust Gas Volume

  ENGINE 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) 4.

• Page 94: Adjusting The Engine Idling Speed

  ENGINE 8. Simultaneously press the “SELECT” and Throttle cable free play “RESET” buttons to return to the cylinder (at the flange of the throttle selection (step 5). grip) 9. Turn the main switch to “OFF” to cancel the 3.0–5.0 mm (0.12–0.20 in) mode.

• Page 95: Checking The Spark Plugs

  ENGINE 6. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.6–0.7 mm (0.0236–0.0276 in) c. Tighten the locknut. EW2D1001 WARNING 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.

• Page 96: Checking The Engine Oil Level

  ENGINE ECA13340 NOTE: CAUTION: The difference in compression pressure Before removing the spark plugs, use com- between cylinders should not exceed 100 kPa pressed air to blow away any dirt accumu- (1 kg/cm², 1 bar, 14.22 psi). lated in the spark plug wells to prevent it c.

• Page 97: Changing The Engine Oil

  ENGINE 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 4. Start the engine, warm it up for several CAUTION: minutes, and then turn it off.

• Page 98: Measuring The Engine Oil Pressure

  ENGINE 5. If the oil filter cartridge is also to be 8. Fill: replaced, perform the following procedure. • Crankcase (with the specified amount of the recom- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil mended engine oil) filter wrench “2”.

• Page 99: Adjusting The Clutch Cable Free Play

  ENGINE to measure the engine oil pressure after NOTE: warming up the engine. Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and 3. Remove: • Oil gallery bolt “1” viscosity, the oil pressure may fluctuate when measuring.

• Page 100: Replacing The Air Filter Element

  ENGINE 2. Adjust • Clutch cable free play ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS20960 Handlebar side REPLACING THE AIR FILTER ELEMENT a. Turn the adjusting dial “1” in direction “b” or 1. Remove: “c” until the specified clutch cable free play • Rider and passenger seat is obtained.

• Page 101: Checking The Throttle Body Joints

  ENGINE 4. Install: 1. Remove: • Air filter case cover • Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4- ECA14400 CAUTION: • Fuel tank Never operate the engine without the air fil- ter element installed. Unfiltered air will Refer to «FUEL TANK»…

• Page 102: Checking The Exhaust System

  ENGINE Refer to «FUEL TANK» on page 7-1. Exhaust pipe nut 2. Check: 20 Nm (2.0 m·kg, 14 ft·lb) • Crankcase breather hose “1” Exhaust pipe and exhaust pipe Cracks/damage → Replace. bracket bolt Loose connection → Connect properly. 20 Nm (2.0 m·kg, 14 ft·lb) ECA13450 Exhaust pipe and muffler bolt CAUTION:…

• Page 103: Checking The Exup Servo Motor

  ENGINE 2. Check: • EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”. Refer to «FUEL INJECTION SYSTEM» on page 8-31. b. Set the engine stop switch to “ ”. c. Check that the EXUP valve operates prop- erly.

• Page 104: Checking The Cooling System

  ENGINE • Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level. ECA13470 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant.

• Page 105
  ENGINE 7. Drain: 4. Drain: • Coolant • Coolant (from the water pump inlet pipe and outlet (from the coolant reservoir) pipe) 5. Remove: 8. Check: • Radiator cap “1” • Copper washers “1” EWA13030 WARNING 9. Install: • Coolant drain bolts “2” A hot radiator is under pressure.
• Page 106
  ENGINE Coolant is potentially harmful and should NOTE: be handled with special care. Before checking the coolant level, wait a few EWA13040 minutes until the coolant has settled. WARNING 18. Install: • If coolant splashes in your eyes, thor- • Rider and passenger seat oughly wash them with water and consult Refer to «GENERAL CHASSIS»…

• Page 107: Chassis

  CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position EAS21160 ADJUSTING THE FRONT DISC BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Adjust: a. Loosen the locknut “1”. • Brake lever position b. Turn the adjusting bolt “2” in direction “a” or (distance “a”…

• Page 108: Checking The Brake Fluid Level

  CHASSIS EAS21240 the brake fluid and could cause vapor CHECKING THE BRAKE FLUID LEVEL lock. 1. Stand the vehicle on a level surface. ECA13540 NOTE: CAUTION: • Place the vehicle on a suitable stand. Brake fluid may damage painted surfaces •…

• Page 109: Checking The Front Brake Hoses

  CHASSIS EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • Brake hose “1” Cracks/damage/wear → Replace. 2. Check: • Brake hose clamp “2” Loose Connection → Tighten the clamp bolt.

• Page 110: Bleeding The Hydraulic Brake System

  CHASSIS nut “2” in direction “a” or “b” until the rear c. Connect a clear plastic hose “1” tightly to brake light comes on at the proper time. the bleed screw “2”. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later.

• Page 111: Adjusting The Shift Pedal

  CHASSIS EWA13110 NOTE: WARNING Place the vehicle on a suitable stand so that After bleeding the hydraulic brake system, the rear wheel is elevated. check the brake operation. 2. Spin the rear wheel several times and find ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the tightest position of drive chain. 3.

• Page 112: Lubricating The Drive Chain

  CHASSIS d. Tighten both locknuts to specification. Refer to «STEERING HEAD» on page 4-57. 4. Adjust: Locknut • Steering head 16 Nm (1.6 m·kg, 12 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring e. Tighten the wheel axle nut to specification. nut “2”, and the rubber washer “3”.

• Page 113: Checking The Front Fork

  CHASSIS 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.

• Page 114: Adjusting The Front Fork Legs

  CHASSIS EWA13120 EWA13150 WARNING WARNING Securely support the vehicle so that there • Always adjust both front fork legs evenly. is no danger of it falling over. Uneven adjustment can result in poor handling and loss of stability. 2. Check: •…

• Page 115
  CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (Right side front fork) Compression damping (Left side front fork) EC2D1006 CAUTION: ECA13590 CAUTION: • Never go beyond the maximum or mini- • Never go beyond the maximum or mini- mum adjustment positions. mum adjustment positions. •…

• Page 116: Adjusting The Rear Shock Absorber Assembly

  CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping EAS21620 ADJUSTING THE REAR SHOCK ECA13590 ABSORBER ASSEMBLY CAUTION: EWA13120 Never go beyond the maximum or minimum WARNING adjustment positions. Securely support the vehicle so that there 1. Adjust: is no danger of it falling over. •…

• Page 117: Checking The Tires

  EAS21650 CHECKING THE TIRES Basic weight (with oil and a full The following procedure applies to both of the fuel tank) tires. FZ1-N 1. Check: 214kg (472lb) • Tire pressure FZ1-S Out of specification → Regulate. 220kg (485lb) Loading condition* 0–90 kg (0–198 lb)

• Page 118
  No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. 1. Tire tread depth Front tire 2.

• Page 119: Checking The Wheels

  CHASSIS EAS21670 EAS21710 CHECKING THE WHEELS LUBRICATING THE PEDAL The following procedure applies to both of the Lubricate the pivoting point and metal-to-metal wheels. moving parts of the pedal. 1. Check: Recommended lubricant • Wheel Damage/out-of-round → Replace. Lithium — soap — based grease EWA13260 WARNING EAS21720…

• Page 120
  A. FZ1-N EAS21780 REPLACING THE HEADLIGHT BULBS B. FZ1-S 1. Remove: 4. Remove: • Headlight side cover bolts “1” (FZ1-N) • Headlight bulb cover “1” (FZ1-S) 2. Disconnect: 5. Remove: • Headlight sub-wire harness coupler “2” • Headlight bulb holder “1”…
• Page 121
  Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. A. FZ1-N B. FZ1-S EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
• Page 122
  ELECTRICAL SYSTEM A. FZ1-N B. FZ1-S ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-37…
• Page 123
  CHASSIS GENERAL CHASSIS………………4-1 REMOVING THE COVER…………… 4-7 INSTALLING THE COVER …………..4-7 FRONT WHEEL ……………….. 4-8 REMOVING THE FRONT WHEEL …………4-10 CHECKING THE FRONT WHEEL…………4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE …….4-11 INSTALLING THE FRONT WHEEL (DISC) ……….4-12 REAR WHEEL ………………..4-14 REMOVING THE REAR WHEEL (DISC) ……….
• Page 124
  REMOVING THE HANDLEBAR …………4-45 CHECKING THE HANDLEBAR…………4-45 INSTALLING THE HANDLEBAR …………4-45 FRONT FORK…………………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 ……….
• Page 126
  GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Passenger seat Rider seat Battery band Battery cover Battery negative lead Battery positive lead Battery Battery seat For installation, reverse the removal procedure.
• Page 127
  GENERAL CHASSIS Removing the headlight and meter assembly (FZ1-N) Order Job/Parts to remove Q’ty Remarks Headlight side cover bolt (left and right) Headlight coupler Disconnect. Headlight sub-wire harness coupler Disconnect. Headlight assembly Headlight bracket Headlight side cover (left and right)
• Page 128
  GENERAL CHASSIS Removing the front cowling (FZ1-S) Order Job/Parts to remove Q’ty Remarks Inner panel Headlight assembly coupler Disconnect. Meter coupler Disconnect. Front cowling assembly Rear view mirror Cowling stay Meter assembly Headlight unit For installation, reverse the removal procedure.
• Page 129
  GENERAL CHASSIS Removing the rear fender (FZ1-N) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Mud guard assembly Rear fender Tail/brake light lead coupler Disconnect.
• Page 130
  GENERAL CHASSIS Removing the rear fender (FZ1-S) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Mud guard assembly Rear fender Tail/brake light lead coupler Disconnect.
• Page 131
  GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Intake air temperature sensor lead cou- Disconnect. pler Intake air temperature sensor Air filter case cover…

• Page 132: General Chassis

  GENERAL CHASSIS EAS21840 REMOVING THE COVER 1. Remove: • Tail cover • Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1. Install: • Rear fender •…

• Page 133
  FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty 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)
• Page 134
  FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassem- bly procedure.

• Page 135: Front Wheel

  FRONT WHEEL EAS21900 Refer to «CHECKING THE TIRES» on page REMOVING THE FRONT WHEEL 3-32 and «CHECKING THE WHEELS» on 1. Stand the vehicle on a level surface. page 3-34. EWA13120 3. Measure: WARNING • Radial wheel runout “1” Securely support the vehicle so that there •…

• Page 136: Adjusting The Front Wheel Static Balance

  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. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Remove the wheel bearings “3” with a gen- a.

• Page 137: Installing The Front Wheel (Disc)

  FRONT WHEEL a. Install a balancing weight “1” onto the rim EAS22000 INSTALLING THE FRONT WHEEL (DISC) exactly opposite the heavy spot “X”. The following procedure applies to both of the NOTE: brake discs. Start with the lightest weight. 1. Lubricate: •…

• Page 138
  FRONT WHEEL EWA13490 WARNING 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…
• Page 139
  REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut (left and right) Loosen. Adjusting bolt (left and right) Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left) Adjusting block (right) Rear wheel Brake caliper bracket For installation, reverse the removal…
• Page 140
  REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty 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 For installation, reverse the removal procedure.
• Page 141
  REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Coller Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassem- bly procedure. 4-16…

• Page 142: Rear Wheel

  REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 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.

• Page 143: Checking And Replacing The Rear Wheel Sprocket

  REAR WHEEL Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22120 CHECKING AND REPLACING THE REAR EAS22150 WHEEL SPROCKET ADJUSTING THE REAR WHEEL STATIC 1. Check: BALANCE • Rear wheel sprocket NOTE: More than 1/4 tooth “a” wear → Replace • After replacing the tire, wheel or both, the the rear wheel sprocket.

• Page 144
  REAR WHEEL EWA13500 WARNING Make sure the brake hose is routed prop- erly. 4-19…

• Page 145: Front Brake

  FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty 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.

