Мануал для yamaha fz1

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  OWNER’S MANUAL FZS1000R FZS1000RC FZS1000SR FZS1000SRC LIT-11626-16-33 5LV-28199-12…
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  EAU03438…
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  EAU00002 Congratulations on your purchase of the Yamaha FZS1000/FZS1000S. 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.
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  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

  IMPORTANT MANUAL INFORMATION EW000000 WARNING PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTOR- CYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT- TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.

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  IMPORTANT MANUAL INFORMATION 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.

• Page 7: Table Of Contents

  TABLE OF CONTENTS EAU00009 1 SAFETY INFORMATION 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX…

• Page 8: Safety Information

  SAFETY INFORMATION Safe riding ………………1-1 Protective apparel …………….1-3 Modifications ………………1-3 Loading and accessories …………..1-3 Gasoline and exhaust gas…………..1-5 Location of important labels ………….. 1-7…

• Page 9: Safe Riding

  S AFETY INFORMATION EAU00014 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 BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1.

• Page 10: Safety Information

  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.

• Page 11: Safety Information

  6. A passenger should also observe the above precautions. 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.

• Page 12: Safety Information

  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.

• Page 13: Gasoline And Exhaust Gas

  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. b.

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  SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe- destrians 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.

• Page 15: Location Of Important Labels

  SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.

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  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 17: Description

  DESCRIPTION Left view ………………… 2-1 Right view………………. 2-2 Controls and instruments …………..2-3…

• Page 18: Left View

  D ESCRIPTION EAU00026 Left view 1. Front fork compression damping 8. Seat lock/helmet holder (page 3-11) force adjusting screw (page 3-14) 9. Shock absorber assembly 2. Front fork rebound damping force compression damping force adjusting screw (page 3-13) adjusting screw (page 3-16) 3.

• Page 19: Right View

  DESCRIPTION Right view 13. Owner’s tool kit (page 6-1) 18. Engine oil filter cartridge (page 6-13) 14. Rear brake fluid reservoir (page 6-30) 19. Engine oil level check window (page 6-12) 15. Battery (page 6-37) 20. Brake pedal (page 3-8) 16.

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  DESCRIPTION Controls and instruments 1. Clutch lever (page 3-7) 6. Tachometer unit (page 3-4) 2. Left handlebar switches (page 3-6) 7. Fuel gauge (page 3-5) 3. Starter (choke) lever (page 3-10) 8. Right handlebar switches (page 3-6) 4. Speedometer unit (page 3-3) 9.

• Page 21: Instrument And Control Functions

  INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock …………..3-1 Indicator and warning lights …………. 3-2 Speedometer unit …………….3-3 Tachometer unit …………….. 3-4 Self-diagnosis devices …………… 3-5 Fuel gauge ………………3-5 Handlebar switches …………….3-6 Clutch lever ………………3-7 Shift pedal ………………3-7 Brake lever ………………

• Page 22: Main Switch/Steering Lock

  I NSTRUMENT AND CONTROL FUNCTIONS EAU00027 1. Push. 2. Turn. EAU00029 EAU00040 Main switch/steering lock LOCK EW000016 The steering is locked, and all electrical WARNING The main switch/steering lock controls systems are off. The key can be the ignition and lighting systems, and is Never turn the key to “OFF”…

• Page 23: Instrument And Control Functions

  4. Oil level warning light “ ” “ON”. Yamaha dealer check the electrical cir- 5. Right turn signal indicator light “ ” If the warning light does not come on 6. Coolant temperature warning light “…

• Page 24: Speedometer Unit

  If the warning light does not come on fuel gauge to estimate the distance that for a few seconds, then go off, have a can be traveled on a full tank of fuel. Yamaha dealer check the electrical cir- cuit.

• Page 25: Tachometer Unit

  INSTRUMENT AND CONTROL FUNCTIONS To set the clock: 1. Push both the “SELECT” and “RESET” buttons for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button to change the minutes.

• Page 26: Self-Diagnosis Devices

  If the tachometer displays such an er- Self-diagnosis devices ror code, note the circuit-specific num- This model is equipped with a self-di- ber of r/min, and then have a Yamaha agnosis device for the following electri- dealer check the motorcycle. cal circuits:…

• Page 27: Handlebar Switches

  INSTRUMENT AND CONTROL FUNCTIONS EAU03889 Turn signal switch “ ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the cen- ter position.

• Page 28: Clutch Lever

  INSTRUMENT AND CONTROL FUNCTIONS 1. Clutch lever 1. Shift pedal 1. Brake lever 2. Brake lever position adjusting dial EAU00152 EAU00157 3. Arrow mark Clutch lever Shift pedal a. Distance between brake lever and handlebar The clutch lever is located at the left The shift pedal is located on the left grip handlebar grip.

• Page 29: Brake Pedal

  INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. NOTE: 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.

• Page 30: Fuel

  INSTRUMENT AND CONTROL FUNCTIONS EAU00185 EAU04265 CAUTION: Recommended fuel: Immediately wipe off spilled fuel UNLEADED GASOLINE ONLY with a clean, dry, soft cloth, since Fuel tank capacity: fuel may deteriorate painted surfac- Total amount: es or plastic parts. 21 L (4.6 Imp gal, 5.5 US gal) Reserve amount: 4 L (0.9 Imp gal, 1.1 US gal) 1.

• Page 31: Starter (Choke) Lever

  INSTRUMENT AND CONTROL FUNCTIONS Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premi- um unleaded fuel.

• Page 32: Seat

  INSTRUMENT AND CONTROL FUNCTIONS 1. Seat lock 1. Projection 1. Helmet holder 2. Unlock. 2. Seat holder 2. Unlock. EAU03956 To install the seat EAU04291 Seat Helmet holder 1. Insert the projection on the front of To open the helmet holder, insert the the seat into the seat holder as To remove the seat key into the seat lock, and then turn the…

• Page 33: Storage Compartment

  INSTRUMENT AND CONTROL FUNCTIONS When storing the owner’s manual or EAU04293 Adjusting the front fork other documents in the storage com- This front fork is equipped with spring partment, be sure to wrap them in a preload adjusting bolts, rebound damp- plastic bag so that they will not get wet.

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  INSTRUMENT AND CONTROL FUNCTIONS 1. Spring preload adjusting bolt 1. Current setting 1. Rebound damping force adjusting screw 2. Front fork cap bolt Spring preload Rebound damping force To increase the spring preload and To increase the rebound damping NOTE: Align the appropriate groove on the ad- thereby harden the suspension, turn force and thereby harden the rebound…

• Page 35: Adjusting The Shock Absorber Assembly

  INSTRUMENT AND CONTROL FUNCTIONS EC000015 EAU04295* Adjusting the shock absorber CAUTION: assembly Never attempt to turn an adjusting This shock absorber assembly is mechanism beyond the maximum equipped with a spring preload adjust- or minimum settings. ing ring, a rebound damping force ad- justing knob and a compression NOTE: Although the total number of clicks of a…

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  INSTRUMENT AND CONTROL FUNCTIONS NOTE: Align the appropriate notch in the adjusting ring with the position in- dicator on the shock absorber. Use the special wrench included in the owner’s tool kit to make the ad- justment. Setting 1. Spring preload adjusting ring 1.
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  7 clicks in direction a* Standard will result in poor damping per- 12 clicks in direction a* Maximum (hard) formance. * With the adjusting screw fully turned in direction b Always have a Yamaha dealer service the shock absorber. 3-16…

• Page 38: Exup System

  Yamaha factory. Changing scribed below and have a Yamaha these settings without sufficient dealer repair it if it does not function technical knowledge may result properly. in poor performance of or dam- age to the engine.

• Page 39: Ignition Circuit Cut-Off System

  If a malfunction is noted, have a It prevents starting when the trans- Yamaha dealer check the sys- mission is in gear and the side- tem before riding. stand is up, but the clutch lever is not pulled.

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  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 41: Pre-Operation Checks

  PRE-OPERATION CHECKS Pre-operation check list …………..4-1…

• Page 42: Pre-Operation Check List

  • If necessary, add recommended coolant to specified level. 6-15–6-16 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. Front brake • Check fluid level in reservoir. 6-29–6-30 • If necessary, add recommended brake fluid to specified level.

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  • Make sure that operation is smooth. • Check cable free play. 6-22, Throttle grip • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and 6-33 grip housing. • Make sure that operation is smooth. Control cables 6-33 •…
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  PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.

• Page 45: Operation And Important Riding Points

  OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine ……….5-1 Starting a warm engine …………..5-3 Shifting ………………..5-4 Engine break-in …………….. 5-5 Parking ………………..5-6…

• Page 46: Starting And Warming Up A Cold Engine

  Consult a Yamaha dealer re- blocked and performance will The transmission is in the neutral garding any control or function suffer.

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  If necessary, add engine should be on, otherwise have a If the fuel level warning light re- Yamaha dealer check the electrical cir- oil, and then check the warning mains on after starting, stop the light again. If, when the key is cuit.

• Page 48: Starting A Warm Engine

  (choke) turned off. To avoid the possi- fuel, have a Yamaha dealer that the starter (choke) is not required bility of excessive exhaust emissions, check the electrical circuit.

• Page 49: Shifting

  OPERATION AND IMPORTANT RIDING POINTS EC000048 EAU02988 To start out and accelerate CAUTION: 1. Pull the clutch lever to disengage Even with the transmission in the clutch. the neutral position, do not 2. Shift the transmission into first coast for long periods of time gear.

• Page 50: Engine Break-In

  OPERATION AND IMPORTANT RIDING POINTS EAU00427 EAU02989 EAU01128 To decelerate Recommended shift points Engine break-in 1. Apply both the front and the rear The recommended shift points during There is never a more important period brakes to slow the motorcycle. acceleration and deceleration are in the life of your engine than the period 2.

• Page 51: Parking

  1,600 km (1,000 mi) and beyond The vehicle can now be operated normally. EC000053 CAUTION: Keep the engine speed out of the tachometer red zone. If any engine trouble should oc- cur during the engine break-in period, immediately have Yamaha dealer check the vehicle.

• Page 52: Periodic Maintenance And Minor Repair

  PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance ……….6-1 Lubricating the drive chain …….. 6-32 Owner’s tool kit …………6-1 Checking and lubricating the cables ….6-33 Periodic maintenance chart for the emission Checking and lubricating the throttle grip and control system ………..6-3 cable ……………

• Page 53: Periodic Maintenance

  RELATED TO EMISSIONS CON- cycle maintenance work, have a manual and the tools provided in the TROL ARE GROUPED SEPARATE- Yamaha dealer do it for you. owner’s tool kit are intended to assist LY. THESE SERVICES REQUIRE you in the performance of preventive SPECIALIZED DATA, KNOWLEDGE, maintenance and minor repairs.

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  PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EW000062 WARNING Modifications approved Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use.

• Page 55: Periodic Maintenance Chart For The Emission Control System

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU00471 Periodic maintenance chart for the emission control system CP-03E INITIAL ODOMETER READINGS 600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km) 1 month…

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  • Check the air cut valve and reed valve Air induction for damage. √ √ √ √ √ system • Replace the entire air induction system if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Page 57: General Maintenance And Lubrication Chart

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU00472 General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km) 1 month 6 months 12 months…

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  PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km) 1 month 6 months 12 months 18 months 24 months 30 months…
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  21 * • Check the screw clamp for looseness. exhaust pipe * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. #1 : Yamaha chain lube #2 : Lithium-soap-based grease (all-purpose grease)

• Page 60: Removing And Installing Panels

  PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Panel C 1. Panel A 2. Panel B 2. Screw EAU01122 EAU04003 Removing and installing Panels A and C To remove one of the panels panels Remove the screw, and then pull the The panels shown above need to be panel off as shown.

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  PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel C 1. Panel B 2. Screw 2. Screw (× 3) To install the panel EAU01315 Place the panel in the original position, Panel B and then install the screw To remove the panel Remove the screws, and then take the panel off.

• Page 62: Checking The Spark Plugs

  Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. 3. Check each spark plug for elec- trode erosion and excessive car- bon or other deposits, and replace 1.

• Page 63: Canister (For California Only)

  PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the spark plug with the spark plug wrench, and then tight- en it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) NOTE: a. Spark plug gap If a torque wrench is not available when installing a spark plug, a good estimate To install a spark plug EAU01796…

• Page 64: Engine Oil And Oil Filter Cartridge

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU04625 To change the engine oil (with or Engine oil and oil filter without oil filter cartridge replace- cartridge ment) The engine oil level should be checked 1. Start the engine, warm it up for before each ride.

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  NOTE: An oil filter wrench is available at a Skip steps 4–6 if the oil filter car- Make sure that the O-ring is properly Yamaha dealer. tridge is not being replaced. seated. When draining the engine oil, use a funnel or similar device to keep the oil away from the exhaust pipe.
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  PERIODIC MAINTENANCE AND MINOR REPAIR 8. Add the specified amount of the ECA00133 CAUTION: recommended engine oil, and In order to prevent clutch slip- then install and tighten the oil filler page (since the engine oil also cap. lubricates the clutch), do not mix any chemical additives.

• Page 67: Coolant

  If the oil level warning light flickers before each ride. In addition, the cool- or remains on, immediately turn the ant must be changed at the intervals engine off and have a Yamaha deal- specified in the periodic maintenance er check the vehicle. and lubrication chart.

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  If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.
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  PERIODIC MAINTENANCE AND MINOR REPAIR EAU04299 To change the coolant 1. Place the motorcycle on the cen- terstand and let the engine cool if necessary. 2. Remove panels A and B. (See pages 6-8 and 6-9 for panel re- moval installation proce- dures.)
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  12. Start the engine, and then check coolant, have a Yamaha dealer the vehicle for coolant leakage. If check the antifreeze content of coolant is leaking, have a Yamaha the coolant as soon as possible, dealer check the cooling system. otherwise the effectiveness of 13.

• Page 71: Cleaning The Air Filter Element

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU04051* Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more fre- quently if you are riding in unusually wet or dusty areas.

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  PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter case cover 1. Air filter element 1. Air filter element 2. Screw (× 4) 7. Pull the air filter element out. 8. Lightly tap the air filter element to 6. Remove the air filter case cover by remove most of the dust and dirt, removing the screws.

• Page 73: Adjusting The Carburetors

  Therefore, all carburetor cylinders may become excessively adjustments should be left to a worn. Yamaha dealer, who has the neces- 10. Install the air filter case cover by sary professional knowledge installing the screws.