• Page 146
  Q’ty Remarks Brake fluid Drain. Refer to «BLEEDING THE HYDRAU- LIC BRAKE SYSTEM» on page 3- 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 Disconnect.
• Page 147
  FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassem- bly procedure. 4-22…
• Page 148
  FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to «BLEEDING THE HYDRAU- LIC BRAKE SYSTEM» on page 3- Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal procedure.
• Page 149
  FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassem- bly procedure. 4-24…

• Page 150: Introduction

  FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING 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, drained, ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…

• Page 151: Replacing The Front Brake Pads

  FRONT BRAKE NOTE: Brake pad lining thickness Tighten the brake disc bolts in stages and in a (inner) crisscross pattern. 4.5 mm (0.18 in) Limit Brake disc bolt 0.5 mm (0.02 in) 18 Nm (1.8 m·kg, 13 ft·lb) Brake pad lining thickness LOCTITE®…

• Page 152: Removing The Front Brake Calipers

  FRONT BRAKE NOTE: NOTE: The arrow mark “a” on the brake pad spring Before removing the brake caliper, drain the must point in the direction of disc rotation. brake fluid from the entire brake system. 1. Remove: • Union bolt “1” •…

• Page 153: Checking The Front Brake Calipers

  FRONT BRAKE c. Remove the brake caliper piston seals. EAS22410 d. Repeat the previous steps to force out the ASSEMBLING THE FRONT BRAKE CALI- right side pistons from the brake caliper. PERS EWA13620 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WARNING • Before installation, all internal brake com- EAS22390 CHECKING THE FRONT BRAKE CALIPERS ponents should be cleaned and lubricated…

• Page 154: Removing The Front Brake Master Cylinder

  FRONT BRAKE “a” touches the projection “b” on the brake ECA13540 CAUTION: caliper. 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»…

• Page 155: Checking The Front Brake Master Cylinder

  FRONT BRAKE EAS22520 ASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER EWA13520 WARNING • 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. 2. Remove: Recommended fluid •…

• Page 156
  FRONT BRAKE • When refilling, be careful that water does Brake hose union bolt not enter the brake master cylinder reser- 30 Nm (3.0 m·kg, 22 ft·lb) voir. Water will significantly lower the boiling point of the brake fluid and could EWA13530 cause vapor lock.

• Page 157: Rear Brake

  REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring For installation, reverse the removal procedure. 4-32…

• Page 158
  REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to «BLEEDING THE HYDRAU- LIC BRAKE SYSTEM» on page 3- Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint…
• Page 159
  REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Hose joint Bushing Brake master cylinder body For assembly, reverse the disassem- bly procedure. 4-34…
• Page 160
  REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose Barke caliper For installation, reverse the removal procedure. 4-35…
• Page 161
  REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty 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.

• Page 162: Introduction

  REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to «CHECKING THE FRONT BRAKE preventive measures: DISCS» on page 4-25. •…

• Page 163: Removing The Rear Brake Caliper

  REAR BRAKE a. Connect a clear plastic hose “1” tightly to Refer to «CHECKING THE BRAKE FLUID the bleed screw “2”. Put the other end of LEVEL» on page 3-23. the hose into an open container. 5. Check: • Brake pedal operation b.

• Page 164: Checking The Rear Brake Caliper

  REAR BRAKE 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. EWA13610 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a.

• Page 165: Installing The Rear Brake Caliper

  REAR BRAKE EAS22670 • Brake caliper INSTALLING THE REAR BRAKE CALIPER Refer to «REPLACING THE REAR BRAKE 1. Install: PADS» on page 4-37. • Brake caliper “1” (temporarily) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) • Copper washers “2” Brake caliper bolt (rear) •…

• Page 166: Removing The Rear Brake Master Cylinder

  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 7. Check: EWA13520 • Brake pedal operation WARNING Soft or spongy feeling →…

• Page 167
  REAR BRAKE 5. Check: 2. Fill: • Brake pedal operation • Brake fluid reservoir Soft or spongy feeling → Bleed the brake (with the specified amount of the recom- system. mended brake fluid) Refer to «BLEEDING THE HYDRAULIC BRAKE SYSTEM» on page 3-25. Recommended fluid 6.

• Page 168: Handlebar

  Job/Parts to remove Q’ty Remarks Front cowling (FZ1-S) Refer to «GENERAL CHASSIS» on page 4-1. Rear view mirror (FZ1-N) Front brake light switch connector Disconnect. Front master cylinder bracket Front brake master cylinder assembly Right handlebar switch Throttle cable housing…

• Page 169
  HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Handlebar Lower handlebar holder For installation, reverse the removal procedure. 4-44…

• Page 170: Removing The Handlebar

  HANDLEBAR EAS22860 EAS22930 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there Securely support the vehicle so that there is no danger of it falling over.

• Page 171
  HANDLEBAR Grip end 26 Nm (2.6 m·kg, 19 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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.
• Page 172
  HANDLEBAR NOTE: • Align the projections «a» on the handlebar switch with the holes «b» in the handlebar. • Threre should be 1–3 mm (0.04–0.12 in) of clearance “c” between the handlebar grip and the grip end. 10. Install: • Front brake master cylinder assembly •…

• Page 173: Front Fork

  FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty 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.

• Page 174
  FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Damper adjusting rod Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube For assembly, reverse the disassem-…

• Page 175: Removing The Front Fork Legs

  FRONT FORK EAS22970 • Nut “3” REMOVING THE FRONT FORK LEGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to both of the a. Press down on the spacer with the fork front fork legs. spring compressor “4”. NOTE: b. Install the rod holder “5” between the nut Each front fork leg is eqipped with a spring “3”…

• Page 176: Checking The Front Fork Legs

  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 3. Remove: • Oil seal clip “1” (with a flat-head screwdriver) ECA14180 CAUTION:…

• Page 177: Assembling The Front Fork Legs

  FRONT FORK • Damper rod assembly bolt • Copper washer 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: 3.

• Page 178
  FRONT FORK 6. Install: 4. Install: • Oil seal clip “1” • Dust seal “1” • Oil seal clip “2” NOTE: • Oil seal “3” Adjust the oil seal clip so that it fits into the • Washer “4” outer tube’s groove. ECA14220 CAUTION: Make sure the numbered side of the oil seal…
• Page 179
  FRONT FORK Rod puller 90890-01437 Rod puller attachment (M10) 90890-01436 11. Before 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- 9.
• Page 180
  FRONT FORK ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the rod puller and adapter. f. Remove the rod puller and the rod puller b. Install the nut. attachment. c. Install the fork spring and spacer. g. Install the nut “1” and position it as speci- fied “b”.

• Page 181: Installing The Front Fork Legs

  FRONT FORK EW2D1003 WARNING • The fork spring is compressed. • Always use a new cap bolt O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: 3. Adjust: Each front fork leg is eqipped with a spring •…

• Page 182: Steering Head

  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- Front fork legs Refer to «FRONT FORK»…

• Page 183
  STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front brake hose joint bracket Horn Horn bracket Lock washer Upper ring nut Rubber washer Lower ring nut Lower bracket Lower bearing Lower bearing dust seal Lower bearing inner race Bearing cover Upper bearing inner race Upper bearing…

• Page 184: Removing The Lower Bracket

  STEERING HEAD Damage/pitting → Replace. EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut “1” 3.

• Page 185: Installing The Steering Head

  STEERING HEAD 4. Check: Steering stem nut • Upper bracket 113 Nm (11.3 m·kg, 82 ft·lb) • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing •…

• Page 186: Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Side cover (left and right) Refer to «GENERAL CHASSIS» on page 4-1.

• Page 187
  REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure. 4-62…

• Page 188: Handling The Rear Shock Absorber

  REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA13740 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling •…

• Page 189: Checking The Connecting Arm And Relay Arm

  REAR SHOCK ABSORBER ASSEMBLY Gas leaks/oil leaks → Replace the rear 3. Tighten: shock absorber assembly. • Rear shock absorber assembly upper nut • Spring Rear shock absorber assembly Damage/wear → Replace the rear shock upper nut absorber assembly. 44 Nm (4.4 m·kg, 32 ft·lb) •…

• Page 190: Swingarm

  SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to «REAR WHEEL» on page 4- Rear brake caliper Refer to «REAR BRAKE» on page 4- Rear shock absorber Refer to «REAR SHOCK ABSORBER ASSEMBLY» on page 4-61.

• Page 191
  SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Drive chain Dust cover Drive chain guide Spacer Bearing For installation, reverse the removal procedure. 4-66…

• Page 192: Removing The Swingarm

  SWINGARM EAS23350 If swingarm vertical movement is not REMOVING THE SWINGARM smooth or if there is binding, check the 1. Stand the vehicle on a level surface. spacers, bearings, washers, and dust cov- EWA13120 ers. WARNING Securely support the vehicle so that there is no danger of it falling over.

• Page 193: Installing The Swingarm

  SWINGARM 5. Check: • Connecting arms “1” • Relay arm “2” Damage/wear → Replace. 3. Install: 6. Check: • Bearings “3” • Rear shock absorber assembly • Oil seals “4” • Rear wheel Damage/pitting → Replace. Refer to «INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY»…

• Page 194: Chain Drive

  CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to «ENGINE REMOVAL» on page 5-2. Drive chain guard Drive chain For installation, reverse the removal procedure. 4-69…

• Page 195: Removing The Drive Chain

  CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2. Check: Place the vehicle on a suitable stand so that •…

• Page 196: Checking The Drive Sprocket

  CHAIN DRIVE • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct 1. Drive chain roller 2. Drive chain sprocket EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to «CHECKING AND REPLACING THE…

• Page 197: Engine

  ENGINE ENGINE REMOVAL ………………5-2 INSTALLING THE ENGINE …………..5-8 CAMSHAFTS………………..5-10 REMOVING THE CAMSHAFTS …………5-12 CHECKING THE CAMSHAFTS …………5-13 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-14 CHECKING THE TIMING CHAIN GUIDES ……….5-14 CHECKING THE TIMING CHAIN TENSIONER……..5-14 INSTALLING THE CAMSHAFTS…………

• Page 198
  CHECKING THE FRICTION PLATES ……….5-49 CHECKING THE CLUTCH PLATES………….5-49 CHECKING THE CLUTCH SPRINGS……….5-50 CHECKING THE CLUTCH HOUSING ……….5-50 CHECKING THE CLUTCH BOSS …………5-50 CHECKING THE PRESSURE PLATE ……….5-50 CHECKING THE PULL LEVER SHAFT AND PULL ROD….5-50 INSTALLING THE CLUTCH …………..5-51 SHIFT SHAFT …………………5-54 REMOVING THE SHIFT SHAFT …………
• Page 199
  CHECKING THE TRANSMISSION …………5-91 INSTALLING THE TRANSMISSION………….5-92…

• Page 200: Engine Removal

  ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Plate For installation, reverse the removal procedure.

• Page 201
  ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty 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…
• Page 202
  ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks Pulley Spring Spring seat For assembly, reverse the disassem- bly procedure.
• Page 203
  ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to «FUEL TANK» on page 7-1. Air filter case Refer to «GENERAL CHASSIS» on page 4-1. Throttle body assembly Refer to «THROTTLE BODIES» on page 7-4.
• Page 204
  ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty 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.
• Page 205
  ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Right front engine mounting bolt 1 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.

• Page 206: Installing The Engine

  ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Right front engine mounting bolt 2 “1” Refer to «CYLINDER HEAD» on page 5-19. 2. Tighten: • Right front engine mounting bolt 2 Right front engine mounting bolt 2 7. Tighten: 50 Nm (5.0 m·kg, 36 ft·lb) •…

• Page 207
  ENGINE REMOVAL Left front engine mounting bolt 45 Nm (4.5 m·kg, 33 ft·lb) Right front engine mounting bolt 1 45 Nm (4.5 m·kg, 33 ft·lb) 8. Tighten: • Lower self-locking nut “1” • Upper self-locking nut “2” Upper self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb)

• Page 208: Camshafts

  CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to «FUEL TANK» on page 7-1. Throttle body assembly Refer to «THROTTLE BODIES» on page 7-4. Radiator assembly Refer to «RADIATOR» on page 6-1. Air cut-off valve Refer to «AIR INDUCTION SYS- TEM»…

• Page 209
  CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty 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»…

• Page 210: Removing The Camshafts

  CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to «CRANKSHAFT POSITION SEN- SOR» on page 5-38. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.

• Page 211: Checking The Camshafts

  CAMSHAFTS 3. Measure: EAS23850 • Camshaft runout CHECKING THE CAMSHAFTS Out of specification → Replace. 1. Check: • Camshaft lobes Camshaft runout limit Blue discoloration/pitting/scratches → 0.03 mm (0.0012 in) Replace the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →…

• Page 212: Checking The Timing Chain And Camshaft Sprocket

  CAMSHAFTS 2. Check: • 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 5. Measure: 1. Timing chain roller • Camshaft journal diameter “a” 2.

• Page 213
  CAMSHAFTS b. Squeeze the timing chain tensioner clip “2” NOTE: and push the timing chain tensioner rod “3”. Squeeze the timing chain tensioner clip, and 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”…

• Page 214: Installing The Camshafts

  CAMSHAFTS EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When position #1 is at TDC, align the “T” mark “a” with the crankcase mating surface “b”.

• Page 215
  CAMSHAFTS • The camshaft cap bolts must be tightened • Timing chain tensioner “1” evenly or damage to the cylinder head, • Timing chain tensioner bolts “2” camshaft caps, and camshafts will result. Timing chain tensioner bolt • Do not turn the crankshaft when installing 10 Nm (1.0 m·kg, 7.2 ft·lb) the camshaft to avoid damage or improper valve timing.
• Page 216
  CAMSHAFTS 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…

• Page 217: Cylinder Head

  CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Engine Refer to «ENGINE REMOVAL» on page 5-2. Intake camshaft Refer to «CAMSHAFTS» on page 5-10. Exhaust camshaft Refer to «CAMSHAFTS» on page 5-10. Cylinder head Cylinder head gasket Dowel pin Coolant pipe…

• Page 218: Removing The Cylinder Head

  CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to «REMOVING THE CAMSHAFTS» on page 5-12. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: a. Place a straightedge “1” and a thickness • Cylinder head nuts gauge “2” across the cylinder head. •…

• Page 219
  CYLINDER HEAD 5. Install: • Gasket “1” • Exhaust camshaft • Dowel pins • Intake camshaft Refer to «INSTALLING THE CAMSHAFTS» on page 5-16. 3. Install: • Cylinder head NOTE: Pass the timing chain through the timing chain cavity. 4. Tighten: •…
• Page 220
  VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to «CYLINDER HEAD» on page 5-19. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve stem seal Intake valve lower spring seat…

• Page 221: Valves And Valve Springs

  VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure. 5-23…

• Page 222: Removing The Valves

  VALVES AND VALVE SPRINGS EAS24280 NOTE: REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “2” and the valve spring compressor attach- NOTE: ment “3”.

• Page 223: Checking The Valves And Valve Guides

  VALVES AND VALVE SPRINGS EAS24290 NOTE: CHECKING THE VALVES AND VALVE To ease valve guide removal and installation, GUIDES and to maintain the correct fit, heat the cylinder The following procedure applies to all of the head to 100°C (212°F) in an oven. valves and valve guides.

• Page 224: Checking The Valve Seats

  VALVES AND VALVE SPRINGS Intake Valve guide remover (ø4) 90890-04111 YM-04111 Exhaust Valve guide remover (ø4.5) 90890-04116 YM-04116 Intake Valve guide installer (ø4) 90890-04112 6. Measure: YM-04112 • Valve stem runout Out of specification → Replace the valve. Exhaust Valve guide installer (ø4.5) NOTE: 90890-04117 •…

• Page 225
  VALVES AND VALVE SPRINGS NOTE: Valve seat width After replacing the cylinder head or replacing Intake the valve and valve guide, the valve seat and 0.90–1.10 mm valve face should be lapped. (0.0354–0.0433 in) Exhaust ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 0.90–1.10 mm a. Apply a coarse lapping compound “a” to (0.0354–0.0433 in) the valve face.

• Page 226: Checking The Valve Springs

  VALVES AND VALVE SPRINGS h. Install the valve into the cylinder head. 2. Measure: i. Press the valve through the valve guide • Compressed valve spring force “a” Out of specification → Replace the valve and onto the valve seat to make a clear impression.

• Page 227: Checking The Valve Lifters

  VALVES AND VALVE SPRINGS 3. Install: EAS24320 • Valve “1” CHECKING THE VALVE LIFTERS • Lower spring seat “2” The following procedure applies to all of the • Valve stem seal “3” valve lifters. • Valve spring “4” 1. Check: •…

• Page 228
  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 Exhaust Valve spring compressor attachment 90890-04108 YM-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.

• Page 229: Generator

  GENERATOR EAS24480 GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Engine oil Drain. Refer to «CHANGING THE ENGINE OIL»…

• Page 230
  GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Bearing Stator coil assembly lead holder Idler gear Idler gear shaft Washer Bearing For assembly, reverse the removal procedure. 5-32…

• Page 231: Removing The Generator

  GENERATOR EAS24490 REMOVING THE GENERATOR 1. Remove: • Plug • Generator rotor cover “1” NOTE: • While pushing generator rotor, remove the generator rotor cover. • Loosen each bolt 1/4 of a turn a time, in stages and in a crisscross pattern. •…

• Page 232
  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.

• Page 233: Starter Clutch

  STARTER CLUTCH EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks Generator rotor Damper Driven gear Washer Starter clutch drive gear Collar Washer Spacer O-ring For assembly, reverse the removal procedure. 5-35…

• Page 234: Removing The Starter Clutch

  STARTER CLUTCH EAS24560 REMOVING THE STARTER CLUTCH 1. Remove: • Spacer “1” • O-ring “2” • Washer “3” EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” Damage/wear → Replace. 2. Remove: • Starter clutch drive gear “1” •…

• Page 235: Installing The Starter Clutch

  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 “B”, it should turn freely, other- • Spacer “3” wise the starter clutch is faulty and must be NOTE: replaced.

• Page 236: Crankshaft Position Sensor

  CRANKSHAFT POSITION SENSOR EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Engine oil Drain.

• Page 237: Removing The Crankshaft Position Sensor

  CRANKSHAFT POSITION SENSOR EAS24530 REMOVING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor lead coupler 2. Remove: • Crankshaft position sensor • O-ring • Pickup coil rotor cover “1” NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

• Page 238: Electric Starter

  ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Throttle body assembly Refer to «THROTTLE BODIES» on page 7-4.

• Page 239
  ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Front cover Lock washer Washer Starter motor yoke Armature assembly O-ring Starter motor lead Brush holder Rear cover For assembly, reverse the disassem- bly procedure. 5-41…

• Page 240: Checking The Starter Motor

  ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the starter Commutator resistance “1”…

• Page 241: Assembling The Starter Motor

  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. 7. Check: • Gear teeth Damage/wear → Replace the gear. EAS24800 ASSEMBLING THE STARTER MOTOR EAS24810 1.

• Page 242: Clutch

  CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to «CHANGING THE ENGINE OIL» on page 3-12. Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal procedure.

• Page 243
  CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 5-45…
• Page 244
  CLUTCH Removing the clutch Order Job/Parts to remove Q’ty 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…
• Page 245
  CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks For assembly, reverse the removal procedure. 5-47…

• Page 246: Removing The Clutch

  CLUTCH EAS25080 4. Remove: REMOVING THE CLUTCH • Clutch plate 1 “1” 1. Remove: • Friction plate 2 • Clutch cover “1” • Gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

• Page 247: Checking The Friction Plates

  CLUTCH • Thrust plate 1. Check: 8. Remove: • Friction plate Damage/wear → Replace the friction • Wire circlip “1” plates as a set. NOTE: 2. Measure: There is a built-in damper between the clutch • Friction plate thickness boss and the clutch plate. It is not necessary to Out of specification →…

• Page 248: Checking The Clutch Springs

  CLUTCH 2. Check: • Bearing Damage/wear → Replace the bearing and EAS25140 CHECKING THE CLUTCH SPRINGS clutch housing. The following procedure applies to all of the clutch springs. EAS25160 CHECKING THE CLUTCH BOSS 1. Check: 1. Check: • Clutch spring Damage →…

• Page 249: Installing The Clutch

  CLUTCH • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 3. Install: • Wire circlip “1” 2. Check: • Pull rod bearing Damage/wear →…

• Page 250
  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.
• Page 251
  CLUTCH 12. Tighten 10. Install: • Clutch cover bolts “1” • Pull lever Clutch cover bolt NOTE: 12 Nm (1.2 m·kg, 8.7 ft·lb) Install the pull lever with the “O“ mark facing toward lower side. • Clutch cover bolt “2” Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE®…

• Page 252: Shift Shaft

  SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to «CLUTCH» on page 5-44. Shift arm and shift rod Refer to «ENGINE REMOVAL» on page 5-2. Circlip Washer Shift shaft Collar Shift shaft spring…

• Page 253
  SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure. 5-55…

• Page 254: Removing The Shift Shaft

  SHIFT SHAFT ET2D1011 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refetr to «CLUTCH» on page 5-44 2. Remove: • Shift arm • Shift rod Refetr to «ENGINE REMOVAL» on page 5- 3. Remove: • Circlip “1” • Washer “2” EAS25420 CHECKING THE SHIFT SHAFT (left side of the engine)

• Page 255
  SHIFT SHAFT • Stopper lever spring “3” • Shift rod • Shift arm Refer to «ENGINE REMOVAL» on page 5- 5. Install: • Clutch assembly Refer to «CLUTCH» on page 5-44. 2. Install: • Washer • Collar • Shift shaft spring “1” •…

• Page 256: Oil Pump

  OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to «CHANGING THE ENGINE OIL» on page 3-12. EXUP cables Refer to «ENGINE REMOVAL» on page 5-2. sensor Refer to «ENGINE REMOVAL»…

• Page 257
  OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin Drain pipe Oil strainer Oil pipe Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar…
• Page 258
  OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly For assembly, reverse the removal procedure. 5-60…
• Page 259
  OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil/water pump driven sprocket Collar Oil pump housing Bearing Oil pump outer roter Oil pump inner roter For assembly, reverse the disassem- bly procedure. 5-61…

• Page 260: Removing The Oil Pan

  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 •…

• Page 261: Checking The Relief Valve

  OIL PUMP EAS24970 CHECKING THE RELIEF VALVE ET2D1013 CHECKING THE OIL NOZZLES 1. Check: The following procedure applies to all of the oil • Relief valve body “1” nozzles. • Relief valve “2” 1. Check: • Spring “3” • Oil nozzle “1” •…

• Page 262: Installing The Oil/Water Pump Assembly

  OIL PUMP NOTE: When installing the inner rotor, align the pin “1” in the oil pump shaft with the groove in the inner rotor “2”. 2. Install: • Washer • Oil/water pump assembly drive chain “1” • Oil/water pump assembly drive sprocket “2” •…

• Page 263: Installing The Oil Pan

  OIL PUMP EAS25050 4. Install: INSTALLING THE OIL PAN 1. Install: • Oil delivery pipe “1” • Dowel pins Oil delivery pipe bolt • Gasket 10 Nm (1.0 m·kg, 7.2 ft·lb) • Oil pan “1” LOCTITE® Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) •…

• Page 264: Crankcase

  CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Air filter case Refer to «GENERAL CHASSIS» on page 4-1. Throttle body assembly Refer to «THROTTLE BODIES» on page 7-4. Engine Refer to «ENGINE REMOVAL» on page 5-2. Cylinder head Refer to «CYLINDER HEAD»…

• Page 265
  CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Oil pump 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) Timing chain guide (exhaust side) Left side cover O-ring Lower crankcase…

• Page 266: Disassembling The Crankcase

  Engine oil 2. Apply: 3. Remove: • Sealant • Lower crankcase ECA13900 Yamaha bond No. 1215 CAUTION: (Three Bond No.1215®) Tap on one side of the crankcase with a 90890-85505 soft-face hammer. Tap only on reinforced portions of the crankcase, not on the NOTE: crankcase mating surfaces.