• Page 74: Adjusting The Throttle Cable Free Play

  The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. a. Throttle cable free play…

• Page 75: Tires

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU03581 CE-22E EW000083 Tire air pressure Tires WARNING (measured on cold tires) To maximize the performance, durabil- Load* Front Rear Proper loading of your motorcycle ity, and safe operation of your motor- 250 kPa 270 kPa is important for several characteris- Up to 90 kg (198 lb) (2.50 kgf/cm…

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  (minimum tread depth), if the tire has a nail or glass fragments in it, or if the side wall is cracked, con- tact a Yamaha dealer immediately and have the tire replaced. CE-09E Minimum tire tread depth 1.0 mm (0.04 in)
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  Tire air valve TR412 Yamaha Motor Co., Ltd. Brand-new tires can have a rela- Valve core #9000A (original) Always make sure that the valve tively poor grip on certain road caps are securely installed to surfaces until they have been prevent air pressure leakage.

• Page 78: 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 79: Adjusting The Clutch Lever Free Play

  Periodically check the clutch lever free Periodically check the brake pedal posi- play and, if necessary, adjust it as fol- tion and, if necessary, have a Yamaha lows. dealer adjust it. To increase the clutch lever free play, turn the adjusting bolt in direction a.

• Page 80: Adjusting The Rear Brake Light Switch

  If there is air in the hydraulic system, have a Yamaha dealer bleed the system be- fore operating the motorcycle. Air in the hydraulic system will diminish 1. Rear brake light switch the braking performance, which 2.

• Page 81: Checking The Front And Rear Brake Pads

  Yamaha dealer replace Before riding, check that the brake fluid ified in the periodic maintenance and the brake pads as a set.

• Page 82: Changing The Brake Fluid

  EAU03976 Rear brake Changing the brake fluid ter the brake fluid reservoir when Have a Yamaha dealer change the refilling. Water will significantly brake fluid at the intervals specified in lower the boiling point of the fluid the NOTE after the periodic mainte- and may result in vapor lock.

• Page 83: Drive Chain Slack

  PERIODIC MAINTENANCE AND MINOR REPAIR Drive chain slack: 40–50 mm (1.6–2.0 in) 5. If the drive chain slack is incorrect, adjust it as follows. a. Drive chain slack 1. Axle nut b. Measurement point: 135 mm (5.3 in) 2. Drive chain slack adjusting bolt 3.

• Page 84: Lubricating The Drive Chain

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 2. Wipe the drive chain dry. NOTE: Lubricating the drive chain Using the alignment marks on each 3. Thoroughly lubricate the drive The drive chain must be cleaned and side of the swingarm, make sure that chain with a special O-ring chain lubricated at the intervals specified in both chain pullers are in the same posi-…

• Page 85: Checking And Lubricating The Cables

  If a cable is damaged the periodic maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. EAU03370 Checking and lubricating the Recommended lubricant: brake and shift pedals…

• Page 86: Checking And Lubricating The Brake And Clutch Levers

  Recommended lubricant: EW000114 WARNING Lithium-soap-based grease If the centerstand or sidestand does (all-purpose grease) not move up and down smoothly, have a Yamaha dealer check or re- pair it. 6-34…

• Page 87: Lubricating The Rear Suspension

  EC000098 CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or re- pair it. 6-35…

• Page 88: Checking The Steering

  EW000115 fork legs and try to move them for- WARNING ward and backward. If any free Securely support the motorcycle so play can be felt, have a Yamaha that there is no danger of it falling dealer check repair over.

• Page 89: Battery

  • EXTERNAL: Flush with plenty To charge the battery Battery of water. Have a Yamaha dealer charge the bat- This motorcycle is equipped with a • INTERNAL: Drink large quan- tery as soon as possible if it seems to sealed-type (MF) battery, which does tities of water or milk and im- have discharged.

• Page 90: Replacing The Fuses

  10 A 5. Signaling system fuse cess to a sealed-type (MF) bat- 6. Odometer and clock fuse (backup fuse) EC000103 tery charger, have a Yamaha 7. Spare fuse (× 2) CAUTION: dealer charge your battery. 8. Spare main fuse Do not use a fuse of a higher amper-…

• Page 91: Replacing A Headlight Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR 1. Headlight bulb cover 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 2. Headlight coupler 3. Unhook the headlight bulb holder, EW000119 EAU04226 WARNING and then remove the defective Replacing a headlight bulb Headlight bulbs get very hot.

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  Take care not to damage the follow- 6. Install the panel. ing parts: 7. Have a Yamaha dealer adjust the Headlight bulb headlight beam if necessary. Do not touch the glass part of the headlight bulb to keep it free…

• Page 93: Replacing A Tail/Brake Light Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR 1. Tail/brake light bulb cover 1. Socket 1. Screw 3. Remove the socket (together with EAU03961 EAU03497 Replacing a tail/brake light Replacing a turn signal light the bulb) by turning it counter- bulb bulb clockwise. 1.

• Page 94: Front Wheel

  4. Remove the brake caliper on each EW000122 side by removing the bolts. WARNING ECA00046 It is advisable to have a Yamaha CAUTION: dealer service the wheel. Do not apply the brake after the Securely support the motor- brake calipers have been removed,…

• Page 95: Rear Wheel

  EW000122 WARNING 5. Install the brake hose holders by installing the bolts. It is advisable to have a Yamaha 6. Tighten the wheel axle, the wheel dealer service the wheel. axle pinch bolt and the brake cali- Securely support the motor- per bolts to the specified torques.

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  PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (× 2) 1. Axle nut 2. Brake torque rod 2. Drive chain slack adjusting bolt 3. Brake torque rod bolt 3. Locknut 4. Brake torque rod nut 6. Turn the drive chain slack adjust- 5.

• Page 97: Troubleshooting

  However, should your motorcycle bolts and brake torque rod nut to iper bracket in the original position. require any repair, take it to a Yamaha the specified torques. 2. Insert the wheel axle through the dealer, whose skilled technicians have…

• Page 98: 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.

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  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 100: Motorcycle Care And Storage

  MOTORCYCLE CARE AND STORAGE Care ………………..7-1 Storage ………………..7-4…

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  M OTORCYCLE CARE AND STORAGE EAU03426 Care Before cleaning Cleaning 1. Cover the muffler outlet with a ECA00010 While the open design of a motorcycle CAUTION: plastic bag after the engine has reveals the attractiveness of the tech- Avoid using strong acidic wheel cooled down.

• Page 102: Motorcycle Care And Storage

  MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical For motorcycles equipped with After riding in the rain, near the sea or products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads sponges which have been in…

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  MOTORCYCLE CARE AND STORAGE ECA00012 After cleaning EWA00001 CAUTION: WARNING 1. Dry the motorcycle with a chamois Make sure that there is no oil or Do not use warm water since it in- or an absorbing cloth. creases the corrosive action of the wax on the brakes or tires.
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  NOTE: fuel tank. To prevent corrosion, avoid Consult a Yamaha dealer for advice on 4. Fill up the fuel tank and add fuel damp cellars, stables (because what products to use. stabilizer (if available) to prevent…
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  MOTORCYCLE CARE AND STORAGE c. Install the spark plug caps onto 7. Check and, if necessary, correct the spark plugs, and then place the tire air pressure, and then lift the spark plugs on the cylinder the motorcycle so that both of its head so that the electrodes are wheels are off the ground.

• Page 106: Specifications

  SPECIFICATIONS Specifications ………………8-1…

• Page 107: Specifications

  S PECIFICATIONS EAU01038 Specifications CS-01E Model FZS1000/FZS1000S Engine oil Dimensions Type Overall length 2,125 mm (83.7 in) 110 130 ˚F Overall width 765 mm (30.1 in) Overall height 1,190 mm (46.9 in) YAMALUBE 4 (10W-30) or SAE 10W-30 Seat height 820 mm (32.3 in) Wheelbase 1,450 mm (57.1 in)

• Page 108
  SPECIFICATIONS Cooling system capacity Number of drive chain (total amount) 2.4 L (2.11 Imp qt, 2.54 US qt) sprocket teeth (front/rear) 16/44 Air filter Dry type element Transmission type Constant-mesh 6-speed Fuel Operation Left foot Type UNLEADED GASOLINE ONLY Gear ratio Fuel tank capacity 21 L (4.6 Imp gal, 5.5 US gal) 2.500…
• Page 109
  SPECIFICATIONS Rear Wheels Type Tubeless tire Front Size 180/55 ZR17 (73W) Type Cast wheel 17 × MT 3.50 180/55 ZR17 M/C (73W) Size 17 M/C × MT 3.50 Manufacturer/ model Bridgestone / BT020R U Rear Maximum load* Type Cast wheel FZS1000/FZS1000S 189 kg (417 lb) 17 ×…
• Page 110
  SPECIFICATIONS Wheel travel Coolant temperature warning light Front 140 mm (5.5 in) Fuses Rear 135 mm (5.3 in) Main fuse 30 A Electrical system Headlight fuse 20 A Ignition system T.C.I. (digital) Radiator fan fuse 10 A Charging system Ignition fuse 20 A Model A.C.

• Page 111: Consumer Information

  Vehicle identification number …………. 9-1 Model label ………………9-2 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 112: Identification Numbers

  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. 1. Key identification number 1.

• Page 113: Model Label

  The model label is affixed to the frame under the seat. (See page 3-11 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

• Page 114: 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 immedi- ately 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 115: Motorcycle Noise Regulation

  CONSUMER INFORMATION EAU01053 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 116: Maintenance Record

  CONSUMER INFORMATION EAU01874 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 117
  CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 28,000 mi (43,000 km) or 42 months 32,000 mi (49,000 km) or 48 months 36,000 mi (55,000 km) or 54 months 40,000 mi (61,000 km) or 60 months…

• Page 118: Yamaha Motor Corporation, U.s.a. Street And Enduro Motorcycle Limited Warranty

  CONSUMER INFORMATION EAU02918 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY…

• Page 119
  CONSUMER INFORMATION…

• Page 120: Yamaha Extended Service (Y.e.s.)

  CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.)

• Page 121
  CONSUMER INFORMATION 9-10…
• Page 122
  INDEX Accessories and replacement parts ..6-26 Dimmer switch……… 3-6 Key identification number ……9-1 Air filter element, cleaning ……6-19 Drive chain, lubricating ……6-32 Drive chain slack ……..6-31 Labels, location ……..1-7 Adjusting ………. 6-31 Battery ………..6-37 Checking………. 6-31 Brake and clutch levers, checking and Main switch/steering lock ……3-1 lubricating ……….6-34 Maintenance and lubrication, periodic ..6-5…
• Page 123
  INDEX Shifting ………… 5-4 Decelerating……..5-5 Valve clearance, adjusting ….6-22 Shift points ……… 5-5 Vehicle identification number….9-1 Starting out and accelerating….5-4 Shift pedal ……….3-7 Warranty, extended……… 9-9 Shock absorber assembly, adjusting ..3-14 Warranty limited ……..9-7 Sidestand ……….
• Page 124
  YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.06-1.8×1 CR…

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• Page 1
  2008 SERVICE MANUAL FZ1-N(X) FZ1-S(X) FZ1-SA FZ1-NA 5D0-28197-E1…
• Page 2
  EAS20040 FZ1-N(X)/FZ1-S(X)/FZ1-SA/FZ1-NA SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. First edition, December 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
• Page 3
  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. •…

• Page 5
  EAS20100 15.Molybdenum-disulfide grease SYMBOLS 16.Silicon grease The following symbols are used in this manual 17.Apply locking agent (LOCTITE®) for easier understanding. 18.Replace the part NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3.

• 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 OUTLINE OF THE FI SYSTEM …………..1-2 FI SYSTEM …………………1-3 INSTRUMENT FUNCTIONS …………..1-4 IMPORTANT INFORMATION …………..1-26 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-26 REPLACEMENT PARTS……………1-26 GASKETS, OIL SEALS AND O-RINGS……….1-26 LOCK WASHERS/PLATES AND COTTER PINS ………1-26 BEARINGS AND OIL SEALS ……………1-27 CIRCLIPS …………………1-27 CHECKING THE CONNECTIONS ………….1-28…

• 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 EAS5D01032 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

• Page 12: Fi System

  FEATURES EAS5D01013 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 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

  FEATURES EAS5D01014 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- perature display 1. Tachometer 2. Speedometer 2. Tachometer red zone 3. Tachometer The electric tachometer allows the rider to 4.

• Page 14
  “TRIP A” and “TRIP B” in off for approximately 3 seconds. If this occurs, the following order: have a Yamaha dealer check the electrical cir- TRIP A → TRIP B → ODO → TRIP A cuit. When the fuel amount in the fuel tank decreases to 3.4 L (0.90 US gal) (0.75…
• Page 15
  • 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”.
• Page 16
  6. Rear wheel sensor 7. Rear wheel sensor rotor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
• Page 17
  FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. •…
• Page 18
  FEATURES e. Less slippery road surface a. Friction force between the tire and road surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d. Slip ratio (%) Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors.
• Page 19
  Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem condition and allows normal braking even if the ABS is not operating properly.
• Page 20
  FEATURES ABS block diagram 8. Rear brake caliper 1. Rear brake master cylinder 9. Front brake caliper 2. Hydraulic unit 10.ABS ECU 3. Hydraulic pump 11.Rear wheel sensor 4. ABS motor 12.Front wheel sensor 5. Buffer chamber 13.ABS warning light 6.
• Page 21
  FEATURES 7. Wheel sensor rotor 4. At low speed 8. Voltage 5. At high speed 9. Time 6. Wheel sensor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is oper- ating properly.
• Page 22
  FEATURES 6. To the front brake master cylinder 1. To the rear brake master cylinder 7. To the rear brake caliper 2. Hydraulic pump 8. To the ABS ECU 3. ABS motor 9. To the front brake caliper 4. Buffer chamber 5.
• Page 23
  FEATURES 3. Spool 1. Orifice 4. Flow control valve 2. Solenoid valve • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 3. Raised piston 1. Buffer chamber (pressurized) 2. Buffer chamber (depressurized) ABS ECU (electronic control unit) The ABS ECU “1”…
• Page 24
  FEATURES B. FZ1-NA A. FZ1-SA As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 1. Battery 16.ABS test coupler 2. Engine stop switch 17.ABS ECU 3.
• Page 25
  FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis These operations are performed once every 8/1000th of a second. When a failure is detected in the ABS, a malfunction code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.
• Page 26
  FEATURES Composition and operation The ABS motor relay is activated by signals transmitted from the ABS ECU and operates simulta- neously when the ABS starts to reduce the hydraulic pressure of the brake fluid. If the solenoid relay is turned off, the ABS motor relay is also deactivated and the motor stops operating if there is a mal- function.
• Page 27
  FEATURES 15.ABS ECU 1. Brake master cylinder 16.ABS warning light 2. Brake light switch 17.Brake fluid pressure 3. ABS motor 18.Time 4. Hydraulic pump 19.Repressurizing 5. Buffer chamber 6. Flow control valve 7. Port A 8. Spool 9. Port B 10.Orifice 11.Port D 12.Solenoid valve…
• Page 28
  FEATURES Emergency braking (ABS activated) 1. Depressurized state When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the spool of the flow control valve compresses the return spring and closes port B “9”.
• Page 29
  FEATURES 9. Port B 10.Orifice 11.Port D 12.Solenoid valve 13.Port C 14.Brake caliper 15.ABS ECU 16.ABS warning light 17.Brake fluid pressure 18.Time 19.Repressurizing 2. Pressurized state Port D “11” is closed by the “pressurization” signal transmitted from the ABS ECU. Before this occurs, the spool of the flow control valve has compressed the return spring and closed port B “9”.
• Page 30
  FEATURES 12.Solenoid valve 1. Brake master cylinder 13.Port C 2. Brake light switch 14.Brake caliper 3. ABS motor 15.ABS ECU 4. Hydraulic pump 16.ABS warning light 5. Buffer chamber 17.Brake fluid pressure 6. Flow control valve 18.Time 7. Port A 19.Repressurizing 8.
• Page 31
  FEATURES Instances when the ABS warning light comes on 1. The ABS warning light comes on when the main switch is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
• Page 32
  FEATURES c. Goes off a. ABS warning light d. Preparation b. Comes on 4. The ABS warning light “1” flashes and a malfunction code “2” is indicated on the multi-function display when the test coupler adapter “3” is connected to the ABS test coupler “4” for trouble- shooting the ABS.
• Page 33
  FEATURES B. FZ1-NA A. FZ1-SA • Diagnosis indication The place where the ABS diagnosis code is displayed is also used for the indication of the FI diag- nosis code, odometer, trip meter and fuel trip. As the priority level of indication, the diagnosis code for FI is the first and the diagnosis code for ABS is the second.
• Page 34
  FEATURES ABS function • A brake system in which the hydraulic control has been performed by the ABS alerts a rider that the wheels had a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.

• Page 35: 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 inferior in quality.

• Page 36: 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 37: 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. •…

• Page 38
  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.
• Page 39
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-13 90890-01426 YU-38411 Rod holder 4-64, 4-69 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-67 90890-01437 Universal damping rod bleeding tool set YM-A8703 Rod puller attachment (M10) 4-67 90890-01436 Universal damping rod bleeding tool set…
• Page 40
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages 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 YM-04114 Middle driven shaft bearing driver 6-11…
• Page 41
  5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Ignition checker 8-148 90890-06754 Opama pet-4000 spark checker YU-34487 Yamaha bond No.1215 5-64, 6-11 (Three Bond No.1215®) 90890-85505 Digital circuit tester 7-8, 7-9 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Pivot shaft wrench…

• Page 42: Special Tools

  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 90890-01476 Pocket tester 1-28, 5-41, 8- 90890-03112 137, 8-138, 8- Analog pocket tester 139, 8-142, 8- YU-03112-C 144, 8-145, 8- 146, 8-147, 8- 148, 8-149, 8- 150, 8-151, 8- 152, 8-153, 8- 154, 8-155, 8- 156, 8-157…

• Page 43
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Camshaft wrench 5-11, 5-16 90890-04143 YM-04143 Test coupler adapter 1-23, 4-54, 4-55 90890-03149 1-34…
• Page 44
  SPECIAL TOOLS 1-35…

• Page 45: Specifications

  SPECIFICATIONS GENERAL SPECIFICATIONS …………..2-1 ENGINE SPECIFICATIONS…………….2-2 CHASSIS SPECIFICATIONS…………….2-8 ELECTRICAL SPECIFICATIONS……………2-11 TIGHTENING TORQUES…………….2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS…….2-14 ENGINE TIGHTENING TORQUES …………2-15 CHASSIS TIGHTENING TORQUES …………2-19 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-22 ENGINE ………………..2-22 CHASSIS ………………..2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS ………2-25 ENGINE OIL LUBRICATION CHART ………..2-25 LUBRICATION DIAGRAMS …………..2-27 COOLING SYSTEM DIAGRAMS ……………2-37…

• Page 46: General Specifications

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

• Page 47: Engine Specifications

  ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm (60.90 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 11.50 : 1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8 kgf/cm /350 r/min)

• Page 48
  ENGINE SPECIFICATIONS Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump 65/43 × 25/32 (1.181) Reduction ratio Max impeller shaft tilt limit 0.15 mm (0.0059 in) Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 12.20–13.00 cm…
• Page 49
  ENGINE SPECIFICATIONS Exhaust 0.21–0.25 mm (0.0083–0.0098 in) Valve dimensions Valve head diameter A (intake) 23.40–23.60 mm (0.9213–0.9291 in) Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in) Valve face width B (intake) 1.760–2.900 mm (0.0693–0.1142 in) Valve face width B (exhaust) 1.760–2.900 mm (0.0693–0.1142 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
• Page 50
  ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) 40.47 mm (1.59 in) Free length (exhaust) 40.53 mm (1.60 in) Installed length (intake) 32.66 mm (1.29 in) Installed length (exhaust) 33.88 mm (1.33 in) Spring rate K1 (intake) 17.53 N/mm (100.10 lb/in) (1.79 kgf/mm) Spring rate K2 (intake) 22.86 N/mm (130.53 lb/in) (2.33 kgf/mm) Spring rate K1 (exhaust)
• Page 51
  ENGINE SPECIFICATIONS End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Oil ring…
• Page 52
  ENGINE SPECIFICATIONS Secondary reduction system Chain drive Secondary reduction ratio 45/17 (2.647) Operation Left foot operation Gear ratio 38/15 (2.533) 33/16 (2.063) 37/21 (1.762) 35/23 (1.522) 27/20 (1.350) 29/24 (1.208) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type…

• Page 53: Chassis Specifications

  ) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm ) (2.90 bar) Loading condition 90–196 kg (198–432 lb) (FZ1-N(X)) 90–190 kg (198–419 lb) (FZ1-S(X)) 90–189 kg (198-417 lb) (FZ1-NA) 90–184 kg (198-406 lb) (FZ1-SA) Front 250 kPa (36 psi) (2.50 kgf/cm ) (2.50 bar)

• Page 54
  Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring free length 194.8 mm (7.67 in) (FZ1-N(X)), (FZ1-S(X)) 169.8 mm (6.69 in) (FZ1-SA), (FZ1-NA) Installed length 181.8 mm (7.16 in) (FZ-N(X)), (FZ1-S(X)) 156.8 mm (6.17 in) (FZ1-SA), (FZ1-NA) Spring rate K1 102.90 N/mm (587.56 lb/in) (10.49 kgf/mm)
• Page 55
  CHASSIS SPECIFICATIONS Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available Enclosed gas/air pressure (STD) 1000 kPa (142.2 psi) (10.0 kgf/cm Drive chain Type/manufacturer 50VA8/DAIDO Link quantity Drive chain slack 25.0–35.0 mm (0.98–1.38 in) 15-link length limit 239.3 mm (9.42 in) 2-10…

• Page 56: Electrical Specifications

  1.12 A Headlight Bulb type Halogen bulb Bulb voltage, wattage × quantity 12 V, 60 W/55.0 W × 1 (FZ1-N(X)), (FZ1-NA) Headlight 12 V, 60 W/55.0 W × 2 (FZ1-S(X)), (FZ1-SA) 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 ×…

• Page 57
  10 W × 2.0 +3.4 W Wattage Oil level gauge Model/manufacturer 5VY/SOMIC ISHIKAWA Servo motor Model/manufacturer 2D1/YAMAHA Fuses Main fuse 50.0 A Headlight fuse 15.0 A (FZ1-N(X)), (FZ1-NA) 25.0 A (FZ1-S(X)), (FZ1-SA) Taillight fuse 10.0 A Signaling system fuse 10.0 A 2-12…
• Page 58
  ELECTRICAL SPECIFICATIONS Ignition fuse 15.0 A 10.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A ABS motor fuse 30.0 A (FZ1-SA), (FZ1-NA) ABS control unit fuse 10.0 A (FZ1-SA), (FZ1-NA) Backup fuse 10.0 A Reserve fuse 30.0 A (FZ1-SA), (FZ1-NA) Reserve fuse 25.0 A (FZ1-S(X)), (FZ1-SA)

• Page 59: 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 60: 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…

• Page 61
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size 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 6 Nm (0.6 m·kg, 4.3 ft·lb) Exhaust pipe and exhaust pipe 20 Nm (2.0 m·kg, 14 ft·lb) bracket bolt…
• Page 62
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Left Shift rod locknut (rear) 7 Nm (0.7 m·kg, 5.1 ft·lb) thread Shift rod joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Neutral switch 20 Nm (2.0 m·kg, 14 ft·lb) Sub-throttle servo motor cover…
• Page 63
  TIGHTENING TORQUES 2-18…

• Page 64: 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…

• Page 65
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive chain guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear fender screw 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake hose holder screw 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)
• Page 66
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle cable adjust nut 4 Nm (0.4 m·kg, 2.9 ft·lb) Clutch cable adjust nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Centerstand bracket nut (FZ1- 55 Nm (5.5 m·kg, 40 ft·lb) S(X), (FZ1-SA)) Centerstand bracket adapter bolt 73 Nm (7.3 m·kg, 53 ft·lb) (FZ1-S(X), (FZ1-SA))

• Page 67: Lubrication Points And Lubricant Types

  Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond No. Cylinder head cover mating surface 1215 Yamaha bond No. Crankcase mating surface 1215 Yamaha bond No.

• Page 68: 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 69
  LUBRICATION POINTS AND LUBRICANT TYPES 2-24…

• Page 70: Lubrication System Chart And Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25…

• Page 71
  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.Piston cooler 13.Piston cooler 14.Chain tensioner…

• Page 72: Lubrication Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27…

• Page 73
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-28…
• Page 74
  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29…
• Page 75
  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 2-30…
• Page 76
  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31…
• Page 77
  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 2-32…
• Page 78
  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33…
• Page 79
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-34…
• Page 80
  LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35…
• Page 81
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-36…

• Page 82: Cooling System Diagrams

  COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-37…

• Page 83
  COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-38…
• Page 84
  COOLING SYSTEM DIAGRAMS 2-39…
• Page 85
  COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-40…

• Page 86: Cable Routing

  CABLE ROUTING EAS20430 CABLE ROUTING 2-41…

• Page 87
  CABLE ROUTING FZ1-N(X)/FZ1-S(X)/FZ1-SA/FZ1-NA R. The clamp attaching position should be in 1. Clutch cable a range from 20 mm to 40 mm (0.79 in to 1.57 in) from the end of the brake hose 2. Left handlebar switch lead grommet. The front wheel sensor lead 3.
• Page 88
  CABLE ROUTING FZ1-N(X) / FZ1-S(X) FZ1-S(X) 2-43…
• Page 89
  CABLE ROUTING FZ1-N(X)/FZ1-S(X) M. To the wire harness 1. Wire harness N. To the coolant reservoir tank 2. Right handlebar switch lead O. Route the radiator fan motor lead (right) so 3. Throttle cable that there is no slack as much as possible in this section.
• Page 90
  CABLE ROUTING 2-45…
• Page 91
  CABLE ROUTING FZ1-SA O. Pass the coolant reservoir hose to the vehi- 1. Throttle cables cle inner side of the radiator inlet hose and route it to the lower outside of the vehicle of 2. Radiator inlet hose the thermostat assembly. 3.
• Page 92
  CABLE ROUTING 2-47…
• Page 93
  CABLE ROUTING FZ1-NA K. Bind the two EXUP cables with the clamp. 1. Throttle cables A part of the clamp should be located within 10 mm (0.39 in) from the edge of 2. Radiator inlet hose wire bending attachment. Clamp opening 3.
• Page 94
  CABLE ROUTING FZ1-N(X) / FZ1-S(X) Q(FZ1-N(X)) PP(FZ1-N(X)) 2-49…
• Page 95
  CABLE ROUTING FZ1-N(X)/FZ1-S(X) H. Route the hose assembly 1 by the vehicle 1. Clutch cable front side where the water pump inlet pipe is routed. For the hose tip position, route 2. Water pump breather hose the hose so that 10 mm (0.39 in) or more 3.
• Page 96
  CABLE ROUTING 2-51…
• Page 97
  CABLE ROUTING FZ1-SA H. Route the water pump breather hose by 1. Clutch cable the vehicle front side where the water pump inlet pipe is routed. For the hose tip 2. Clutch cable swaging metal position, route the hose so that 10 mm 3.
• Page 98
  CABLE ROUTING 2-53…
• Page 99
  CABLE ROUTING AC.Route the water pump breather hose finally in the guide after passing other hoses so that it can be positioned on the outside of the vehicle. AD.Route the coolant reservoir tank drain hose so that it is positioned at the inner- most part in hoses and leads.
• Page 100
  CABLE ROUTING 2-55…
• Page 101
  CABLE ROUTING FZ1-NA H. Route the water pump breather hose in 1. Clutch cable front of the water pump inlet pipe. Route the hose so that 10 mm (0.39 in) or more 2. Clutch cable swaging metal can be assured as shown in the illustration. 3.
• Page 102
  CABLE ROUTING FZ1-N(X) / FZ1-S(X) 2-57…
• Page 103
  CABLE ROUTING FZ1-N(X)/FZ1-S(X) 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…
• Page 104
  CABLE ROUTING FZ1-N(X) / FZ1-S(X) 2-59…
• Page 105
  CABLE ROUTING AL.Clamp each lead at the positioning taping R. Pass the license plate light lead and turn section (white) and then insert it to the signal light lead under the turn signal relay. cover. (In random order) S. Pass the turn signal light lead (right) and AM.Clamp each lead at the positioning taping license plate light lead under the rear section (blue) and then insert it to the…
• Page 106
  CABLE ROUTING 2-61…
• Page 107
  CABLE ROUTING FZ1-SA 53.Radiator fan motor lead (left) 1. Throttle cables 54.Oil level switch lead 2. Right handlebar switch lead 55.O sensor lead 3. Throttle cable (pull side) 56.Sidestand switch lead 4. Throttle cable (return side) 57.Speed sensor lead 5. Coolant reservoir tank hose 58.Radiator fan motor lead (Right) 6.
• Page 108
  CABLE ROUTING 2-63…
• Page 109
  CABLE ROUTING AJ.Installation procedure 1. Secure the main M. Route the fuse box lead under the radiator switch lead and immobilizer lead with Vel- fan motor relay. cro strap. 2. Secure the left handlebar N. Route the battery positive lead under the switch lead with Velcro strap.
• Page 110
  CABLE ROUTING FZ1-NA 2-65…
• Page 111
  CABLE ROUTING FZ1-NA 53.Frame 1. Throttle cables 54.Cover 2. Throttle cable (pull side) 55.Direct ignition coil lead 3. Throttle cable (return side) 56.Fuel hose 4. Wire harness 57.Radiator fan motor lead (right) 5. Right handlebar switch lead 58.Radiator fan motor lead (left) 6.
• Page 112
  CABLE ROUTING FZ1-NA 2-67…
• Page 113
  CABLE ROUTING AK.Installation procedure 1. Secure the main O. Route the fuse box lead under the radiator switch lead and immobilizer lead with Vel- fan motor relay. cro strap. 2. Secure the left handlebar P. Route the battery positive lead under the switch lead with Velcro strap.
• Page 114
  CABLE ROUTING FZ1-S(X) 2-69…
• Page 115
  CABLE ROUTING FZ1-S(X) 1. Clutch cable 2. Left handlebar switch lead 3. Immobilizer lead 4. Main switch lead 5. Protector 6. Throttle cables 7. Right handlebar switch lead 8. Throttle cable (pull side) 9. Throttle cable (return side) 10.Bracket 11.Wire harness 12.Turn signal light lead 13.Seat lock cable 14.Tail/brake light lead…
• Page 116
  CABLE ROUTING 2-71…
• Page 117
  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.
• Page 118
  CABLE ROUTING 2-73…