• Page 267
  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·lb) 3rd: +60° Bolt “11”–“16” 24 Nm (2.4 m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2 m·kg, 8.7 ft·lb) *Following the tightening order, loosen the 3.

• Page 268: Crankshaft

  CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to «CRANKCASE» on page 5- Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring…

• Page 269
  CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Crankcase Separate. Refer to «CRANKCASE» on page 5- Connecting rod and connecting rod Refer to «REMOVING THE CON- caps NECTING RODS AND PISTONS» on page 5-72. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear…

• Page 270: Removing The Connecting Rods And Pistons

  CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND Piston pin puller set PISTONS 90890-01304 The following procedure applies to all of the Piston pin puller connecting rods and pistons. YU-01304 1. Remove: • Connecting rod cap “1” • Big end bearings NOTE: •…

• Page 271: Checking The Cylinder And Piston

  CRANKSHAFT 4 mm (0.16 in) “a” from the bottom edge of NOTE: the piston Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its Piston size “P” original place. 76.975 — 76.990 mm (3.0305 — 3.0311 in) ET2D1032 CHECKING THE CYLINDER AND PISTON…

• Page 272: Checking The Piston Pins

  CRANKSHAFT Piston ring side clearance Piston ring end gap Top ring Top ring 0.030–0.065 mm 0.15–0.25 mm (0.0012–0.0026 in) (0.0059–0.0098 in) Limit Limit 0.115 mm (0.0045 in) 0.50 mm (0.0197 in) 2nd ring 2nd ring 0.020–0.055 mm 0.30–0.45 mm (0.0008–0.0022 in) (0.0118–0.0177 in) Limit Limit…

• Page 273: Checking The Big End Bearings

  CRANKSHAFT end bearings must be installed in their orig- Piston pin bore inside diameter inal positions. 17.002–17.013 mm a. Clean the big end bearings, crankshaft (0.6694–0.6698 in) pins, and the inside of the connecting rods Limit halves. 17.043 mm (0.6710 in) b.

• Page 274
  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. e. Tighten the connecting rod bolts. Connecting rod bolt 20 Nm (2.0 m·kg, 14 ft·lb) NOTE:…
• Page 275
  CRANKSHAFT p. After the installation, check that the section ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ shown “a” is flush with each other by touch- 2. Select: ing the surface. • Big end bearings (P1 – P4) • Side machined face “a” NOTE: EWA13120 • The numbers “A” stamped into the crank- WARNING shaft wed and the numbers “1”…

• Page 276: Installing The Connecting Rod And Piston

  CRANKSHAFT EAS26190 (with the recommended lubricant) INSTALLING THE CONNECTING ROD AND PISTON Recommended lubricant The following procedure applies to all of the Engine oil connecting rods and pistons. 4. Offset: 1. Install: • Piston ring end gaps • Top ring “1” •…

• Page 277
  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) • Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…
• Page 278
  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. c. Put a mark “1” on the connecting rod bolt “2” and the connecting rod cap “3”. 11.

• Page 279: Checking The Crankshaft

  CRANKSHAFT • 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.

• Page 280
  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 “11”–“16” 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” d.

• Page 281: Installing The Crankshaft

  CRANKSHAFT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • Crankshaft journal bearings (J1–J5) NOTE: • The numbers “A” stamped into the crank- shaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. • “J1–J5” refer to the bearings shown in the crankshaft illustration.

• Page 282
  CRANKSHAFT NOTE: • Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place. 3. Install: • Crankshaft 4. Install: •…

• Page 283: Transmission

  TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Crankcase lower Separate. Refer to «CRANKCASE» on page 5- Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L”…

• Page 284
  TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Main axle assembly Oil pipe O-ring Oil baffle plate For installation, reverse the removal procedure. 5-86…
• Page 285
  TRANSMISSION Disassembling the main axle assenbly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 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 For assembly, reverse the disassem- bly procedure.
• Page 286
  TRANSMISSION Disassembling the drive axle assenbly Order Job/Parts to remove Q’ty 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…
• Page 287
  TRANSMISSION Disassembling the drive axle assenbly Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Drive axle For assembly, reverse the disassem- bly procedure. 5-89…

• Page 288: Removing The Transmission

  TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Drive axle asseembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork “L” and “R” • Shift drum assembly • Shift fork “C” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.

• Page 289: Checking The Shift Drum Assembly

  TRANSMISSION Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 3. Check: • Shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. 2.

• Page 290
  TRANSMISSION 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” 3. Install: •…
• Page 291
  TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-93…
• Page 292
  COOLING SYSTEM RADIATOR………………..6-1 CHECKING THE RADIATOR…………..6-3 INSTALLING THE RADIATOR …………..6-3 OIL COOLER ………………..6-4 CHECKING THE OIL COOLER………….. 6-5 INSTALLING THE OIL COOLER …………6-5 THERMOSTAT ………………..6-6 CHECKING THE THERMOSTAT…………6-8 ASSEMBLING THE THERMOSTAT ASSEMBLY ……..6-8 INSTALLING THE THERMOSTAT ASSEMBLY ……..6-8 WATER PUMP ………………..6-10 DISASSEMBLING THE WATER PUMP ……….
• Page 293
  RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Air filter case Refer to «GENERAL CHASSIS» on page 4-1.
• Page 294
  RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Water pump inlet pipe O-ring For installation, reverse the removal procedure.
• Page 295
  RADIATOR 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. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
• Page 296
  OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to «CHANGING THE ENGINE OIL» on page 3-12. Oil cooler inlet hose Oil cooler bolt Washer Oil cooler O-ring Water pump outlet pipe O-ring Water jacket joint inlet hose O-ring…

• Page 297: Oil Cooler

  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»…

• Page 298
  THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Air filter case Refer to «GENERAL CHASSIS» on page 4-1.
• Page 299
  THERMOSTAT Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks Thermostat housing cover Thermostat Thermostat housing O-ring For assembly, reverse the disassem- bly procedure.
• Page 300
  THERMOSTAT EAS26450 • Thermostat housing “2” CHECKING THE THERMOSTAT Cracks/damage → Replace. 1. Check: • Thermostat Does not open at 71 – 85°C (160 – 185°F) → Replace. EAS26460 ASSEMBLING THE THERMOSTAT ASSEM- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container 1.
• Page 301
  THERMOSTAT Below the specified pressure → Replace the radiator cap. Refer to «CHECKING THE RADIATOR» on page 6-3.

• Page 302: Water Pump

  WATER PUMP EAS26500 WATER PUMP Removing the impeller shaft Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to «OIL PUMP» on page 5-58. Oil pump roter Refer to «OIL PUMP» on page 5-58. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing…

• Page 303
  WATER PUMP 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. EAS26540 CHECKING THE WATER PUMP 1. Check: •…
• Page 304
  (4). tools. ECA14090 • Before installing the water pump seal, apply CAUTION: Yamaha bond No.1215 (Three Bond Make sure the rubber damper and rubber No.1215® ) “2” to the water pump housing damper holder are flush with the impeller. “3”.
• Page 305
  WATER PUMP 6-13…
• Page 306
  FUEL SYSTEM FUEL TANK ………………..7-1 REMOVING THE FUEL TANK…………..7-2 REMOVING THE FUEL PUMP……………7-2 CHECKING THE FUEL PUMP BODY …………7-2 CHECKING THE FUEL PUMP OPERATION ………7-2 INSTALLING THE FUEL PUMP …………. 7-2 INSTALLING THE FUEL TANK……………7-3 THROTTLE BODIES………………7-4 CHECKING THE INJECTORS ……………7-8 CHECKING THE THROTTLE BODIES ……….
• Page 307
  FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel hose Disconnect. Fuel sender coupler Disconnect. Fuel pump coupler Disconnect. Fuel tank drain hose Disconnect.

• Page 308: Fuel Tank

  FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK CAUTION: 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •…

• Page 309
  FUEL TANK 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.

• Page 310: Throttle Bodies

  THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to «GENERAL CHASSIS» on page 4-1. Fuel tank Refer to «FUEL TANK» on page 7-1. Air filter case Refer to «GENERAL CHASSIS» on page 4-1.

• Page 311
  THROTTLE BODIES Removing the throttle bodies Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal procedure.
• Page 312
  THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks 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.
• Page 313
  THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Washer Link Sub-throttle servo motor assembly Throttle position sensor Throttle body assembly For installation, reverse the removal procedure.
• Page 314
  THROTTLE BODIES EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. c. Connect the pressure gauge “2” and adapter “3” to the fuel hose (fuel tank to pri- mary injector fuel rail). EAS26990 CHECKING THE THROTTLE BODIES Vacuum/pressure pump gauge 1.
• Page 315
  THROTTLE BODIES 1. Check: ET2D1024 ADJUSTING THE SUB-THROTTLE POSI- • Throttle position sensor TION SENSOR Refer to «CHECKING THE THROTTLE 1. Check: POSITION SENSOR» on page 8-109. • Sub-throttle position sensor 2. Adjust: Refer to «CHECKING THE SUB-THROT- • Throttle position sensor angle TLE POSITION SENSOR»…
• Page 316
  THROTTLE BODIES 4. Adjust: • Sub-throttle position sensor voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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” •…
• Page 317
  THROTTLE BODIES Out of specification → Replace. a. Before adjusting the distance, push the rod ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ “b” in order to be fitted in several times by hand. a. Check whether or not the sub-throttle valve is seized. b. Measure the outside air temperature, and 1 Turn the nut of worm shaft of the sub-throt- adjust the distance “a”…
• Page 318
  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…

• Page 319: Air Induction System

  AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses Order Job/Parts to remove Q’ty 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.

• Page 320
  AIR INDUCTION SYSTEM 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.
• Page 321
  AIR INDUCTION SYSTEM Out of specification → Replace the reed • Plate valve. • Reed valve assembly • Reed valve cap Reed valve bending limit 2. Install: 0.4 mm (0.016 in) • Air cut-off valve • Air cut-off valve hose 1 •…

• Page 322: General Information

  CIRCUIT DIAGRAM…………….8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION……8-7 TROUBLESHOOTING…………….8-9 CHARGING SYSTEM …………….. 8-11 CIRCUIT DIAGRAM…………….8-11 TROUBLESHOOTING…………….8-13 LIGHTING SYSTEM ……………….8-15 CIRCUIT DIAGRAM (FZ1-N) …………..8-15 CIRCUIT DIAGRAM (FZ1-S) …………..8-17 TROUBLESHOOTING…………….8-19 SIGNALING SYSTEM…………….. 8-21 CIRCUIT DIAGRAM…………….8-21 TROUBLESHOOTING…………….8-23 COOLING SYSTEM………………8-27 CIRCUIT DIAGRAM…………….8-27 TROUBLESHOOTING…………….8-29…

• Page 323
  ELECTRICAL COMPONENTS…………..8-89 CHECKING THE SWITCHES……………8-93 CHECKING THE BULBS AND BULB SOCKETS………8-96 CHECKING THE FUSES…………..8-97 CHECKING AND CHARGING THE BATTERY……..8-97 CHECKING THE RELAYS…………..8-100 CHECKING THE TURN SIGNAL/HAZARD RELAY ……8-102 CHECKING THE RELAY UNIT (DIODE) ……….8-102 CHECKING THE IGNITION COILS…………8-103 CHECKING THE CRANKSHAFT POSITION SENSOR…..8-104 CHECKING THE LEAN ANGLE SENSOR………8-105 CHECKING THE STARTOR MOTOR OPERATION ……8-105…