• Page 119: 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…………3-10 MEASURING THE COMPRESSION PRESSURE …….3-10 CHECKING THE ENGINE OIL LEVEL ……….3-11 CHANGING THE ENGINE OIL………….3-12…

• Page 120
  LUBRICATING THE CENTERSTAND (FZ1-S(X)/FZ1-SA)….3-35 LUBRICATING THE REAR SUSPENSION ……….3-35 ELECTRICAL SYSTEM…………….3-36 CHECKING AND CHARGING THE BATTERY……..3-36 CHECKING THE FUSES…………..3-36 REPLACING THE HEADLIGHT BULBS……….3-36 ADJUSTING THE HEADLIGHT BEAM ……….3-37…

• Page 122: 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-…

• Page 123
  √ √ √ √ pedal pivot grease. shafts (FZ1-SA) Sidestand • Check operation. √ √ √ √ √ (FZ1-N(X))/ • Lubricate. (FZ1-NA) Sidestand, cen- • Check operation. √ √ √ √ √ ter stand (FZ1- • Lubricate. S(X)/FZ1-SA) Sidestand √…
• Page 124
  PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 Moving parts √ √ √ √ √ • Lubricate. and cables • Check operation and free play. Throttle grip • Adjust the throttle cable free play if √…

• Page 125: 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.

• Page 126
  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 Valve lapping tool YM-A8998 NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase.

• Page 127: Synchronizing The Throttle Bodies

  ENGINE Example: • The valve lifter must turn smoothly when If the valve pad is marked “158”, the pad rotated by hand. thickness is 1.58 mm (0.062 in) d. Calculate the sum of the values obtained in g. Install the exhaust and intake camshafts, steps (b) and (c) to determine the required timing chain and camshaft caps.

• Page 128
  ENGINE 2. Remove: 8. Adjust: • Rider and passenger seat • Throttle body synchronization Refer to “GENERAL CHASSIS” on page ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4-1. a. With throttle body #3 as standard, adjust • Fuel tank throttle bodies #1, #2, and #4 using the air Refer to “FUEL TANK”…

• Page 129: Adjusting The Exhaust Gas Volume

  ENGINE 9. Measure: • Engine idling speed Out of specification → Adjust. Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment. 11. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”…

• Page 130: Adjusting The Engine Idling Speed

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

• Page 131: Checking The Spark Plugs

  ENGINE (with a spark plug cleaner or wire brush) 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. EWA5D01003 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…

• Page 132: 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 133: Changing The Engine Oil

  ENGINE Type SAE10W-30 or SAE10W-40 or SAE15W-40 or SAE20W-40 or SAE20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13360 CAUTION: • Engine oil also lubricates the clutch and 4. Start the engine, warm it up for several the wrong oil types or additives could minutes, and then turn it off.

• Page 134: 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 135: Adjusting The Clutch Cable Free Play

  ENGINE EWA12980 only as a reference when measuring the WARNING engine oil pressure. The engine, muffler and engine oil are extremely hot. Engine oil pressure Possible causes • Faulty oil pump • Clogged oil filter Below specification • Leaking oil passage •…

• Page 136: Replacing The Air Filter Element

  ENGINE 2. Adjust • Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting dial “1” in direction “b” or “c” until the specified clutch cable free play is obtained. Direction “b” Clutch cable free play is increased. Direction “c” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

• Page 137: Checking The Throttle Body Joints

  ENGINE 4. Install: 1. Remove: • Air filter case cover • Rider and passenger seat ECA14400 Refer to “GENERAL CHASSIS” on page CAUTION: 4-1. • Fuel tank Never operate the engine without the air fil- Refer to “FUEL TANK” on page 7-1. ter element installed.

• Page 138: Checking The Exhaust System

  ENGINE 2. Check: Exhaust pipe nut • Crankcase breather hose “1” 20 Nm (2.0 m·kg, 14 ft·lb) Cracks/damage → Replace. Exhaust pipe and exhaust pipe Loose connection → Connect properly. bracket bolt ECA13450 20 Nm (2.0 m·kg, 14 ft·lb) CAUTION: Exhaust pipe and muffler bolt Make sure the crankcase breather hose is 20 Nm (2.0 m·kg, 14 ft·lb)

• Page 139: 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 140: Checking The Cooling System

  ENGINE 2. Check: • Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level. ECA13470 CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant.

• Page 141
  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 142
  ENGINE Handling notes for coolant NOTE: Coolant is potentially harmful and should Before checking the coolant level, wait a few be handled with special care. minutes until the coolant has settled. EWA13040 WARNING 18. Install: • Rider and passenger seat •…

• Page 143: 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 144: Checking The Brake Fluid Level

  CHASSIS EAS21240 will significantly lower the boiling point of CHECKING THE BRAKE FLUID LEVEL the brake fluid and could cause vapor 1. Stand the vehicle on a level surface. lock. NOTE: ECA13540 • Place the vehicle on a suitable stand. CAUTION: •…

• Page 145: Checking The Front Brake Hoses

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

• Page 146: Bleeding The Hydraulic Brake System

  CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • The system is disassembled. • A brake hose is loosened, disconnected or replaced. • The brake fluid level is very low. A. Front brake caliper •…

• Page 147
  CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Bleeding the ABS brake EWA14010 WARNING Bleed the ABS whenever: • the system is disassembled. A. Front • a brake hose is loosened, disconnected B. Rear or replaced.

• Page 148: Adjusting The Shift Pedal

  CHASSIS EWA14020 NOTE: WARNING Place the vehicle on a suitable stand so that After bleeding the ABS, check the brake the rear wheel is elevated. operation. 2. Spin the rear wheel several times and find ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the tightest position of drive chain. 3.

• Page 149: Lubricating The Drive Chain

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

• Page 150: Checking The Front Fork

  CHASSIS c. Hook a spring gauge “2” onto the plastic locking tie. 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, d. Hold the spring gauge at a 90° angle from remove the lower bracket and check the the handlebar, pull the spring gauge, and upper and lower bearings.

• Page 151: 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 152
  CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (Right side front fork) Compression damping (Left side front fork) ECA5D01014 CAUTION: ECA5D01019 CAUTION: • Never go beyond the maximum or mini- • Never go beyond the maximum or mini- mum adjustment positions. mum adjustment positions. •…

• Page 153: 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 154: Checking The Tires

  Rear 290 kPa (2.9 kg/cm , 2.9 bar, 42 psi) Maximum load* 196 kg (432 lb) (FZ1-N(X)) 190 kg (419 lb) (FZ1-S(X)) 184 kg (406 lb) (FZ1-SA) 189 kg (417 lb) (FZ1-NA) * Total weight of rider, passenger, cargo and accessories.

• Page 155
  Minimum tire tread depth concerning handling characteristics can be 1.6 mm (0.06 in) given if a tire combination other than one approved by Yamaha is used on this vehi- EWA14080 WARNING cle. • Do not use a tubeless tire on a wheel…

• Page 156: Checking The Wheels

  CHASSIS • Install the tire with the mark pointing in the NOTE: direction of wheel rotation. Hold the cable end upright and pour a few • Align the mark “2” with the valve installation drops of lubricant into the cable sheath or use point.

• Page 157: Electrical System

  A. FZ1-N(X)/FZ1-NA EAS21780 REPLACING THE HEADLIGHT BULBS B. FZ1-S(X)/FZ1-SA 1. Remove: 4. Remove: • Headlight side cover bolts “1” (FZ1-N(X)), • Headlight bulb cover “1” (FZ1-S(X)/FZ1- (FZ1-NA) 2. Disconnect: 5. Remove: • Headlight sub-wire harness coupler “2” • Headlight bulb holder “1”…

• Page 158
  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(X)/FZ1-NA B. FZ1-S(X)/FZ1-SA 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 159
  ELECTRICAL SYSTEM A. FZ1-N(X)/FZ1-NA B. FZ1-S(X)/FZ1-SA ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-38…
• Page 160
  ELECTRICAL SYSTEM 3-39…
• Page 161
  CHASSIS GENERAL CHASSIS………………4-1 REMOVING THE COVER……………4-8 INSTALLING THE COVER …………..4-8 FRONT WHEEL ………………..4-9 REMOVING THE FRONT WHEEL …………4-12 CHECKING THE FRONT WHEEL…………4-12 [D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR …………4-13 ADJUSTING THE FRONT WHEEL STATIC BALANCE …….4-14 INSTALLING THE FRONT WHEEL …………4-15 REAR WHEEL ………………..4-17 REMOVING THE REAR WHEEL …………4-21…
• Page 162
  INSTALLING THE REAR BRAKE MASTER CYLINDER……4-48 ABS (ANTI-LOCK BRAKE SYSTEM) …………4-50 [D-5] MAINTENANCE OF THE HYDRAULIC UNIT……4-52 HYDRAULIC UNIT OPERATION TEST ……….4-53 [D-6-5] TRIAL RUN …………….4-57 HANDLEBAR………………..4-58 REMOVING THE HANDLEBAR …………4-59 CHECKING THE HANDLEBAR…………4-59 INSTALLING THE HANDLEBAR …………4-59 FRONT FORK…………………4-62 REMOVING THE FRONT FORK LEGS ……….4-64 DISASSEMBLING THE FRONT FORK LEGS ……..4-64 CHECKING THE FRONT FORK LEGS……….4-65…

• Page 164: General Chassis

  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 proce- dure.

• Page 165
  GENERAL CHASSIS Removing the headlight and meter assembly (FZ1-N(X)), (FZ1-NA) 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 166
  GENERAL CHASSIS Removing the front cowling (FZ1-S(X)/FZ1-SA) 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 proce- dure.
• Page 167
  GENERAL CHASSIS Removing the under cowling (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Under cowling Rectifier/regulator Right under cowling bracket Left under cowling bracket For installation, reverse the removal proce- dure.
• Page 168
  GENERAL CHASSIS Removing the rear fender (FZ1-N(X)), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Mud guard assembly…
• Page 169
  GENERAL CHASSIS Removing the rear fender (FZ1-S(X)/FZ1-SA) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Mud guard assembly Rear fender Tail/brake light lead coupler Disconnect.
• Page 170
  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 coupler Disconnect. Intake air temperature sensor Air filter case cover Air filter…

• Page 171: Removing The Cover

  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 172: Front Wheel

  FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs (FZ1-N(X)/FZ1-S(X)) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel axle pinch bolt Front wheel axle Collar Dust cover Front wheel Front brake disc For installation, reverse the removal proce- dure.

• Page 173
  FRONT WHEEL Removing the front wheel sensor and sensor rotor (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel sensor Front wheel axle pinch bolt Front wheel axle Collar Sensor housing Dust cover Front wheel Front brake disc For installation, reverse the removal proce-…
• Page 174
  FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-11…

• Page 175: Removing The Front Wheel

  FRONT WHEEL EAS21900 Refer to “CHECKING THE TIRES” on REMOVING THE FRONT WHEEL page 3-33 and “CHECKING THE 1. Stand the vehicle on a level surface. WHEELS” on page 3-35. EWA13120 3. Measure: WARNING • Radial wheel runout “1” Securely support the vehicle so that there •…

• Page 176: [D-3] Maintenance Of The Front Wheel Sensor And Sensor Rotor

  FRONT WHEEL Keep them away from dirt and do not sub- ject them to shocks. • The ABS wheel sensor cannot be disas- sembled. Do not attempt to disassemble it. If faulty, replace with a new one. Removing the front wheel sensor 1.

• Page 177: Adjusting The Front Wheel Static Balance

  FRONT WHEEL • Brake hose holder “4” NOTE: The wheel sensor rotor of the vehicle is NOTE: inserted under pressure by a special process When installing the front wheel sensor, check and cannot be replaced as a single unit. To the wheel sensor lead for twists and the sensor replace the sensor rotor, replace the wheel electrode for foreign materials.

• Page 178: Installing The Front Wheel

  FRONT WHEEL b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. Turn the front wheel 90° so that the “X ” c. If the heavy spot does not stay in that posi- mark is positioned as shown. tion, install a heavier weight.

• Page 179
  FRONT WHEEL 4. Lower the front wheel so that it is on the ground. 5. Tighten: • Wheel axle Wheel axle nut 72 Nm (7.2 m·kg, 52 ft·lb) • Wheel axle pinch bolt Wheel axle pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) ECA14140 CAUTION: Before tightening the front wheel axle, push…

• Page 180: Rear Wheel

  REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel (FZ1-N(X)/FZ1-S(X)) Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut Loosen. Adjusting bolt Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left) Adjusting block (right) Rear wheel Brake caliper bracket For installation, reverse the removal proce- dure.