• Page 325: Ignition System

  IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM…

• Page 326
  IGNITION SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 17.Crankshaft position sensor 21.Lean angle sensor 23.ECU 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Ignition coil #4 28.Spark plug 56.Engine stop switch 60.Clutch switch 78.Fuse (ignition)
• Page 327
  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. NG→ (Main and ignition) Replace the fuse(s). Refer to «CHECKING THE FUSES»…
• Page 328
  IGNITION SYSTEM 8 Check the engine stop switch. NG→ Refer to «CHECKING THE Replace the right handlebar switch. SWITCHES» on page 8-93. OK↓ 9 Check the neutral switch. NG→ Refer to «CHECKING THE Replace the neutral switch. SWITCHES» on page 8-93. OK↓…

• Page 329: Electric Starting System

  ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM…

• Page 330
  ELECTRIC STARTING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 9. Starter relay 10.Starter motor 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 56.Engine stop switch 57.Start switch 60.Clutch switch 78.Fuse (ignition)
• Page 331
  ELECTRIC STARTING SYSTEM 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: •…
• Page 332
  ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
• Page 333
  ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case NG→ 1 Check the fuses. (Main and ignition) Replace the fuse(s). Refer to «CHECKING THE FUSES»…
• Page 334
  ELECTRIC STARTING SYSTEM 8 Check the main switch. NG→ Refer to «CHECKING THE Replace the immobilizer kit. SWITCHES» on page 8-93. OK↓ 9 Check the engine stop switch. NG→ Refer to «CHECKING THE Replace the right handlebar switch. SWITCHES» on page 8-93. OK↓…

• Page 335: Charging System

  CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11…

• Page 336
  CHARGING SYSTEM 2. Rectifier/regulator 3. A.C.magneto 6. Fuse (main) 7. Battery 8-12…
• Page 337
  CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 1 Check the fuse. NG→ (Main) Replace the fuse. Refer to «CHECKING THE FUSES» on page 8-97. OK↓…
• Page 338
  CHARGING SYSTEM 8-14…

• Page 339: Lighting System

  LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM (FZ1-N) 8-15…

• Page 340
  LIGHTING SYSTEM 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) 8-16…
• Page 341
  LIGHTING SYSTEM ET2D1026 CIRCUIT DIAGRAM (FZ1-S) 8-17…
• Page 342
  LIGHTING SYSTEM 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) 8-18…
• Page 343
  LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the each bulbs and bulb NG→…
• Page 344
  Replace the headlight relay. Refer to «CHECKING THE RELAYS» on page 8-100. OK↓ 10 Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to «CIRCUIT DIAGRAM system’s wiring. (FZ1-N)» on page 8-15. OK↓ This circuit is OK. 8-20…

• Page 345: Signaling System

  SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21…

• Page 346
  SIGNALING SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 11.Relay unit 14.Neutral switch 16.Fuel pump 19.Speed sensor 23.ECU 42.Fuel level warning light 43.Oil level warning light 44.Neutral indicator light 45.Tacho meter 46.Multi function meter 48.Coolant temperature indicator light 50.Turn signal indicator light (left) 51.Turn signal indicator light (right) 53.Oil level switch 55.Front brake light switch…
• Page 347
  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): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses.
• Page 348
  SIGNALING SYSTEM 3 Check the entire signaling system’s NG→ 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→…
• Page 349
  SIGNALING SYSTEM 3 Check the hazard switch. NG→ Refer to «CHECKING THE Replace the left handlebar switch. SWITCHES» on page 8-93. OK↓ 4 Check the turn signal/hazard relay. NG→ Refer to «CHECKING THE Replace the turn signal/hazard relay. RELAYS» on page 8-100. OK↓…
• Page 350
  SIGNALING SYSTEM 1 Check the fuel sender. NG→ Refer to «CHECKING THE FUEL Replace the fuel pump assembly. SENDER» on page 8-107. OK↓ 2 Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to «CIRCUIT DIAGRAM» on ing system’s wiring.

• Page 351: Cooling System

  COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27…

• Page 352
  COOLING SYSTEM 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…
• Page 353
  COOLING SYSTEM EAS27320 TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case 1 Check the fuses. NG→ (Main, ignition and radiator fan motor) Replace the fuse(s). Refer to «CHECKING THE FUSES» on page 8-97.
• Page 354
  COOLING SYSTEM 8-30…

• Page 355: Fuel Injection System

  FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31…

• Page 356
  FUEL INJECTION SYSTEM 1. Main switch 4. Fuse (backup) 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Sidestand switch 16.Fuel pump 17.Crankshaft position sensor 18.Cylinder identification sensor 19.Speed sensor 20.Atmospheric pressure sensor 21.Lean angle sensor 22.O…
• Page 357
  FUEL INJECTION SYSTEM EAS27370 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case NG→ 1 Check the fuses. (Main, backup, fuel injection and ignition) Replace the fuse(s).
• Page 358
  FUEL INJECTION SYSTEM 8 Check the main switch. NG→ Refer to «CHECKING THE Replace the immobilizer kit. SWITCHES» on page 8-93. OK↓ 9 Check the engine stop switch. NG→ Refer to «CHECKING THE Replace the right handlebar switch. SWITCHES» on page 8-93. OK↓…
• Page 359
  FUEL INJECTION SYSTEM 17 Checking the aomospheric pres- NG→ sure sensor. Replace the atomospheric pressure Refer to «CHECKING THE ATMO- sensor. SPHERIC PRESSURE SENSOR» on page 8-111. OK↓ 18 Check the injector. NG→ Refer to «CHECKING THE INJEC- Replace the injector. TORS»…
• Page 360
  FUEL INJECTION SYSTEM 24 Check the entire ignition system’s NG→ wiring. Properly connect or repair the ignition Refer to «CIRCUIT DIAGRAM» on system’s wiring page 8-1. OK↓ Replace the ECU. 8-36…
• Page 361
  FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

• Page 362: Self-Diagnostic Function Table

  FUEL INJECTION SYSTEM a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light off d. Engine trouble warning light on for 1.4 sec- onds 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.

• Page 363
  FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Coolant temperature Coolant temperature sensor: sensor open or short circuit detected. Able Able (open or short circuit) Intake air temperature Intake air temperature sensor: sensor open or short circuit detected.
• Page 364
  FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Injector Injector: Able Able (open circuit) open circuit detected. (depend- (depend- ing on ing on the num- the num- ber of ber of faulty faulty cylin- cylin-…
• Page 365
  FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive ECU internal malfunc- No signals are received from the ECU Er-2 tion within the specified duration. Unable Unable (output signal error) ECU internal malfunc- Data from the ECU cannot be received Er-3 tion…
• Page 366
  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.
• Page 367
  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 “…
• Page 368
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. When the main switch is • Atmospheric pressure sensor hose is turned to “ON”, the atmo- clogged. spheric pressure sensor • Intake air pressure sensor hose is clogged, voltage and intake air pres- kinked, or pinched.
• Page 369
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. Open circuit detected in the • Open or short circuit in wire harness. primary lead of the cylinder- • Malfunction in ignition coil. #4 ignition coil. • Malfunction in a component of ignition cut- off circuit system.
• Page 370
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. No signals are received • Improper connection in wire harness. Er-2 from the ECU within the • Malfunction in meter. — specified duration. • Malfunction in ECU. Data from the ECU cannot •…
• Page 371
  FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code 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…
• Page 372
  FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction code reinstate • No mulfunction code — • Malfunction code exists Fault code 24 To reinstate, set the engine • (If more than one code stop switch to “ “…
• Page 373
  FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Injector #3 Actuates the injector #3 five Check the operating sound times at one-second inter- of the injector #3 five times. vals. Illuminates the engine trou- ble warning light. Injector #4 Actuates the injector #4 five Check the operating sound times at one-second inter-…
• Page 374
  FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code 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. Illuminates the engine trou- ble warning light only while the motor is runnning.
• Page 375
  FUEL INJECTION SYSTEM No normal signals are received from the crankshaft posi- Fault code No. Symptom tion sensor. Diagnostic code No. — — Orde Item/components and probable Reinstatement Check or maintenance job cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
• Page 376
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor:open or short circuit detected. Diagnostic code No. Intake air pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause method Connections • Check the couplers for any pins Turn the main •…
• Page 377
  FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor:open or short circuit detected. Diagnostic code No. Throttle position sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
• Page 378
  FUEL INJECTION SYSTEM Fault code No. 16 Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of throttle position • Check the installed area for Reinstated by sensor.
• Page 379
  FUEL INJECTION SYSTEM Fault code No. 18 Symptom EXUP servo motor is stuck. Diagnostic code No. EXUP servo motor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •…
• Page 380
  FUEL INJECTION SYSTEM When the main switch is turned to “ON”, the atmospheric Fault code No. Symptom pressure sensor voltage and intake air pressure sensor voltage differ greatly. Atmospheric pressure sensor Diagnostic code No. Intake air pressure sensor Orde Item/components and probable Reinstatement Check or maintenance job cause…
• Page 381
  FUEL INJECTION SYSTEM Intake air temperature sensor:open or short circuit Fault code No. 22 Symptom detected. Diagnostic code No. Intake air temperature sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •…
• Page 382
  FUEL INJECTION SYSTEM Atmospheric pressure sensor:open or short circuit Fault code No. 23 Symptom detected. Diagnostic code No. Atmospheric pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •…
• Page 383
  FUEL INJECTION SYSTEM No normal signal is received from the O sensor. Fault code No. 24 Symptom Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of O sensor. Check for looseness or pinching. Start and warm up the engine Connections •…
• Page 384
  FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 33 Symptom #1 ignition coil. Diagnostic code No. Cylinder-#1 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •…
• Page 385
  FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 34 Symptom #2 ignition coil Diagnostic code No. Cylinder-#2 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •…
• Page 386
  FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 35 Symptom #3 ignition coil Diagnostic code No. Cylinder-#3 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •…
• Page 387
  FUEL INJECTION SYSTEM Open circuit detected in the primary lead of the cylinder- Fault code No. 36 Symptom #4 ignition coil Diagnostic code No. Cylinder-#4 ignition coil Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •…
• Page 388
  FUEL INJECTION SYSTEM Fault code No. 39 Symptom Open circuit detected in a injector. Injector #1 Injector #2 Diagnostic code No. Injector #3 Injector #4 Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Start the engine •…
• Page 389
  FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor:open or short circuit detected. Diagnostic code No. Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •…
• Page 390
  FUEL INJECTION SYSTEM A. No normal signals are received from the speed sen- Fault code No. 42 Symptom sor. B. Open circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause method…
• Page 391
  FUEL INJECTION SYSTEM A. No normal signals are received from the speed sen- Fault code No. 42 Symptom sor. B. Open circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause method…
• Page 392
  FUEL INJECTION SYSTEM Power supply to the injectors and fuel pump is not nor- Fault code No. Symptom mal. Diagnostic code No. Fuel system voltage (battery voltage) Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Starting the •…
• Page 393
  FUEL INJECTION SYSTEM An error is detected while reading or writing on EEPROM Fault code No. Symptom (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Orde Item/components and probable Reinstatement Check or maintenance job cause method Malfunction in ECU •…
• Page 394
  FUEL INJECTION SYSTEM Power supply to the fuel injection system relay is not nor- Fault code No. 46 Symptom mal. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections. • Check the coupler for any pins Starting the •…
• Page 395
  FUEL INJECTION SYSTEM Sub-throttle position sensor:open or short circuit Fault code No. 47 Symptom detected. Diagnostic monitor- Sub-throttle servo motor ing code No. Item/components and probable Reinstatement Order Check or maintenance job cause method Installed state of sub-throttle position • Check for looseness or pinch- Turning the sensor.
• Page 396
  FUEL INJECTION SYSTEM Fault code No. 48 Symptom Sub-throttle servo motor:stuck. Diagnostic code No. Sub-throttle servo motor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the • Sub-throttle servo motor coupler that may be pulled out.
• Page 397
  FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •…
• Page 398
  FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any pins Turning the •…