• Page 181
  REAR WHEEL Removing the rear wheel sensor and sensor rotor (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor protector Rear wheel sensor Rear wheel sensor lead stay Rear brake caliper Lock nut Loosen. Adjusting nut Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left)
• Page 182
  REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (left and right) Dust cover Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
• Page 183
  REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-20…

• Page 184: Removing The Rear Wheel

  REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 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 185: Checking And Replacing The Rear Wheel Sprocket

  REAR WHEEL EAS22120 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING AND REPLACING THE REAR WHEEL SPROCKET EAS22200 1. Check: [D-4] MAINTENANCE OF THE REAR • Rear wheel sprocket WHEEL SENSOR AND SENSOR ROTOR More than 1/4 tooth “a” wear → Replace ECA5D01002 the rear wheel sprocket. CAUTION: Bent teeth →…

• Page 186
  REAR WHEEL 3. Remove: • Rear wheel sensor protector • Rear wheel sensor “4” 2. Install: • Rear wheel Refer to “INSTALLING THE REAR WHEEL” on page 4-24. 4. Remove: ECA14470 • Rear wheel CAUTION: Refer to “REMOVING THE REAR Make sure there are no foreign materials in WHEEL”…

• Page 187: Adjusting The Rear Wheel Static Balance

  REAR WHEEL • Rear wheel sensor coupler “5” 4. Check: • Check the clearance “a” between the rear ECA14500 CAUTION: wheel sensor and sensor rotor. Out of specification → Check the exist- To route the rear wheel sensor lead, refer to ence of foreign matters in the wheel sen- “CABLE ROUTING”…

• Page 188
  REAR WHEEL • Wheel axle nut • Brake caliper bolts Wheel axle nut 150 Nm (15 m·kg, 108 ft·lb) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) 22 Nm (2.2 m·kg, 16 ft·lb) EWA13500 WARNING Make sure the brake hose is routed prop- erly.

• Page 189: 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 proce- dure.

• Page 190
  Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Right rear view mirror (FZ1-N(X)), (FZ1-NA) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder diaphragm Brake lever Front brake light switch lead coupler Disconnect.
• Page 191
  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 disassembly pro- cedure. 4-28…
• Page 192
  FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure.
• Page 193
  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 dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

• Page 194: 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 195: Replacing The Front Brake Pads

  FRONT BRAKE NOTE: Brake 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 lining thickness LOCTITE®…

• Page 196: 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 197: Checking The Front Brake Calipers

  FRONT BRAKE • Do not loosen the bolts “3”. EAS22410 ASSEMBLING THE FRONT BRAKE CALI- c. Remove the brake caliper piston seals. PERS d. Repeat the previous steps to force out the EWA13620 right side pistons from the brake caliper. WARNING ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

• Page 198: Removing The Front Brake Master Cylinder

  FRONT BRAKE ECA14170 • When refilling, be careful that water does CAUTION: not enter the brake fluid reservoir. Water will significantly lower the boiling point of When installing the brake hose onto the brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.

• Page 199: 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 brake fluid •…

• Page 200
  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 201: 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 proce- dure.

• Page 202
  REAR BRAKE Removing the rear brake master cylinder (FZ1-N(X)/FZ1-S(X)) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm…
• Page 203
  REAR BRAKE Removing the rear brake master cylinder (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-25. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Hose joint…
• Page 204
  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 disassembly pro- cedure. 4-41…
• Page 205
  REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure. 4-42…
• Page 206
  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 dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

• Page 207: 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 preventive measures: BRAKE DISCS” on page 4-31. •…

• Page 208: Removing The Rear Brake Caliper

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

• Page 209: Checking The Rear Brake Caliper

  REAR BRAKE Scratches/wear → Replace the brake cal- iper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA13610 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING a.

• Page 210: Installing The Rear Brake Caliper

  REAR BRAKE EAS22670 Refer to “REPLACING THE REAR INSTALLING THE REAR BRAKE CALIPER BRAKE PADS” on page 4-44. 1. Install: • Brake caliper “1” Brake caliper bolt (front) (temporarily) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) • Copper washers “2” 22 Nm (2.2 m·kg, 16 ft·lb) •…

• Page 211: 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 212
  Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-23. A. FZ1-N(X)/FZ1-S(X) B. FZ1-SA/FZ1-NA 2. Fill: • Brake fluid reservoir (with the specified amount of the recom- 5.
• Page 213
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Passenger seat Refer to “GENERAL CHASSIS” on page 4-1. Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”…
• Page 214
  ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit (FZ1-SA), (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose (hydraulic unit to rear brake caliper) Union bolt Copper washer Brake hose (rear brake master cylinder to hydraulic unit) ABS motor coupler Hydraulic unit solenoid coupler Brake hose holder…

• Page 215: [D-5] Maintenance Of The Hydraulic Unit

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS22770 • Brake hose “3” (to the rear brake caliper) [D-5] MAINTENANCE OF THE HYDRAULIC • Brake hose “4” (from the rear brake mas- UNIT ter cylinder) ECA15060 CAUTION: Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve.

• Page 216: Hydraulic Unit Operation Test

  ABS (ANTI-LOCK BRAKE SYSTEM) Installing the hydraulic unit EWA13940 Proceed in the reverse order of disassembly. WARNING Pay attention to the following items. The brake hoses to the front and rear brake 1. Install: calipers can be distinguished by the rubber •…

• Page 217
  ABS (ANTI-LOCK BRAKE SYSTEM) action that is generated in the brake lever Test coupler adapter and brake pedal when the ABS is activated. 90890-03149 • Hydraulic unit operation test 2: this test checks the function of the ABS after the sys- tem was disassembled, adjusted, or ser- viced.
• Page 218
  ABS (ANTI-LOCK BRAKE SYSTEM) When the main switch is set to “ON”, the Hydraulic unit operation test 2 ABS warning light comes on for 2 seconds, EWA13120 WARNING goes off for 3 seconds, then starts flashing. When the ABS warning light starts flashing, Securely support the vehicle so that there the brake lever “1”…
• Page 219
  ABS (ANTI-LOCK BRAKE SYSTEM) 10. After the pulsating action has stopped in the brake lever, it is generated in the brake A. FZ1-SA pedal “2” 0.5 second after and continues B. FZ1-NA for approximately 1 second. 6. Set the engine stop switch to “ ”.

• Page 220: [D-6-5] Trial Run

  ABS (ANTI-LOCK BRAKE SYSTEM) • If the pulsating action is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hydraulic unit. 12. Set the main switch to “OFF”. 13. Remove the test coupler adaptor from the test coupler.

• Page 221: Handlebar

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

• Page 222: 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 223
  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 224
  HANDLEBAR NOTE: • Align the projections “a” on the handlebar switch with the holes “b” in the handlebar. • There should be 1–3 mm (0.04–0.12 in) of clearance “c” between the handlebar grip and the grip end. 10. Install: • Front brake master cylinder assembly •…

• Page 225: Front Fork

  FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Refer to “CHECKING THE TIRES” on page Front wheel 3-33 and “CHECKING THE WHEELS” on Front brake calipers page 3-35. Front fender Cap bolt Loosen.

• Page 226
  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 disassembly pro-…

• Page 227: Removing The Front Fork Legs

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

• Page 228: Checking The Front Fork Legs

  FRONT FORK 3. Remove: • Oil seal clip “1” (with a flat-head screwdriver) ECA14180 CAUTION: Do not scratch the inner tube. EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: •…

• Page 229: Assembling The Front Fork Legs

  FRONT FORK 3. Check: NOTE: • Damper rod “1” The left side (for the compression) damper rod Damage/wear → Replace. assembly has the four holes of oil path, unlike Obstruction → Blow out all of the oil pas- the right side. sages with compressed air.

• Page 230
  FRONT FORK 4. Install: NOTE: • Dust seal “1” Adjust the oil seal clip so that it fits into the • Oil seal clip “2” outer tube’s groove. • Oil seal “3” • Washer “4” ECA14220 CAUTION: Make sure the numbered side of the oil seal faces up.
• Page 231
  FRONT FORK 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- ual air. 12. Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without 9.

• Page 232: Installing The Front Fork Legs

  FRONT FORK d. Press down in the spacer with the fork h. Set the cap bolt distance “c” to specifica- spring compressor “1” tion. e. Pull up the rod puller and install the rod holder “2” between the damper adjusting Distance “c”…

• Page 233
  FRONT FORK 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: • Lower bracket pinch bolt “1” Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) •…

• Page 234: Steering Head

  Front brake calipers Refer to “FRONT BRAKE” on page 4-26. Front cowling (FZ1-S(X)/FZ1-SA) Refer to “GENERAL CHASSIS” on page 4-1. Headlight and meter assembly (FZ1-N(X)), Refer to “GENERAL CHASSIS” on page 4-1. (FZ1-NA) Handlebar Refer to “HANDLEBAR” on page 4-58.

• Page 235
  STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower bearing Lower bearing dust seal Lower bearing inner race Bearing cover Upper bearing inner race Upper bearing Bearing outer race For installation, reverse the removal proce- dure. 4-72…

• Page 236: 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 237: 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 238: 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. Brake fluid reservoir tank bolt Refer to “REAR BRAKE”…

• Page 239: 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 240: Checking The Connecting Arm And Relay Arm

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

• Page 241: Swingarm

  SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-17. Rear brake caliper Refer to “REAR BRAKE” on page 4-38. Refer to “REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY” on page 4-75. Drive sprocket Refer to “ENGINE REMOVAL”…

• Page 242: 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 243: Installing The Swingarm

  SWINGARM 5. Check: • Connecting arms “1” • Relay arm “2” Damage/wear → Replace. 3. Install: 6. Check: • Rear shock absorber assembly • Bearings “3” • Oil seals “4” • Rear wheel Damage/pitting → Replace. Refer to “INSTALLING THE REAR 7.

• Page 244: 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 5-1. Drive chain guard Drive chain For installation, reverse the removal proce- dure. 4-81…

• Page 245: 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 246: Checking The Drive Sprocket

  CHAIN DRIVE EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: • 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.

• Page 247: Engine

  ENGINE ENGINE REMOVAL ………………5-1 INSTALLING THE ENGINE …………..5-7 CAMSHAFTS………………..5-9 REMOVING THE CAMSHAFTS …………5-11 CHECKING THE CAMSHAFTS …………5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-13 CHECKING THE TIMING CHAIN GUIDES ……….5-13 CHECKING THE TIMING CHAIN TENSIONER ……..5-13 INSTALLING THE CAMSHAFTS …………5-15 CYLINDER HEAD………………5-18 REMOVING THE CYLINDER HEAD …………5-19 CHECKING THE CYLINDER HEAD …………5-19…

• Page 248
  CHECKING THE CLUTCH PLATES………….5-47 CHECKING THE CLUTCH SPRINGS ……….5-48 CHECKING THE CLUTCH HOUSING ……….5-48 CHECKING THE CLUTCH BOSS …………5-48 CHECKING THE PRESSURE PLATE ……….5-48 CHECKING THE PULL LEVER SHAFT AND PULL ROD….5-49 INSTALLING THE CLUTCH…………..5-49 SHIFT SHAFT …………………5-52 REMOVING THE SHIFT SHAFT …………5-53 CHECKING THE SHIFT SHAFT …………5-53 CHECKING THE STOPPER LEVER…………5-53 INSTALLING THE SHIFT SHAFT …………5-53…
• Page 249
  INSTALLING THE TRANSMISSION………….5-88…

• Page 250: 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 proce- dure.

• Page 251
  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 252
  ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks Pulley Spring Spring seat For assembly, reverse the disassembly pro- cedure.
• Page 253
  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. Drain.
• Page 254
  ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks For assembly, reverse the removal proce- dure.
• Page 255
  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 proce- dure.

• Page 256: 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- 2. Tighten: • Right front engine mounting bolt 2 Right front engine mounting 7. Tighten: bolt 2 •…

• Page 257
  ENGINE REMOVAL 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) NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut.

• Page 258: 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. Refer to “AIR INDUCTION SYSTEM”…

• Page 259
  CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Refer to “CRANKSHAFT POSITION SEN- Pickup rotor cover SOR” on page 5-37. Camshaft sprocket bolt Loosen. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Refer to “REMOVING THE CAMSHAFTS” Dowel pin on page 5-11.

• Page 260: Removing The Camshafts

  CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to “CRANKSHAFT POSITION SENSOR” on page 5-37. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. 5.

• Page 261: 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 262: 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: • Camshaft journal diameter “a” 1. Timing chain roller Out of specification →…

• Page 263
  CAMSHAFTS • Timing chain tensioner spring “3” b. Squeeze the timing chain tensioner clip “2” and push the timing chain tensioner rod “3”. NOTE: Squeeze the timing chain tensioner clip, and NOTE: then remove the timing chain tensioner spring When the timing chain tensioner rod “3” is and timing chain tensioner rod.

• Page 264: 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 265
  CAMSHAFTS • The camshaft cap bolts must be tightened • Gasket evenly or damage to the cylinder head, • Timing chain tensioner “1” camshaft caps, and camshafts will result. • Timing chain tensioner bolts “2” • Do not turn the crankshaft when installing the camshaft to avoid damage or Timing chain tensioner bolt improper valve timing.
• Page 266
  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 5-37. 5-17…
• Page 267
  CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Refer to Engine “ENGINE REMOVAL” on page 5-1. Refer to Intake camshaft “CAMSHAFTS” on page 5-9. Refer to Exhaust camshaft “CAMSHAFTS” on page 5-9. Cylinder head Cylinder head gasket Dowel pin Coolant pipe…

• Page 268: Cylinder Head

  CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAM- SHAFTS” on page 5-11. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: a. Place a straightedge “1” and a thickness • Cylinder head nuts gauge “2” across the cylinder head. •…

• Page 269
  CYLINDER HEAD 2. Install: • Gasket “1” • Dowel pins 5. Install: • Exhaust camshaft • Intake camshaft Refer to “INSTALLING THE CAM- 3. Install: SHAFTS” on page 5-15. • Cylinder head NOTE: Pass the timing chain through the timing chain cavity.
• Page 270
  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 5-18. 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 271: Valves And Valve Springs

  VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-22…

• Page 272: 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 273: 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 274: 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 275
  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 (0.0354–0.0433 valve face should be lapped. Exhaust ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 0.90–1.10 mm (0.0354–0.0433 a. Apply a coarse lapping compound “a” to the valve face.

• Page 276: 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 277: 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 278
  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 Valve spring compressor attachment 90890-04114 Valve spring compressor adapter YM-04114 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter (22 mm) YM-04108 5.

• Page 279: 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. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-12.