• Page 399: Fuel Pump System

  FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-75…

• Page 400
  FUEL PUMP SYSTEM 1. Main switch 6. Fuse (main) 7. Battery 8. Fuse (fuel injection) 13.Fuel pump relay 16.Fuel pump 23.ECU 46.Multi function meter 56.Engine stop switch 78.Fuse (ignition) 8-76…
• Page 401
  FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1 Rider and passenger seat 2 Fuel tank 3 Air filter case NG→ 1 Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
• Page 402
  FUEL PUMP SYSTEM 8-78…

• Page 403: Immobilizer System

  IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-79…

• Page 404
  IMMOBILIZER SYSTEM 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…
• Page 405
  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 •…
• Page 406
  IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration Acces- bilizer unit Standard requirement sory lock* Main Immobi- and key switch lizer unit All keys have been Code re-registering ✓ ✓ ✓ ✓ lost (including code key and standard re-registering key) keys Code re-registering…
• Page 407
  IMMOBILIZER SYSTEM Standby mode d. LED off a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on 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.
• Page 408
  IMMOBILIZER SYSTEM Standard key registration h. Second standard key a. Main switch “ON” i. Registration mode b. Main switch “OFF” c. LED on A. Registration of the second standard key is complete. d. LED off B. Immobilizer system indicator light stops e.
• Page 409
  IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turn “ON”, the indicator light does not come on or flashing. 1 Check the fuses. NG→ (Main, ignition and backup) Replace the fuse(s). Refer to «CHECKING THE FUSES» on page 8-97. OK↓…
• Page 410
  IMMOBILIZER SYSTEM Error Detection Symptoms Trouble Measures code IMMOBILIZER Codes do not match 1 Disturbed by other 1 Place the immobi- UNIT between the key and transponder. lizer unit away immobilizer unit. Failed to verify continu- more than 50 mm ally for ten times.
• Page 411
  IMMOBILIZER SYSTEM a. Light on b. Light off 8-87…
• Page 412
  IMMOBILIZER SYSTEM 8-88…

• Page 413: Electrical Components

  ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-89…

• Page 414
  ELECTRICAL COMPONENTS 1. Main switch (immobilizer unit) 2. Front brake light switch 3. Starter relay 4. Battery 5. Fuse box 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Radiator fan motor 11.Horn 12.Ignition coil 8-90…
• Page 415
  ELECTRICAL COMPONENTS 8-91…
• Page 416
  ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Intake air temperature sensor 3. Intake air pressure sensor 4. Fuel pump 5. ECU 6. Lean angle sensor 7. Starting circuit cut-off relay 8. Headlight relay (on/off) 9. Radiator fan motor relay 10.Turn signal relay 11.Recifier/regulator 12.Throttle position sensor 13.Sub-throttle position sensor…
• Page 417
  ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-93…
• Page 418
  ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Dimmer switch 4. Pass switch 5. Turn signal switch 6. Hazard switch 7. Clutch switch 8. Sidestand switch 9. Engine stop switch 10.Front brake light switch 11.Start switch 12.Oil level switch 13.Neutral switch 14.Rear brake light switch 15.Fuse box…
• Page 419
  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.
• Page 420
  ELECTRICAL COMPONENTS EAS27990 hands away from the bulb until it has CHECKING THE BULBS AND BULB SOCK- cooled down. ECA14380 Check each bulb and bulb socket for damage CAUTION: or wear, proper connections, and also for conti- • Be sure to hold the socket firmly when nuity between the terminals.
• Page 421
  Amperage Q’ty rating NOTE: Check each bulb socket for continuity in the Main 50 A same manner as described in the bulb section; Headlight (FZ1-N) 15 A however, note the following. Headlight (FZ1-S) 25 A Signaling system 10 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…
• Page 422
  ELECTRICAL COMPONENTS • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NOT SMOKE when charging or han- dling batteries. • KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
• Page 423
  ELECTRICAL COMPONENTS into the battery quickly and can cause c. Make sure that the current is higher than battery overheating and battery plate the standard charging current written on damage. the battery. • If it is impossible to regulate the charging NOTE: current on the battery charger, be careful If the current is lower than the standard charg-…
• Page 424
  “2”. Relay operation Continuity/No continuity (between “3” to “4”) Relay unit (starting circuit cut-off relay) FZ1-N 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. FZ1-S 9.
• Page 425
  Result (between “3” to “4”) Continuity/No continuity (between “3” to “4”) Headlight relay (on/off) (FZ1-S) Relay unit (fuel pump relay) FZ1-N FZ1-S 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity/No continuity (between “3”…
• Page 426
  ELECTRICAL COMPONENTS b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input voltage. 1. Positive battery terminal ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: 2. Negative battery terminal • Turn signal/hazard relay output voltage 3. Positive tester probe Out of specification → Replace. 4.
• Page 427
  Continuity FZ1-S Positive tester probe → Sky blue “1” Negative tester probe → Yel- low/Black “2” (FZ1-N) Black/ Yellow “2” (FZ1-S) No continuity Positive tester probe → Yel- low/Black “2” (FZ1-N) Black/ Yellow “2” (FZ1-S) Negative tester probe →…
• Page 428
  ELECTRICAL COMPONENTS 3. Check: • Positive tester probe • Ignition spark gap “a” Ignition coil terminal Out of specification → Replace. • Negative tester probe Ignition coil terminal Minimum ignition spark gap 6.0 mm (0.24 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the spark plug.
• Page 429
  ELECTRICAL COMPONENTS a. Connect the pocket tester (Ω × 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 c. When turn the lean angle sensor to 65°. Black “2”…
• Page 430
  ELECTRICAL COMPONENTS Out of specification → Replace the startor • Charging voltage Out of specification → Replace the rectifier/ coil. regulator. EAS28150 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: 14 V at 5000 r/min • Stator coil coupler (from the wire harness) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…
• Page 431
  ELECTRICAL COMPONENTS (from the fuel tank) Pocket tester 4. Check: 90890-03112 • Fuel sender resistance Analog pocket tester YU-03112-C Fuel sender resistance Full position of the float • Positive tester probe 19–21Ω at 20°C (68°F) Horn terminal “1” Empty position of the float 139–141 Ω…
• Page 432
  ELECTRICAL COMPONENTS EWA14130 • Positive tester probe WARNING White/Yellow “1” • Handle the coolant temperature sensor • Negative tester probe with special care. Black/Blue “2” • Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor is dropped, replace it. 2.
• Page 433
  ELECTRICAL COMPONENTS • Tester positive lead → Blue “1” • Tester negative lead → 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 kΩ…
• Page 434
  ELECTRICAL COMPONENTS NOTE: When installing the throttle position sensor, adjust its angle properly. Refer to «ADJUST- ING THE THROTTLE POSITION SENSOR» on page 7-8. EAS2D1010 g. While slowly opening the sub-throttle worm CHECKING THE SUB-THROTTLE POSITION nut, check that the sub-throttle position SENSOR sensor resistance is within the specified 1.
• Page 435
  ELECTRICAL COMPONENTS Air induction system solenoid Pocket tester resistance 90890-03112 18–22 Ω at 20°C (68°F) Analog pocket tester YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the Air induction system solenoid • Positive tester probe coupler from the wire harness. Pink “1” b. Connect the pocket tester (Ω × 1) to the Air •…
• Page 436
  ELECTRICAL COMPONENTS EAS28420 CHECKING THE INTAKE AIR TEMPERA- TURE SENSOR 1. Remove: • Intake air temperature sensor (from the air filter case.) EWA14110 WARNING b. Set the main switch to “ON”. • Handle the intake air temperature sensor c. Rotate the crankshaft. with special care.
• Page 437
  ELECTRICAL COMPONENTS 8-113…
• Page 438
  TROUBLESHOOTING TROUBLESHOOTING ……………… 9-1 GENERAL INFORMATION…………..9-1 STARTING FAILURES…………….9-1 INCORRECT ENGINE IDLING SPEED ……….9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY GEAR SHIFTING …………..9-2 SHIFT PEDAL DOES NOT MOVE…………9-2 JUMPS OUT OF GEAR…………….9-2 FAULTY CLUTCH ………………. 9-2 OVERHEATING ………………9-2 OVERCOOLING ………………9-3 POOR BRAKING PERFORMANCE …………9-3 FAULTY FRONT FORK LEGS …………..9-3…

• Page 439: Fuel System

  TROUBLESHOOTING EAS28450 • Sucked-in air TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery NOTE: • Faulty battery The following guide for troubleshooting does 2. Fuse(s) not cover all the possible causes of trouble. It • Blown, damaged or incorrect fuse should be helpful, however, as a guide to basic •…

• Page 440: Troubleshooting

  TROUBLESHOOTING • Improper throttle cable free play • Improperly assembled transmission • Flooded throttle body EAS28550 • Faulty air induction system JUMPS OUT OF GEAR Electrical system Shift shaft 1. Battery • Incorrect shift pedal position • Discharged battery • Improperly returned stopper lever •…

• Page 441
  TROUBLESHOOTING 2. Engine oil • Faulty brake caliper seal • Incorrect oil level • Loose union bolt • Incorrect oil viscosity • Damaged brake hose • Inferior oil quality • Oil or grease on the brake disc • Oil or grease on the brake pad Cooling system •…
• Page 442
  TROUBLESHOOTING • Uneven tire pressures (front and rear) • Improperly grounded circuit • Incorrect tire pressure • Faulty battery • Uneven tire wear • Blown, damaged or incorrect fuse 7. Wheel(s) Turn signal blinks slowly • Incorrect wheel balance • Faulty turn signal relay •…
• Page 443
  55. Front brake light switch Br/W Brown/White WIRING DIAGRAM 56. Engine stop switch Br/Y Brown/Yellow 57. Start switch FZ1-N (V) 2006 Green/Black 58. Rear brake light switch 1. Main switch Green/Red 59. Left handlebar switch 2. Rectifier/regulator Green/White 60. Clutch switch 3.
• Page 444
  FZ1-S (V) 2006 58. Rear brake light switch Green/Black 59. Left handlebar switch 1. Main switch Green/Red 60. Clutch switch 2. Rectifier/regulator Green/White 61. Pass switch 3. A.C.magneto Green/Yellow 62. Dimmer switch 4. Fuse (backup) Gy/G Gray/Green 63. Hazard switch 5.
• Page 445
  YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…
• Page 446
  FZ1-N (V) 2006 FZ1-N (V) 2006 FZ1-N (V) 2006 FZ1-N (V) 2006 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N (V) 2006…
• Page 447
  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…
• Page 448
  FZ1-N (V) 2006 FZ1-N (V) 2006 FZ1-N (V) 2006 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N (V) 2006 HEADLIGHT WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS FREE…
• Page 449
  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 HEADLIGHT WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 SUB-WIRE HARNESS 2…
• Page 450
  FZ1-N (V) 2006 FZ1-N (V) 2006 FZ1-N (V) 2006 FZ1-N (V) 2006 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N (V) 2006…
• Page 451
  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 HEADLIGHT WIRE HARNESS WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 SUB-WIRE HARNESS 2…

• Page 1
  OWNER’S MANUAL FZS1000S FZS1000SC LIT-11626-17-40 5LV-28199-13…
• Page 2
  EAU10041…
• Page 3
  Congratulations on your purchase of the Yamaha FZS1000/FZS1000C. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

• Page 4: Important Manual Information

  This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.

• Page 5
  IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZS1000S/FZS1000SC OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

• Page 6: Table Of Contents

  TABLE OF CONTENTS SAFETY INFORMATION ….1-1 Sidestand ……..3-15 Adjusting the throttle cable Location of important labels ….1-5 Ignition circuit cut-off system ..3-16 free play ……..6-19 Adjusting the valve clearance ..6-20 DESCRIPTION ……..2-1 PRE-OPERATION CHECKS ….. 4-1 Tires ……….