• Page 280
  GENERATOR Removing the generator Order Job/Parts to remove Q’ty Remarks Washer Bearing For assembly, reverse the removal proce- dure. 5-31…

• Page 281: 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 282
  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 283: 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 proce- dure. 5-34…

• Page 284: 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 285: Installing The Starter Clutch

  STARTER CLUTCH b. When turning the starter clutch drive gear counterclockwise “A”, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear clockwise “B”, it should turn freely, other- wise the starter clutch is faulty and must be replaced.

• Page 286: 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. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”…

• Page 287: 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 288: 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. Starter motor lead Starter motor For assembly, reverse the removal proce-…

• Page 289
  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 disassembly pro- cedure. 5-40…

• Page 290: 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 Commutator resistance “1” starter motor.

• Page 291: 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 292: Clutch

  CLUTCH EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil 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 proce- dure.

• Page 293
  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 proce- dure. 5-44…
• Page 294
  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 295: 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 296: 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 297: Checking The Clutch Springs

  CLUTCH 2. Check: • Bearing Damage/wear → Replace the bearing EAS25140 CHECKING THE CLUTCH SPRINGS and 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 298: Checking The Pull Lever Shaft And Pull Rod

  CLUTCH EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • Pull lever shaft pinion gear teeth “1” • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 3.

• Page 299
  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 300
  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 301: 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 5-43. Shift arm and shift rod Refer to “ENGINE REMOVAL” on page 5-1. Circlip Washer Shift shaft Collar Shift shaft spring…

• Page 302: Removing The Shift Shaft

  SHIFT SHAFT EAS5D01019 REMOVING THE SHIFT SHAFT 1. Remove: • Clutch assembly Refer to “CLUTCH” on page 5-43 2. Remove: • Shift arm • Shift rod Refer to “ENGINE REMOVAL” on page 5- 3. Remove: • Circlip “1” • Washer “2” EAS25420 CHECKING THE SHIFT SHAFT (left side of the engine)

• Page 303
  SHIFT SHAFT • Stopper lever spring “3” 4. Install: • Shift rod • Shift arm Refer to “ENGINE REMOVAL” on page 5- 5. Install: • Clutch assembly Refer to “CLUTCH” on page 5-43. 2. Install: • Washer • Collar • Shift shaft spring “1” •…

• Page 304: Oil Pump

  OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-12. EXUP cables Refer to “ENGINE REMOVAL” on page 5-1. sensor Refer to “ENGINE REMOVAL”…

• Page 305
  OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Oil delivery pipe Relief valve assembly Oil/water pump assembly drive chain guide Collar Oil/water pump assembly drive sprocket Washer Oil/water pump assembly drive chain Dowel pin Oil/water pump assembly For assembly, reverse the removal proce- dure.
• Page 306
  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 rotor Oil pump inner rotor For assembly, reverse the disassembly pro- cedure. 5-57…

• Page 307: 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 308: Checking The Relief Valve

  OIL PUMP EAS24970 CHECKING THE RELIEF VALVE EAS25600 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 309: 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 310: Installing The Oil Pan

  OIL PUMP EAS25050 INSTALLING THE OIL PAN 1. Install: • Dowel pins • Gasket • Oil pan “1” Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) • Oil level switch “2” Oil level switch bolt 4. Install: 10 Nm (1.0 m·kg, 7.2 ft·lb) •…

• Page 311: 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 5-1. Cylinder head Refer to “CYLINDER HEAD”…

• Page 312
  CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Lower crankcase Dowel pin Damper For assembly, reverse the removal proce- dure. 5-63…

• Page 313: 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 314
  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 315: 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 5-62. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring…

• Page 316
  CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-62. Refer to “REMOVING THE CONNECTING Connecting rod and connecting rod caps RODS AND PISTONS” on page 5-68. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear…

• Page 317: 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 318: 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) EAS24390 CHECKING THE CYLINDER AND PISTON…

• Page 319: Checking The Piston Pins

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

• Page 320: 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 (0.6694– a. Clean the big end bearings, crankshaft 0.6698 in) pins, and the inside of the connecting rods Limit halves. 17.043 mm (0.6710 in) b.

• Page 321
  CRANKSHAFT j. 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 322
  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: EWA5D01010 • The numbers “A” stamped into the crank- WARNING shaft wed and the numbers “1”…

• Page 323: 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 324
  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 325
  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 326: 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 327
  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 (2.4 m·kg, 17 ft·lb) Bolt “17”–“26” 12 Nm (1.2 m·kg, 8.7 ft·lb) M9 x 105 mm (4.1 in) bolts: “1”–“10” d.

• Page 328: 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 329
  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 330: Transmission

  TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase lower Refer to “CRANKCASE” on page 5-62. Drive axle assembly Circlip Oil seal Bearing Washer Shift fork guide bar retainer Spring Shift fork guide bar Shift fork “L”…

• Page 331
  TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure. 5-82…
• Page 332
  TRANSMISSION Disassembling the main axle assembly 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 disassembly pro- cedure.
• Page 333
  TRANSMISSION Disassembling the drive axle assembly 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 334
  TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks For assembly, reverse the disassembly pro- cedure. 5-85…

• Page 335: Removing The Transmission

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

• Page 336: 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 337
  TRANSMISSION EAS26350 INSTALLING THE TRANSMISSION 1. Install: • Bearing “1” NOTE: Make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. • Oil pipe “2” 3. Install: •…
• Page 338
  TRANSMISSION 4. Check: • Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5-89…

• Page 339: Cooling System

  COOLING SYSTEM RADIATOR………………..6-1 CHECKING THE RADIATOR…………..6-2 INSTALLING THE RADIATOR …………..6-2 OIL COOLER ………………..6-3 CHECKING THE OIL COOLER…………..6-4 INSTALLING THE OIL COOLER …………6-4 THERMOSTAT ………………..6-5 CHECKING THE THERMOSTAT…………6-7 ASSEMBLING THE THERMOSTAT ASSEMBLY ……..6-7 INSTALLING THE THERMOSTAT ASSEMBLY ……..6-7 WATER PUMP ………………..6-9 DISASSEMBLING THE WATER PUMP……….6-10 CHECKING THE WATER PUMP …………6-10 ASSEMBLING THE WATER PUMP…………6-10…

• Page 340
  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. Drain.

• Page 341: Radiator

  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 342: Oil Cooler

  OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil 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 343: Checking The 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 344: Thermostat

  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. Drain.

• Page 345
  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 disassembly pro- cedure.

• Page 346: Checking The Thermostat

  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 347
  THERMOSTAT 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

• Page 348: Water Pump

  WATER PUMP EAS26500 WATER PUMP Removing the impeller shaft Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-55. Oil pump rotor Refer to “OIL PUMP” on page 5-55. Water pump cover O-ring Impeller shaft (along with the impeller) Water pump seal Oil seal Bearing…

• Page 349: Disassembling The Water Pump

  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 350
  (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 351: Fuel System

  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 ……………7-7 CHECKING THE THROTTLE BODIES ……….7-7 CHECKING THE FUEL PRESSURE…………7-7 ADJUSTING THE THROTTLE POSITION SENSOR ……7-7…

• Page 352: Fuel Tank

  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 353: Fuel Tank

  FUEL TANK EAS26630 • Do not touch the base section of the fuel REMOVING THE FUEL TANK sender. 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. EAS26670 2. Remove: CHECKING THE FUEL PUMP BODY •…

• Page 354
  FUEL TANK EAS5D01024 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 355: 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. Sub-wire harness coupler Disconnect.

• Page 356
  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 357
  THROTTLE BODIES Removing the injectors Order Job/Parts to remove Q’ty Remarks Throttle position sensor Throttle body assembly For installation, reverse the removal proce- dure.
• Page 358
  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- EAS26990 mary injector fuel rail). CHECKING THE THROTTLE BODIES 1. Check: Vacuum/pressure pump gauge •…
• Page 359
  THROTTLE BODIES 1. Check: EAS5D01025 ADJUSTING THE SUB-THROTTLE POSI- • Throttle position sensor TION SENSOR Refer to “CHECKING THE THROTTLE 1. Check: POSITION SENSOR” on page 8-153. • Sub-throttle position sensor 2. Adjust: Refer to “CHECKING THE SUB-THROT- • Throttle position sensor angle TLE POSITION SENSOR”…
• Page 360
  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 361
  THROTTLE BODIES EAS2D1011 EAS5D01026 CHECKING THE SUB-THROTTLE SERVO ADJUSTING THE THERMO WAX MOTOR 1. Adjust: 1. Check: • Thermo wax the end face distance “a” • Sub-throttle servo motor operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Out of specification → Replace. a. Before adjusting the distance, push the rod “b”…
• Page 362
  THROTTLE BODIES NOTE: • Setup tolerance of the longitudinal axis should be ± 0.2 mm (± 0.008 in). • After adjusting the thermo wax, check that the first idling is released at the coolant tem- perature around 60°C (140°F) by idling. •…

• Page 363: 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 364
  AIR INDUCTION SYSTEM EAS27060 A. From the air cleaner CHECKING THE AIR INDUCTION SYSTEM B. To the cylinder head Air injection 1. Check: The air induction system burns unburned • Hoses exhaust gases by injecting fresh air (second- Loose connections → Connect properly. ary air) into the exhaust port, reducing the Cracks/damage →…
• Page 365
  AIR INDUCTION SYSTEM c. Measure the air induction system solenoid resistance. Air induction system solenoid resistance 18–22Ω at 20°C (68°F) d. Out of specification → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS27070 INSTALLING THE AIR INDUCTION SYSTEM 1. Install: • Plate • Reed valve assembly •…
• Page 366
  AIR INDUCTION SYSTEM 7-15…

• Page 367: Electrical System

  ELECTRIC STARTING SYSTEM…………..8-5 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(X)) …………8-15 CIRCUIT DIAGRAM (FZ1-S(X)) …………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 368
  ABS (ANTI-LOCK BRAKE SYSTEM) …………8-89 CIRCUIT DIAGRAM (FZ1-SA)…………..8-89 CIRCUIT DIAGRAM (FZ1-NA)…………..8-91 ABS COMPONENTS CHART……………8-93 ABS CONNECTOR LOCATION CHART ……….8-97 ABS ECU AND ABS MOTOR RELAY……….8-101 [D-1] MAINTENANCE OF THE ABS ECU ……….8-103 [D-2] MAINTENANCE OF THE ABS MOTOR RELAY ……8-104 ABS TROUBLESHOOTING OUTLINE ……….8-105 BASIC INSTRUCTION FOR TROUBLESHOOTING ……8-106 BASIC PROCESS FOR TROUBLESHOOTING ………8-107…
• Page 369
  CHECKING THE INTAKE AIR PRESSURE SENSOR …….8-156 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ….8-156…

• Page 370: Ignition System

  IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM…

• Page 371
  IGNITION SYSTEM 1. Main switch 6. Main fuse 7. Battery 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 17.Crankshaft position sensor 21.Lean angle sensor 23.ECU (engine control unit) 24.Ignition coil #1 25.Ignition coil #2 26.Ignition coil #3 27.Ignition coil #4 28.Spark plug 56.Engine stop switch 60.Clutch switch…

• Page 372: Passenger Seat

  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 373
  IGNITION SYSTEM 8. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-135. OK↓ NG→ 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-135. OK↓…

• Page 374: Electric Starting System

  ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM…

• Page 375
  ELECTRIC STARTING SYSTEM 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Sidestand switch 56.Engine stop switch 57.Start switch 60.Clutch switch 78.Ignition fuse…
• Page 376
  ELECTRIC STARTING SYSTEM 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 377
  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 378
  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 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES”…
• Page 379
  ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the immobilizer kit. SWITCHES” on page 8-135. OK↓ NG→ 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-135. OK↓…

• Page 380: Charging System

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

• Page 381
  CHARGING SYSTEM 2. Rectifier/regulator 3. AC magneto 6. Main fuse 7. Battery 8-12…
• Page 382
  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 8-139. OK↓…
• Page 383
  CHARGING SYSTEM 8-14…

• Page 384: Lighting System

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

• Page 385
  LIGHTING SYSTEM 1. Main switch 6. Main fuse 7. Battery 23.ECU (engine control unit) 49.High beam indicator light 52.Meter light 61.Pass switch 62.Dimmer switch 72.Auxiliary light 73.Headlight 74.License plate light 75.Tail/brake light 76.Headlight relay (on/off) 77.Taillight fuse 81.Headlight fuse 8-16…
• Page 386
  LIGHTING SYSTEM EAS5D01027 CIRCUIT DIAGRAM (FZ1-S(X)) 8-17…
• Page 387
  LIGHTING SYSTEM 1. Main switch 6. Main fuse 7. Battery 23.ECU (engine control unit) 49.High beam indicator light 52.Meter light 61.Pass switch 62.Dimmer switch 72.Auxiliary light 73.Headlight 74.License plate light 75.Tail/brake light 76.Headlight relay (on/off) 77.Headlight relay (dimmer) 78.Taillight fuse 82.Headlight fuse 8-18…
• Page 388
  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 NG→…
• Page 389
  Replace the headlight relay. Refer to “CHECKING THE RELAYS” on page 8-142. 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(X))” on page 8-15. OK↓ This circuit is OK. 8-20…

• Page 390: Signaling System

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

• Page 391
  SIGNALING SYSTEM 1. Main switch 6. Main fuse 7. Battery 11.Relay unit 14.Neutral switch 16.Fuel pump 19.Speed sensor 23.ECU (engine control unit) 42.Fuel level warning light 43.Oil level warning light 44.Neutral indicator light 45.Tachometer 46.Multi-function meter 48.Coolant temperature indicator light 50.Left turn signal indicator light 51.Right turn signal indicator light 53.Oil level switch…
• Page 392
  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.
• Page 393
  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 394
  SIGNALING SYSTEM 3. Check the hazard switch. NG→ Refer to “CHECKING THE Replace the left handlebar switch. SWITCHES” on page 8-135. OK↓ NG→ 4. Check the turn signal/hazard relay. Refer to “CHECKING THE Replace the turn signal/hazard relay. RELAYS” on page 8-142. OK↓…
• Page 395
  SIGNALING SYSTEM 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 8-21. OK↓ This circuit is OK. The fuel level warning light fails to come on. 1.
• Page 396
  COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27…
• Page 397
  COOLING SYSTEM 1. Main switch 6. Main fuse 7. Battery 23.ECU (engine control unit) 38.Coolant temperature sensor 78.Ignition fuse 82.Radiator fan motor relay 83.Left radiator fan motor fuse 84.Right radiator fan motor fuse 85.Left radiator fan motor 86.Right radiator fan motor 8-28…
• Page 398
  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 8-139.
• Page 399
  COOLING SYSTEM 8-30…

• Page 400: Fuel Injection System

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

• Page 401
  FUEL INJECTION SYSTEM 1. Main switch 4. Buckup fuse 6. Main fuse 7. Battery 8. Fuse injection system fuse 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Sidestand switch 16.Fuel pump 17.Crankshaft position sensor 18.Cylinder identification sensor 19.Speed sensor 20.Atmospheric pressure sensor 21.Lean angle sensor…
• Page 402
  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 1. Check the fuses. NG→…
• Page 403
  FUEL INJECTION SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the immobilizer kit. SWITCHES” on page 8-135. OK↓ NG→ 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-135. OK↓…
• Page 404
  FUEL INJECTION SYSTEM 17.Checking the atmospheric pres- NG→ sure sensor. Replace the atmospheric pressure Refer to “CHECKING THE ATMO- sensor. SPHERIC PRESSURE SENSOR” on page 8-155. OK↓ 18.Check the injector. NG→ Refer to “CHECKING THE INJEC- Replace the injector. TORS” on page 7-7. OK↓…
• Page 405
  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 406
  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 407
  FUEL INJECTION SYSTEM d. Engine trouble warning light on for 1.4 sec- a. Main switch “OFF” onds b. Main switch “ON” c. Engine trouble warning light off EAS27362 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
• Page 408
  FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Coolant temperature Coolant temperature sensor: sensor Able Able open or short circuit detected. (open or short circuit) Intake air temperature Intake air temperature sensor: sensor Able Able…
• Page 409
  FUEL INJECTION SYSTEM Able/ Able/ Fault Item Symptom unable unable code No. to start to drive Able Able (depend- (depend- ing on ing on Injector Injector: the num- the num- (open circuit) open circuit detected. ber of ber of faulty faulty cylin- cylin-…
• Page 410
  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 Unable Unable within the specified duration. (output signal error) ECU internal malfunc- Data from the ECU cannot be received Er-3 tion…
• Page 411
  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 412
  FUEL INJECTION SYSTEM The data representing the operating conditions of the sensor appears on the odometer/ tripmeter/fuel reserve tripmeter LCD. • Actuator operation Set the engine stop switch to “ ” to operate the actuator. NOTE: If the engine stop switch is set to “ ”, set it to “…
• Page 413
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Atmospheric pressure sensor hose is clogged. When the main switch is • Intake air pressure sensor hose is clogged, turned to “ON”, the atmo- kinked, or pinched. spheric pressure sensor •…
• Page 414
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. Open circuit detected in the • Malfunction in ignition coil. primary lead of the cylinder- • Malfunction in a component of ignition cut- #4 ignition coil.
• Page 415
  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. •…
• Page 416
  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 417
  FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction code reinstate • No malfunction code — • Malfunction code exists Fault code 24 To reinstate, set the engine • (If more than one code stop switch to “ ”.
• Page 418
  FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the injector #3 five times at one-second inter- Check the operating sound Injector #3 vals. of the injector #3 five times. Illuminates the engine trou- ble warning light. Actuates the injector #4 five times at one-second inter- Check the operating sound Injector #4…
• Page 419
  FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuate the servo motor turns to close side and to open Check the operating sound side. Sub-throttle servo motor of the Sub-throttle servo Illuminates the engine trou- motor. ble warning light only while the motor is running.
• Page 420
  FUEL INJECTION SYSTEM No normal signals are received from the crankshaft Fault code No. Symptom position sensor. Diagnostic code No. — — Item/components and probable Reinstatement Order Check or maintenance job cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor engine.
• Page 421
  FUEL INJECTION SYSTEM Intake air pressure sensor: open or short circuit Fault code No. Symptom detected. Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstatement Order Check or maintenance job cause method Connections • Check the couplers for any Turn the main •…
• Page 422
  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 423
  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 424
  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 425
  FUEL INJECTION SYSTEM When the main switch is turned to “ON”, the atmo- Fault code No. Symptom spheric pressure sensor voltage and intake air pressure sensor voltage differ greatly. Atmospheric pressure sensor Diagnostic code No. Intake air pressure sensor Item/components and probable Reinstatement Order Check or maintenance job…
• Page 426
  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 427
  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 428
  FUEL INJECTION SYSTEM Fault code No. 30 Symptom No normal signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Item/components and probable Reinstatement Order Check or maintenance job cause method The vehicle has overturned. Raise the vehicle upright. Turning the main switch to Installed state of the lean angle sen-…
• Page 429
  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 430
  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 431
  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 432
  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 433
  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 434
  FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. 42 Symptom B. Open circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstate- Order Check or maintenance job cause…
• Page 435
  FUEL INJECTION SYSTEM A. No normal signals are received from the speed sensor. Fault code No. 42 Symptom B. Open circuit is detected in the neutral switch. 07 Speed sensor Diagnostic code No. 21 Neutral switch Item/components and probable Reinstatement Order Check or maintenance job cause…
• Page 436
  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 437
  FUEL INJECTION SYSTEM An error is detected while reading or writing on Fault code No. Symptom EEPROM (CO adjustment value). Diagnostic code No. EEPROM fault cylinder No. Item/components and probable Reinstatement Order Check or maintenance job cause method Malfunction in ECU •…
• Page 438
  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 439
  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 •…
• Page 440
  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 441
  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 442
  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 443
  FUEL INJECTION SYSTEM 8-74…

• Page 444: Fuel Pump System

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

• Page 445
  FUEL PUMP SYSTEM 1. Main switch 6. Main fuse 7. Battery 8. Fuel injection system fuse 13.Fuel pump relay 16.Fuel pump 23.ECU (engine control unit) 46.Multi-function meter 56.Engine stop switch 78.Ignition fuse 8-76…
• Page 446
  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 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s).
• Page 447
  FUEL PUMP SYSTEM 8-78…

• Page 448: Immobilizer System

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

• Page 449
  IMMOBILIZER SYSTEM 1. Main switch 4. Backup fuse 5. Immobilizer unit 6. Main fuse 7. Battery 23.ECU (engine control unit) 41.Immobilizer indicator 46.Multi-function meter 78.Ignition fuse 8-80…
• Page 450
  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 451
  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 √ Standard key is lost New standard key All keys have been Code re-registering √ √ √…
• Page 452
  IMMOBILIZER SYSTEM e. Standby mode on f. Standby mode off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. NOTE: Do not start the engine with a standard key that has not been registered.
• Page 453
  IMMOBILIZER SYSTEM Voiding the standard key code: If a standard key has been lost, it is possible to disable its use by re-registering the remaining stan- dard key. Standard key registration erases the stored standard key code from the memory, thus dis- abling the lost standard key.
• Page 454
  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 8-139. OK↓…
• Page 455
  IMMOBILIZER SYSTEM EAS27720 SELF-DIAGNOSIS FAULT CODE INDICATION When the system failure occurred, the error code number is indicated in the immobilizer system indi- cator light blinks at the same time. The pattern of blinking also shows the error code. Error Detection Symptoms Trouble…
• Page 456
  IMMOBILIZER SYSTEM Error Detection Symptoms Trouble Measures code IMMOBILIZER Key code registra- Same standard key was Prepare the new UNIT tion error. attempted to continu- standard key and ously two times register. register it. Undefinition code is Noise interference or dis- 1.
• Page 457
  IMMOBILIZER SYSTEM 8-88…
• Page 458
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM (FZ1-SA) 8-89…
• Page 459
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-SA 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 12.Starting circuit cut-off relay 14.Neutral switch 46.Multi-function meter 53.ABS warning light 56.Front brake light switch 57.Engine stop switch 58.Start switch 59.Rear brake light switch 76.Tail/brake light 82.Signal fuse 84.ABS fuse…
• Page 460
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS22C1001 CIRCUIT DIAGRAM (FZ1-NA) 8-91…
• Page 461
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 1. Main switch 6. Main fuse 7. Battery 9. Starter relay 10.Starter motor 12.Starting circuit cut-off relay 14.Neutral switch 46.Multi-function meter 53.ABS warning light 56.Front brake light switch 57.Engine stop switch 58.Start switch 59.Rear brake light switch 76.Tail/brake light 81.Signal fuse 83.ABS fuse…
• Page 462
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART FZ1-SA 8-93…
• Page 463
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-SA 1. ABS warning light 2. ABS test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. ABS ECU 9. ABS motor relay 10.Fuse box 8-94…
• Page 464
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 8-95…
• Page 465
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 1. ABS warning light 2. ABS test coupler 3. Front sensor rotor 4. Front wheel sensor 5. Hydraulic unit 6. Rear sensor rotor 7. Rear wheel sensor 8. ABS ECU 9. ABS motor relay 10.Fuse box 8-96…
• Page 466
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS CONNECTOR LOCATION CHART FZ1-SA 8-97…
• Page 467
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-SA 1. ABS ECU coupler 2. Front wheel sensor coupler 3. Rear wheel sensor coupler 4. Hydraulic unit coupler 5. ABS motor relay 6. ABS test coupler 7. Multi-function coupler 8-98…
• Page 468
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 8-99…
• Page 469
  ABS (ANTI-LOCK BRAKE SYSTEM) FZ1-NA 1. Front wheel sensor coupler 2. Rear wheel sensor coupler 3. Hydraulic unit coupler 4. ABS ECU coupler 5. ABS motor relay 6. ABS test coupler 7. Multi-function coupler 8-100…
• Page 470
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27760 ABS ECU AND ABS MOTOR RELAY Removing the ABS ECU and ABS motor relay (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Right front cowling inner panel Refer to “GENERAL CHASSIS” on page 4-1. Refer to “ABS (ANTI-LOCK BRAKE SYS- Under cover TEM)”…
• Page 471
  ABS (ANTI-LOCK BRAKE SYSTEM) Removing the ABS ECU and ABS motor relay (FZ1-NA) Order Job/Parts to remove Q’ty Remarks Right front cowling inner panel Refer to “GENERAL CHASSIS” on page 4-1. Refer to “ABS (ANTI-LOCK BRAKE SYS- Under cover TEM)” on page 4-50. Rear fender lower cover ABS motor relay ABS motor relay coupler…
• Page 472
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 [D-1] MAINTENANCE OF THE ABS ECU Removing the ABS ECU 1. Remove: • ABS ECU “1” NOTE: When removing the ABS ECU, take care not to damage the ABS ECU or ABS ECU couplers. A. FZ1-SA B.
• Page 473
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27780 [D-2] MAINTENANCE OF THE ABS MOTOR RELAY Removing the ABS motor relay 1. Remove: • ABS motor relay coupler NOTE: Do not pull the ABS motor relay leads to remove the ABS motor relay coupler. Always press on the lock to disconnect the ABS motor relay coupler from the ABS motor relay.
• Page 474
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27790 ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light on the meter assembly indicates a malfunction.
• Page 475
  ABS (ANTI-LOCK BRAKE SYSTEM) Differences between the normal handling and services on a vehicle • Care should be taken not to damage components by shocks and pulling too much since the ABS components are precisely adjusted. • ABS ECU, HU, Wheel sensors and ABS motor relay cannot be disassembled. •…
• Page 476
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-107…

• Page 477: Meter Coupler

  ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when the service is finished. EWA14050 WARNING Always execute the “final check” when the components related to ABS are checked and ser- viced.

• Page 478
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS4S81020 [B-3] THE ABS WARNING LIGHT FLASHES NOTE: Check the battery voltage before proceeding. Check the test coupler located in the left inner panel (front cowling). Is the T/C terminal ground? 1. Yes → Disconnect the grounding lead from the T/C terminal and install the protective cap onto the test coupler.
• Page 479
  ABS (ANTI-LOCK BRAKE SYSTEM) B. FZ1-NA A. FZ1-SA 1. Indicate the malfunction code (Example: malfunction code 11) 2. ABS warning light flashes every 0.5 second for more than 6 seconds. → [C-4, C-5] If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has not been stored in the memory of the ECU (ABS).
• Page 480
  ABS (ANTI-LOCK BRAKE SYSTEM) 7. ABS warning light terminal (White/Red) 1. ABS test coupler 8. Test coupler adapter 2. Lock plate 9. Light green 3. Protective cap 10.Black 4. Grounding 11.White/Red 5. T/C terminal 6. T/F terminal As an example, “10 digits/1 digit pattern” of tester reading is shown below. 8-111…

• Page 481: Meter Assembly

  ABS (ANTI-LOCK BRAKE SYSTEM) C. Time (second) A. This example is the pattern which shows malfunction code 12. B. This example is the pattern which shows malfunction code 21. EAS4S81021 [C] DETERMINING THE CAUSE AND LOCATION OF THE MALFUNCTION EAS4S81022 [C-1] ONLY THE ABS WARNING LIGHT DOES NOT COME ON WHEN THE MAIN SWITCH IS SET TO “ON”…

• Page 482: Rectifier/Regulator

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS4S81024 [C-3] ABS WARNING LIGHT FLASHES 1. When the warning light flashes “ON” for 0.25 seconds and “OFF” for 0.75 seconds, check the stop switch or 3-4), 5). 2. When the warning light flashes “ON” for 0.75 seconds and “OFF” for 0.25 seconds, the starter motor monitor is defective.