• Page 7
  STORAGE ……….7-1 Care ……….7-1 Storage ………..7-3 SPECIFICATIONS ……8-1 CONSUMER INFORMATION…..9-1 Identification numbers ….9-1 Reporting safety defects ….9-3 Motorcycle noise regulation ….9-4 Maintenance record ……9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY …….9-7 YAMAHA EXTENDED SERVICE (Y.E.S.) ……..9-9…

• Page 8: Safety Information

  SAFETY INFORMATION EAU10270 AND/OR WHEN MADE NECES- • Ride where other motorists can SARY BY MECHANICAL CONDI- see you. Avoid riding in another MOTORCYCLES SINGLE TIONS. motorist’s blind spot. TRACK VEHICLES. THEIR SAFE USE Many accidents involve inexperi- AND OPERATION ARE DEPENDENT Safe riding enced operators.

• Page 9
  Modifications made to this motorcycle other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re- The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren- passenger is important for proper Always wear an approved helmet.
• Page 10
  Since Yamaha cannot should be kept to a minimum. 188 kg (415 lb) (CAL) test all other accessories that may be •…
• Page 11
  SAFETY INFORMATION Gasoline and exhaust gas • Do not park the motorcycle on a GASOLINE IS HIGHLY FLAMMA- slope or soft ground, otherwise it BLE: may fall over. • Always turn the engine off when • Do not park the motorcycle near refueling.

• Page 12: Location Of Important Labels

  SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.

• Page 13
  SAFETY INFORMATION California only CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 5JW-00 (5JW-2835Y-00)

• Page 14: Description

  DESCRIPTION EAU10410 Left view 1. Front fork compression damping force adjusting screw (page 3-11) 9. Shock absorber assembly compression damping force adjusting screw (page 3-13) 2. Front fork rebound damping force adjusting screw (page 3-11) 10.Shock absorber assembly spring preload adjusting ring (page 3-13) 3.

• Page 15: Right View

  DESCRIPTION EAU10420 Right view 1. Owner’s tool kit (page 6-1) 9. Coolant reservoir (page 6-14) 2. Rear brake fluid reservoir (page 6-26) 3. Battery (page 6-33) 4. Front brake fluid reservoir (page 6-26) 5. Radiator cap (page 6-14) 6. Engine oil filter cartridge (page 6-12) 7.

• Page 16: Controls And Instruments

  DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-6) 9. Brake lever (page 3-7) 2. Left handlebar switches (page 3-5) 10.Throttle grip (page 6-19) 3. Starter (choke) lever (page 3-9) 4. Speedometer unit (page 3-3) 5. Main switch/steering lock (page 3-1) 6.

• Page 17: Instrument And Control Functions

  INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10680 To unlock the steering Main switch/steering lock LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is Push the key in, and then turn it to used to lock the steering.

• Page 18: Indicator And Warning Lights

  “ON”. 1. Left turn signal indicator light “ ” Yamaha dealer check the electrical cir- 2. Neutral indicator light “ ” If the warning light does not come on cuit.

• Page 19: Speedometer Unit

  INSTRUMENT AND CONTROL FUNCTIONS ECA10020 EAU11810 be traveled on a full tank of fuel. This in- Speedometer unit CAUTION: formation will enable you to plan future fuel stops. Do not operate the engine if it is overheated. To set a mode Push the “SELECT”…

• Page 20: Tachometer Unit

  INSTRUMENT AND CONTROL FUNCTIONS EAU11890 To set the clock EAU12100 Tachometer unit Self-diagnosis devices 1. Push both the “SELECT” and “RE- This model is equipped with a self-diag- SET” buttons for at least two sec- nosis device for the following electrical onds.

• Page 21: Fuel Gauge

  If the tachometer displays such an error EAU12110 EAU12341 Fuel gauge Handlebar switches code, note the circuit-specific number of r/min, and then have a Yamaha deal- Left er check the vehicle. ECA10040 CAUTION: When the tachometer displays an er- ror code, the vehicle should be checked as soon as possible in or- der to avoid engine damage.

• Page 22: Clutch Lever

  INSTRUMENT AND CONTROL FUNCTIONS EAU12400 ECA10050 EAU12820 Dimmer switch “ ” Clutch lever CAUTION: Set this switch to “ ” for the high See page 5-1 for starting instruc- beam and to “ ” for the low beam. tions prior to starting the engine. EAU12460 Turn signal switch “…

• Page 23: Shift Pedal

  INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12930 EAU12941 Shift pedal Brake lever Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle- bar grip. 1. Shift pedal 1. Brake pedal The shift pedal is located on the left The brake pedal is on the right side of side of the engine and is used in com-…

• Page 24: Fuel Tank Cap

  INSTRUMENT AND CONTROL FUNCTIONS EAU13070 EAU13210 Fuel tank cap NOTE: Fuel The fuel tank cap cannot be closed un- less the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. EWA11090 WARNING Make sure that the fuel tank cap is…

• Page 25: Starter (Choke) Lever

  1. Starter (choke) lever “ ” Fuel tank capacity: mended by Yamaha because it can 21.0 L (5.55 US gal) (4.62 Imp.gal) Starting a cold engine requires a richer cause damage to the fuel system or ve-…

• Page 26: Seat

  INSTRUMENT AND CONTROL FUNCTIONS EAU13940 EAU14290 Seat Helmet holder To remove the seat 1. Insert the key into the seat lock, and then turn it clockwise. 1. Projection 2. Seat holder 1. Helmet holder 2. Push the rear of the seat down to 2.

• Page 27: Storage Compartment

  INSTRUMENT AND CONTROL FUNCTIONS EAU14450 When washing the vehicle, be careful EAU14750 Storage compartment Adjusting the front fork not to let any water enter the storage This front fork is equipped with spring compartment. preload adjusting bolts, rebound damp- ing force adjusting screws and com- pression damping force…

• Page 28
  INSTRUMENT AND CONTROL FUNCTIONS load thereby soften Rebound damping force Compression damping force suspension, turn the adjusting bolt on each fork leg in direction (b). NOTE: Align the appropriate groove on the ad- justing mechanism with the top of the front fork cap bolt.

• Page 29: Adjusting The Shock Absorber Assembly

  INSTRUMENT AND CONTROL FUNCTIONS ECA10100 EAU15041 To increase the spring preload and Adjusting the shock absorber CAUTION: thereby harden the suspension, turn assembly the adjusting ring in direction (a). To de- Never attempt to turn an adjusting This shock absorber assembly is crease the spring preload and thereby mechanism beyond the maximum or equipped with a spring preload adjust-…

• Page 30
  INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Compression damping force NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec- ifications due to small differences in production, the actual number of clicks always represents the entire adjusting range.

• Page 31: Exup System

  EAU15300 EXUP system Sidestand sorber to an open flame or other This model is equipped with Yamaha’s The sidestand is located on the left side high heat sources, otherwise it EXUP (EXhaust Ultimate Power valve) of the frame. Raise the sidestand or may explode due to excessive system.

• Page 32: Ignition Circuit Cut-Off System

  INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re- EAU15321 Ignition circuit cut-off system pair it if it does not function proper- The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions.

• Page 33
  5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.

• Page 34: Pre-Operation Checks

  PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.

• Page 35: Pre-Operation Check List

  • If necessary, add recommended coolant to specified level. 6-14 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.

• Page 36
  • Make sure that operation is smooth. • Check cable free play. Throttle grip 6-19, 6-30 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-29 •…

• Page 37: Operation And Important Riding Points

  Never start the engine or oper- EWA10290 Yamaha dealer check the electrical cir- WARNING ate it in a closed area for any cuit. length of time. Exhaust fumes Before…

• Page 38
  35 seconds with the starter does not go off after starting starting with sufficient fuel, (choke) turned on, then about 2.5 min- have a Yamaha dealer check the with sufficient engine oil, have a utes with the starter (choke) in the half- electrical circuit.

• Page 39: Starting A Warm Engine

  OPERATION AND IMPORTANT RIDING POINTS EAU16640 EAU16671 ECA10260 Starting a warm engine Shifting CAUTION: Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm.

• Page 40: Engine Break-In

  OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points 3. Shift the transmission into the neu- EAU16841 Engine break-in shown in the following table, close tral position when the motorcycle There is never a more important period the throttle, and at the same time, is almost completely stopped.

• Page 41: Parking

  Do not park on a slope or on soft the tachometer red zone. ground, otherwise the vehicle If any engine trouble should oc- may overturn. cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle.

• Page 42: Periodic Maintenance And Minor Repair

  TRAINED AND EQUIPPED TO PER- wrench may be necessary to perform FORM THESE PARTICULAR SER- certain maintenance work correctly. VICES. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

• Page 43
  PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications approved Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before at- tempting any changes.

• Page 44: Periodic Maintenance Chart For The Emission Control System

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months…

• Page 45
  • Check the air cut-off valve, reed Air induction sys- √ √ √ √ √ 10 * valve, and hose for damage. • Replace any damaged parts. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Page 46: General Maintenance And Lubrication Chart

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months…

• Page 47
  PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months 30 months…
• Page 48
  Throttle grip hous- √ √ √ √ √ 24 * if necessary. ing and cable • Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
• Page 49
  PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17630 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service •…

• Page 50: Removing And Installing Panels

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU18770 The panels shown above need to be re- Removing and installing moved to perform some of the mainte- panels nance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. EAU19292 Panels A and C To remove one of the panels…

• Page 51: Checking The Spark Plugs

  Do not attempt to diagnose such 1. Spark plug cap problems yourself. Instead, have a 2. Remove the spark plug as shown, Yamaha dealer check the vehicle. with the spark plug wrench includ- ed in the owner’s tool kit. 6-10…

• Page 52: Canister (For California Only)

  PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for elec- 2. Clean the surface of the spark plug EAU19671 Canister (for California only) trode erosion and excessive car- gasket and its mating surface, and bon or other deposits, and replace then wipe off any grime from the it if necessary.

• Page 53: Engine Oil And Oil Filter Cartridge

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU19890 2. Place an oil pan under the engine Engine oil and oil filter NOTE: to collect the used oil. The engine oil should be between the cartridge 3. Remove the engine oil filler cap minimum and maximum level marks.

• Page 54
  Make sure that the O-ring is properly 17 Nm (1.7 m·kgf, 12 ft·lbf) An oil filter wrench is available at a seated. Yamaha dealer. 7. Install the engine oil drain bolt, and 6. Install the new oil filter cartridge then tighten it to the specified 5.

• Page 55: Coolant

  EAU20101 ECA11620 or remains on, immediately turn the To check the coolant level CAUTION: engine off and have a Yamaha dealer 1. Place the vehicle on the center- In order to prevent clutch slip- check the vehicle. stand. page (since the engine oil also 10.

• Page 56
  If water has been added to the page 6-9.) el A (See page 6-9.), remove the coolant, have a Yamaha dealer 3. Place a container under the engine reservoir cap, add coolant to the check the antifreeze content of to collect the used coolant.
• Page 57
  If water has been added to the Recommended antifreeze: coolant, have a Yamaha dealer High-quality ethylene glycol anti- freeze containing corrosion inhibitors check the antifreeze content of for aluminum engines…

• Page 58: Cleaning The Air Filter Element

  12. Start the engine, and then check 3-10.) the vehicle for coolant leakage. If 2. Remove the fuel tank bolts. coolant is leaking, have a Yamaha dealer check the cooling system. 13. Install the panels. 1. Rubber cover 2. Rubber cover holder 1.

• Page 59
  Before installing the fuel tank, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, other- 1. Air filter case cover wise fuel may leak.

• Page 60: Adjusting The Carburetors

  Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary profes- sional knowledge and experience. 1. Throttle cable free play The throttle cable free play should mea- sure 3.0–5.0 mm (0.12–0.20 in) at the…

• Page 61: Adjusting The Valve Clearance

  Rear: from occurring, the valve clearance regarding the specified tires. 270 kPa (39 psi) (2.70 kgf/cm²) must be adjusted by a Yamaha dealer 90–188 kg (198–415 lb) (CAL) at the intervals specified in the periodic Tire air pressure 90–189 kg (198–417 lb) (U49): maintenance and lubrication chart.