• Page 483
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27880 [C-5] DIAGNOSIS BY THE MALFUNCTION CODE Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “[B-4] MAL- FUNCTION CHECK BY THE ABS SELF-DIAGNOSIS (PAST MALFUNCTION)” and “[B-5] MAL- FUNCTION CHECK BY THE ABS SELF-DIAGNOSIS (PRESENT MALFUNCTION)”.) The malfunction codes are explained in the following table.
• Page 484
  ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Stop light failure • Adjust the brake light switch. Malfunction (Brake system circuit has failure.) • Brake light switch code 24 • Bulb has burned out. • Check the wire harness for the brake light system circuit.
• Page 485
  ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Disconnection is detected between • ABS harness circuit (from ABS Malfunction the ABS ECU and solenoid sys- ECU to the solenoid) code 35 tem. • Solenoid coupler Downstream side of the solenoid •…
• Page 486
  ABS (ANTI-LOCK BRAKE SYSTEM) Malfunc- Problem Check point Reference tion code Sensor power supply failure • Wire harness circuit Malfunction • Battery terminal is disconnected code 63 63 (front) • Replace the ABS ECU (front) and 64 64 (rear) (rear) Present ABS ECU may be malfunctioning •…
• Page 487
  ABS (ANTI-LOCK BRAKE SYSTEM) • ABS ECU coupler terminal is disconnected. → [D-1] 2. ABS warning light goes on for 2 seconds then goes off. 1. With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is not a malfunction.
• Page 488
  ABS (ANTI-LOCK BRAKE SYSTEM) 1. Check the wheel sensor signal Measure the wheel sensor signal output voltage. Refer to “CHECKING THE WHEEL SENSOR” on page 8-149. 2. Check the appearance. 3. Check the wire harness. 1. Disconnection of the ABS ECU coupler terminal 2.
• Page 489
  ABS (ANTI-LOCK BRAKE SYSTEM) 5. Front solenoid 1. ABS ECU 6. Rear solenoid 2. Red 7. Green 3. Red 8. White/Red 4. Red *Continuity between: “A”–“B”, “A”–“C”, “D”–“G”, “E”–“F” • Check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal. 4.
• Page 490
  ABS (ANTI-LOCK BRAKE SYSTEM) 5. Yellow 1. Front brake light switch 6. Brake light 2. Rear brake light switch 7. Yellow 3. Green/Yellow 8. ABS ECU 4. Yellow *Continuity between: “A”–“B” Malfunction code 25 (At the beginning of running, there is no pulse from the front wheel sen- sor.) •…
• Page 491
  ABS (ANTI-LOCK BRAKE SYSTEM) 4. When the items 1 to 3 are normal, replace the ABS ECU. Malfunction code 32 (Circuit malfunction of ABS ECU is detected. Upstream side of the sole- noid relay.) NOTE: Check following the steps in sequence. 1.
• Page 492
  ABS (ANTI-LOCK BRAKE SYSTEM) • Check for continuity between the positive battery terminal and the battery end of the ABS motor fuse terminal (terminal “B” shown in the above illustration). • Remove the ABS ECU and the ABS motor relay from the wire harness (ABS), and then check for continuity between the white/black lead terminals of ABS ECU coupler and the white/red lead terminals of ABS motor coupler.
• Page 493
  • Check the brake hose lines for kinks and deterioration. EWA4S81009 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the front brake caliper from the hydraulic unit are correct.
• Page 494
  EWA4S81011 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the rear brake caliper from the hydraulic unit are correct.
• Page 495
  ABS (ANTI-LOCK BRAKE SYSTEM) Terminal color Solenoid side Wire harness side (ABS) Front Red, Green Red, Green Rear Red, Blue Red, White/Red 6. Hydraulic unit If the malfunction is not corrected after performing steps 1 to 5, replace the hydraulic unit. Be sure to connect the brake hose lines and couplers correctly and securely.
• Page 496
  ABS (ANTI-LOCK BRAKE SYSTEM) Refer to “Malfunction code 42”. 6. Hydraulic unit Refer to “Malfunction code 42”. 7. Battery voltage Measure the battery voltage. Malfunction code 61 (front), 62 (rear) (Sensor power supply is low) 1. Battery voltage low Charge, check or replace the battery. 2.
• Page 497
  ABS (ANTI-LOCK BRAKE SYSTEM) EAS5D01005 [D-6-4] DELETING THE MALFUNCTION CODE 1. Connect the test coupler adapter “1” to the test coupler “2”. Refer to “[B-5] MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)” A. FZ1-SA B. FZ1-NA 2. Turn the main switch on. •…
• Page 498
  ABS (ANTI-LOCK BRAKE SYSTEM) e. Flashing a. ABS warning light f. 2 seconds b. ON g. 3 seconds c. Main switch on h. 0.5 seconds d. Main switch off 7. Turn the main switch off. 8. Disconnect the test coupler adapter from the test coupler, and install the protective cap with the test coupler adapter.
• Page 499
  ABS (ANTI-LOCK BRAKE SYSTEM) 6. Check: • ECU-to-start-switch-lead continuity Connect the pocket tester (Ω × 1) to the ECU coupler and start switch coupler. Tester positive probe → Blue/White “1” (start switch) Tester negative probe → Green/White “2” (ECU) No continuity → Replace or repair the wire harness. 7.

• Page 500: Electrical Components

  ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-131…

• Page 501
  ELECTRICAL COMPONENTS 1. Main switch (immobilizer unit) 2. Front brake light switch 3. Battery 4. Fuse box 5. Starter relay 6. Rear brake light switch 7. Neutral switch 8. Sidestand switch 9. Oil level switch 10.Ignition coil 11.Radiator fan motor 12.Horn 8-132…
• Page 502
  ELECTRICAL COMPONENTS 8-133…
• Page 503
  ELECTRICAL COMPONENTS 1. ABS ECU (FZ1-SA), (FZ1-NA) 2. ECU (engine control unit) 3. Intake air temperature sensor 4. Fuel pump 5. Headlight relay (on/off) 6. Radiator fan motor relay 7. Lean angle sensor 8. Starting circuit cut-off relay 9. Turn signal relay 10.Rear wheel sensor (FZ1-SA), (FZ1-NA) 11.Rectifier/regulator 12.ABS motor relay (FZ1-SA), (FZ1-NA)
• Page 504
  ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-135…
• Page 505
  7. Turn signal switch 8. Hazard switch 9. Clutch switch 10.Sidestand switch 11.Engine stop switch 12.Front brake light switch 13.Start switch 14.Oil level switch 15.Neutral switch 16.Rear brake light switch 17.Fuse box 18.Left handlebar switch lead (FZ1-N(X)/FZ1- 19.Left handlebar switch lead (FZ1-S(X)/FZ1- 8-136…
• Page 506
  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 507
  ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely Check each bulb and bulb socket for damage hot, keep flammable products and your or wear, proper connections, and also for conti- hands away from the bulb until it has nuity between the terminals.
• Page 508
  YU-03112-C Amperage Fuses Q’ty rating NOTE: Main 50 A Check each bulb socket for continuity in the Headlight (FZ1-N(X), same manner as described in the bulb section; 15 A FZ1-SA) however, note the following. Headlight (FZ1-S(X), 25 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ FZ1-SA) a.
• Page 509
  ELECTRICAL COMPONENTS EWA13310 ferent from those of conventional batter- WARNING ies. The MF battery should be charged as explained in the charging method illustra- Never use a fuse with an amperage rating other than that specified. Improvising or tions. If the battery is overcharged, the electrolyte level will drop considerably.
• Page 510
  ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- • As shown in the following illustration, the cuit voltage equals or exceeds 12.8 V. open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging b. Check the charge of the battery, as shown has been completed.
• Page 511
  ELECTRICAL COMPONENTS g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more — Charging is complete. 12.7 V or less — Recharging is required. Under 12.0 V — Replace the battery. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…
• Page 512
  2. Negative battery terminal Continuity/No continuity 3. Positive tester probe (between “3” to “4”) 4. Negative tester probe Relay unit (starting circuit cut-off relay) Result FZ1-N(X)/FZ1-S(X)/FZ1-NA Continuity/No continuity (between “3” to “4”) Headlight relay (on/off) (FZ1-N(X))/FZ1-NA FZ1-SA 1. Positive battery terminal 2.
• Page 513
  ELECTRICAL COMPONENTS Headlight relay (dimmer) ABS motor relay resistance FZ1-S(X)/FZ1-SA) 50–150 Ω Pocket tester 90890-03112 Analog Pocket tester YU-03112-C • Tester positive probe →Terminal “2” • Tester negative probe → Terminal “1” Tester reading is “∞”. → Replace the ABS motor relay.
• Page 514
  ELECTRICAL COMPONENTS EAS5D01009 CHECKING THE SOLENOID VALVES AND Pocket tester MOTOR 90890-03112 Analog Pocket tester ECA4S81023 CAUTION: YU-03112-C When check the hydraulic unit solenoid • Positive tester probe → relay and ABS motor, do not remove the terminal “3” brake hoses. •…
• Page 515
  ELECTRICAL COMPONENTS EAS5D01028 CHECKING THE TURN SIGNAL/HAZARD Pocket tester RELAY 90890-03112 1. Check: Analog Pocket tester • Turn signal/hazard relay input voltage YU-03112-C Out of specification → The wiring circuit • Positive tester probe → from the main switch to the turn signal/ hazard relay coupler is faulty and must be Brown/White “1”…
• Page 516
  ELECTRICAL COMPONENTS FZ1-N(X)/FZ1-S(X)/FZ1-NA Continuity Positive tester probe → Sky blue “1” Negative tester probe → Yel- low/Black “2” (FZ1-N(X)/FZ1- S(X)/FZ1-NA) Black/Yellow “2” (FZ1-SA) No continuity Positive tester probe → Yel- low/Black “2” (FZ1-N(X)/FZ1- FZ1-SA S(X)/FZ1-NA) Black/Yellow “2” (FZ1-SA) Negative tester probe → Sky blue “1”…
• Page 517
  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 518
  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” c. When turn the lean angle sensor to 65°. •…
• Page 519
  CHECKING THE STARTER MOTOR OPERA- Stator coil resistance 0.144–0.176 Ω at 20 °C (68 °F) TION 1. Check: (FZ1-S(X), FZ1-N(X), FZ1-SA) 0.153–0.187 Ω at 20 °C (68 °F) • Starter motor operation Does not operate → Perform the electric (FZ1-NA) starting system troubleshooting, starting ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…
• Page 520
  ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe a. Set the engine tachometer to the ignition Horn terminal “1” coil of cylinder #1. • Negative tester probe b. Connect the pocket tester (AC 20 V) to the Horn terminal “2” rectifier/regulator coupler as shown. Pocket tester 90890-03112 Analog pocket tester…
• Page 521
  ELECTRICAL COMPONENTS Fuel sender resistance Full position of the float 19–21Ω at 20 °C (68 °F) Empty position of the float 139–141 Ω at 20 °C (68 °F) b. Set the main switch to “ON”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 10) to the c.
• Page 522
  ELECTRICAL COMPONENTS 2. Check: d. Slowly heat the coolant, and then let it cool • Coolant temperature sensor resistance to the specified temperature indicated in Out of specification → Replace. the table. e. Check the coolant temperature sensor for Coolant temperature sensor continuity at the temperatures indicated in…
• Page 523
  ELECTRICAL COMPONENTS d. While slowly opening the throttle, check • Tester positive lead → that the throttle position sensor resistance Blue “1” is within the specified range. • Tester negative lead → The resistance does not change or it Black/Blue “2” changes abruptly →…
• Page 524
  ELECTRICAL COMPONENTS c. Measure the Air induction system solenoid ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ resistance. 3. Install: • Sub-throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE: EAS28380 When installing the throttle position sensor, CHECKING THE ATMOSPHERIC PRES- adjust its angle properly. Refer to “CHECKING SURE SENSOR THE SUB-THROTTLE POSITION SENSOR” 1.
• Page 525
  ELECTRICAL COMPONENTS EAS28390 CHECKING THE CYLINDER IDENTIFICA- Intake air pressure sensor out- TION SENSOR put voltage 1. Check: 3.75–4.25 V • Cylinder identification sensor output volt- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the Out of specification → Replace. intake air pressure sensor coupler (wire Cylinder identification…
• Page 526
  ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Brown/White “1” • Negative tester probe Black/Blue “2” b. Measure the intake air temperature sensor resistance.

• Page 527: Troubleshooting

  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 OVER COOLING ………………9-3 POOR BRAKING PERFORMANCE …………9-3 FAULTY FRONT FORK LEGS …………..9-3 UNSTABLE HANDLING…………….9-3…

• Page 528
  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 529
  TROUBLESHOOTING • Improper throttle cable free play EAS28550 JUMPS OUT OF GEAR • Flooded throttle body • Faulty air induction system Shift shaft • Incorrect shift pedal position Electrical system • Improperly returned stopper lever 1. Battery • Discharged battery Shift forks •…
• Page 530
  TROUBLESHOOTING • 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 • Incorrect brake fluid level 1. Coolant • Low coolant level EAS28660 FAULTY FRONT FORK LEGS 2.
• Page 531
  TROUBLESHOOTING 7. Wheel(s) Turn signal blinks slowly • Incorrect wheel balance • Faulty turn signal relay • Deformed cast wheel • Faulty main switch • Damaged wheel bearing • Faulty turn signal switch • Bent or loose wheel axle • Incorrect turn signal bulb •…
• Page 532
  TROUBLESHOOTING • Defective starter motor monitor • Other defective ABS warning light flashes every 0.5 sec- onds • Voltage drop (Less than 10 V) • Battery • Rectifier/regulator • AC magneto • Strong radio waves or static electricity • Test coupler adapter is connected to test coupler ABS Warning light continues to come on •…
• Page 533
  TROUBLESHOOTING…

• Page 534: Wiring List

  55. Front brake light switch Br/W Brown/White WIRING DIAGRAM 56. Engine stop switch Br/Y Brown/Yellow 57. Start switch FZ1-N(X) 2008 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 535
  FZ1-S(X) 2008 59. Left handlebar switch Green/White 60. Clutch switch 1. Main switch Green/Yellow 61. Pass switch 2. Rectifier/regulator Gy/G Gray/Green 62. Dimmer switch 3. AC magneto Gy/R Gray/Red 63. Hazard switch 4. Backup fuse Blue/Black 64. Turn signal switch 5.
• Page 536
  FZ1-SA 2008 59. Rear brake light switch Black/White 60. Left handlebar switch 1. Main switch Black/Yellow 61. Clutch switch 2. Rectifier/regulator Br/G Brown/Green 62. Pass switch 3. AC magneto Br/L Brown/Blue 63. Dimmer switch 4. Backup fuse Br/R Brown/Red 64. Hazard switch 5.
• Page 537
  FZ1-NA 2008 59. Rear brake light switch Black/White 60. Left handlebar switch 1. Main switch Black/Yellow 61. Clutch switch 2. Rectifier/regulator Br/G Brown/Green 62. Pass switch 3. AC magneto Br/L Brown/Blue 63. Dimmer switch 4. Backup fuse Br/R Brown/Red 64. Hazard switch 5.
• Page 538
  YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…

• Page 539: Wiring Diagrams

  FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N(X) 2008…

• Page 540
  FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-S(X) 2008…
• Page 541
  FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-SA 2008…
• Page 542
  FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-NA 2008 G/B R/B R/L Gy/R Gy/R O R/B O/G L/R Dg B/G L O/B L/B Y/R Gy/G Br/R W/B Br/R L Gy/G B Ch B/Y Br/W G/Y Br/W Y Y/W…
• Page 543
  FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 FZ1-N(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-N(X) 2008…
• Page 544
  FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 FZ1-S(X) 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-S(X) 2008…
• Page 545
  FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 FZ1-SA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-SA 2008…
• Page 546
  FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 FZ1-NA 2008 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DE FZ1-NA 2008…

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