• Page 62
  (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, con- tact a Yamaha dealer immediately and have the tire replaced. Minimum tire tread depth (front and rear): 1.0 mm (0.04 in)
• Page 63
  Tire air valve: tires listed below have been ap- TR412 proved this model Valve core: Yamaha Motor Co., Ltd. #9000A (original) Always make sure that the valve EWA10600 caps are securely installed to WARNING prevent air pressure leakage. This motorcycle is fitted with super- Use only the tire valves and high-speed tires.

• Page 64: Cast Wheels

  The accessories or replace- fore each ride. If any damage is ment parts you choose for your found, have a Yamaha dealer re- motorcycle should be designed spe- place the wheel. Do not attempt cifically for this model, and they…

• Page 65: Adjusting The Clutch Lever Free Play

  Yamaha dealer check the internal clutch mechanism. 1. Clutch lever free play adjusting bolt 1. Distance between brake pedal and footrest 2. Clutch lever free play…

• Page 66: Adjusting The Rear Brake Light Switch

  PERIODIC MAINTENANCE AND MINOR REPAIR the braking performance, which may EAU22270 EAU22321 Adjusting the rear brake light Checking the front and rear result in loss of control and an acci- switch brake pads dent. Front brake 1. Rear brake light switch 2.

• Page 67: Checking The Brake Fluid Level

  When checking the fluid level, point that the wear indicator groove has make sure that the top of the brake almost disappeared, have a Yamaha fluid reservoir is level. dealer replace the brake pads as a set. Use only the recommended quality 1.

• Page 68: Changing The Brake Fluid

  EAU22760 Changing the brake fluid Drive chain slack ter the brake fluid reservoir when Have a Yamaha dealer change the The drive chain slack should be refilling. Water will significantly brake fluid at the intervals specified in checked before each ride and adjusted…

• Page 69
  PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, and then NOTE: tighten the axle nut to the specified Using the alignment marks on each torque. side of the swingarm, make sure that both chain pullers are in the same posi- Tightening torque: tion for proper wheel alignment.

• Page 70: Lubricating The Drive Chain

  Service the drive chain as ed if necessary. If a cable is damaged follows. or does not move smoothly, have a ECA10580 Yamaha dealer check or replace it. CAUTION: The drive chain must be lubricated Recommended lubricant: Yamaha Chain and Cable Lube or…

• Page 71: Checking And Lubricating The Throttle Grip And Cable

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 EAU23131 EAU23140 Checking and lubricating the Checking and lubricating the Checking and lubricating the throttle grip and cable brake and shift pedals brake and clutch levers The operation of the throttle grip should be checked before each ride. In addi- tion, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.

• Page 72: Checking And Lubricating The Centerstand And Sidestand

  If the centerstand or sidestand does push down hard on the handlebars not move up and down smoothly, several times to check if the front have a Yamaha dealer check or re- fork compresses and rebounds pair it. smoothly. Recommended lubricant:…

• Page 73: Checking The Steering

  Securely support the vehicle so that fork does not operate smoothly, there is no danger of it falling over. have a Yamaha dealer check or re- pair it. 2. Hold the lower ends of the front fork legs and try to move them for- ward and backward.

• Page 74: Checking The Wheel Bearings

  WARNING Electrolyte is poisonous and To charge the battery dangerous since it contains sul- Have a Yamaha dealer charge the bat- furic acid, which causes severe tery as soon as possible if it seems to burns. Avoid any contact with have discharged.

• Page 75: Replacing The Fuses

  (See sealed-type (MF) battery charg- check if the device operates. page 3-10.) er, have a Yamaha dealer 4. If the fuse immediately blows If a fuse is blown, replace it as follows. charge your battery.

• Page 76: Replacing A Headlight Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU23730 Headlight bulb Replacing a headlight bulb Do not touch the glass part of This model is equipped with two quartz the headlight bulb to keep it free bulb headlights. If a headlight bulb from oil, otherwise the transpar- burns out, replace it as follows.

• Page 77: Replacing A Tail/Brake Light Bulb

  Replacing a tail/brake light and then connect the coupler. bulb 6. Install the panel. 1. Remove the seat. (See page 7. Have a Yamaha dealer adjust the 3-10.) headlight beam if necessary. 2. Remove the tail/brake light bulb cover. 1. Tail/brake light bulb socket 4.

• Page 78: Replacing A Turn Signal Light Bulb

  To remove the front wheel by removing the screw. EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger of it falling over.

• Page 79: Rear Wheel

  2. Insert the wheel axle. EWA10820 3. Lower the front wheel so that it is WARNING on the ground. It is advisable to have a Yamaha 4. Install the brake calipers by install- dealer service the wheel. ing the bolts. Securely support the motor-…

• Page 80
  PERIODIC MAINTENANCE AND MINOR REPAIR 3. Disconnect the brake torque rod 6. Turn the drive chain slack adjust- EAU25841 To install the rear wheel from the brake caliper by removing ing bolts fully in direction (a). 1. Place the wheel and the brake cal- the nut and the bolt.

• Page 81: Troubleshooting

  However, should your motorcycle require any repair, take it to a Yamaha Tightening torques: dealer, whose skilled technicians have Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf)

• Page 82: Troubleshooting Charts

  Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.

• Page 83
  Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

• Page 84: Motorcycle Care And Storage

  MOTORCYCLE CARE AND STORAGE EAU26010 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.

• Page 85
  MOTORCYCLE CARE AND STORAGE After normal use ECA10790 5. Use spray oil as a universal clean- CAUTION: Remove dirt with warm water, a mild er to remove any remaining dirt. detergent, and a soft, clean sponge, 6. Touch up minor paint damage Do not use warm water since it in- and then rinse thoroughly with clean caused by stones, etc.

• Page 86: Storage

  CAUTION: NOTE: fuel from deteriorating. Storing the motorcycle in a Consult a Yamaha dealer for advice on 5. Perform the following steps to pro- poorly ventilated room or cover- what products to use. tect the cylinders, piston rings, etc.

• Page 87
  MOTORCYCLE CARE AND STORAGE EWA10950 °C (90 °F)]. For more information WARNING on storing the battery, see page To prevent damage or injury from 6-33. sparking, make sure to ground the NOTE: spark plug electrodes while turning Make any necessary repairs before the engine over.

• Page 88: Specifications

  SPECIFICATIONS Dimensions: Engine oil: Carburetor: Overall length: Type: Manufacturer: 2125 mm (83.7 in) YAMALUBE 4, SAE10W30 or SAE20W40 MIKUNI Overall width: Type x quantity: 0° 10° 30° 50° 70° 90° 110° 130°F 765 mm (30.1 in) BSR37 x 4 YAMALUBE 4 (10W30) Overall height: Spark plug(s): or SAE 10W30…

• Page 89
  SPECIFICATIONS 3rd: (Total weight of rider, passenger, cargo and Front brake: 30/20 (1.500) accessories) Type: 4th: Tire air pressure (measured on cold Dual disc brake 28/21 (1.333) tires): Operation: 5th: Right hand operation Loading condition: 30/25 (1.200) Recommended fluid: 0–90 kg (0–198 lb) 6th: Dot 4 Front:…
• Page 90
  SPECIFICATIONS Battery: Headlight fuse: 20.0 A Model: Signaling system fuse: GT14B-4 20.0 A Voltage, capacity: Ignition fuse: 12 V, 12.0 Ah 20.0 A Headlight: Radiator fan fuse: Bulb type: 10.0 A Halogen bulb Backup fuse: Bulb voltage, wattage x quantity: 10.0 A Headlight: 12 V, 60 W/55.0 W ×…

• Page 91: Consumer Information

  Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.

• Page 92
  1. Model label The model label is affixed to the frame under the seat. (See page 3-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

• Page 93: Reporting Safety Defects

  If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

• Page 94: Motorcycle Noise Regulation

  CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

• Page 95: Maintenance Record

  CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.

• Page 96
  CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months…

• Page 97: Yamaha Motor Corporation, U.s.a. Street And Enduro Motorcycle Limited Warranty

  CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY…

• Page 98
  CONSUMER INFORMATION…

• Page 99: Yamaha Extended Service (Y.e.s.)

  This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts.

• Page 100
  Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
• Page 101
  INDEX EXUP system ……..3-15 Accessories and replacement parts ..6-23 Neutral indicator light ……3-2 Air filter element, cleaning ….6-17 Front and rear brake pads, Noise regulation……..9-4 checking……….6-25 Front fork, adjusting ……3-11 Battery ……….6-33 Oil level warning light ……3-2 Front fork, checking…….6-31 Brake and clutch levers, checking Fuel …………3-8…
• Page 102
  INDEX Tachometer unit ……..3-4 Tail/brake light bulb, replacing ….6-36 Throttle cable free play, adjusting ..6-19 Throttle grip and cable, checking and lubricating ……..6-30 Tires …………6-20 Tool kit ………… 6-1 Troubleshooting ……..6-40 Troubleshooting charts ……6-41 Turn signal indicator lights ……
• Page 104
  YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.06-0.8×1 CR…

OWNER’S MANUAL

FZS1000R

FZS1000RC

FZS1000SR

FZS1000SRC

AFFIX DEALER

LABEL HERE

EAU04247

FZS1000R/FZS1000RC/FZS1000SR/FZS1000SRC

OWNER’S MANUAL

©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, May 2002

All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan.

P/N LIT-11626-16-33

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS

1 BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD:

1.OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.

2.OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.

3.OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

4.OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding

1.Always make pre-operation checks. Careful checks may help prevent an accident.

2.This motorcycle is designed to carry the operator and a passenger.

3.The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who

did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

a.Wear a brightly colored jacket.

b.Use extra caution when you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.

c.Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

SAFETY INFORMATION

4.Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license.

a.Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.

b.Know your skills and limits. Staying within your limits may help you to avoid an accident.

c.We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls.

5.Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).

a.Always obey the speed limit and never travel faster than warranted by road and traffic conditions.

b.Always signal before turning or changing lanes. Make sure that other motorists can see you.

6.The posture of the operator and passenger is important for proper control.

a.The operator should keep both hands on the handlebar and both feet on the operator footrests

during operation to maintain control of the motorcycle.

b.The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.

c.Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

7.Never ride under the influence of alcohol or other drugs.

8.This motorcycle is designed for on-road use only. It is not suitable for off-road use.

SAFETY INFORMATION

Protective apparel

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:

SAFETY INFORMATION

Loading

The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of FZS1000, FZS1000S: 189 kg (417 lb) / FZS1000C, FZS1000SC: 188 kg (415 lb). When loading within this weight limit, keep the following in mind:

1.Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.

2.Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

3.Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such items as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response.

Accessories

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.

Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.

1.Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

SAFETY INFORMATION

a.Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front

fork area, they must be as lightweight as possible and should be kept to a minimum.

1 b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles.

c.Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended.

2.Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.

Gasoline and exhaust gas

1.GASOLINE IS HIGHLY FLAMMABLE:

a.Always turn the engine off when refueling.

b.Take care not to spill any gasoline on the engine or exhaust system when refueling.

c.Never refuel while smoking or in the vicinity of an open flame.

2.Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.

3.Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following:

SAFETY INFORMATION

a.The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.

b.Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.

c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open 1 flame), otherwise it could catch fire.

4.When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.

5.If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.

6

SAFETY INFORMATION

EAU02977

Location of important labels

Please read the following important labels carefully before operating this motorcycle.

1

solvent will damage windshield.

Use neutral detergent.

5JW-00 (5JW-2835Y-00)

2

6

Left view

2

DESCRIPTION

Right view

2

DESCRIPTION

Controls and instruments

2

3

1. Push.

2. Turn.

EAU00061

Neutral indicator light “ ”

This indicator light comes on when the transmission is in the neutral position.

To close the fuel tank cap

1.Push the fuel tank cap into position with the key inserted in the lock.

INSTRUMENT AND CONTROL FUNCTIONS