Yamaha Fz6n Manual
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SWINGARM AND DRIVE CHAIN4-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 4-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 5 ENGINE ENGINE5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET. 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST PIPE 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVER 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 5-14. . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD5-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEAD 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEAD 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD 5-21. . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS5-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 5-25. . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER CLUTCH AND GENERATOR5-32 . . . . . . . . . . . . . . . . . . . . . . . . . STATOR COIL ASSEMBLY 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE GENERATOR 5-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE STARTER CLUTCH 5-35. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 5-36. . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STARTER CLUTCH 5-36. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE GENERATOR 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT5-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT AND STOPPER LEVER 5-39. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 5-41. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR5-42 . . . . . . . REMOVING THE PICKUP ROTOR 5-44. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PICKUP ROTOR 5-44. . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH5-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 5-49. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS 5-50. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 5-51. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 5-51. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-52. . . . . . . INSTALLING THE CLUTCH 5-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN AND OIL PUMP5-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 5-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-59. . . . . . . . . CHECKING THE OIL STRAINER 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL NOZZLES 5-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE5-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 5-64. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS 5-65. . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS AND PISTONS5-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS 5-68. . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 5-69. . . . . . . . . . . . . . . . . CHECKING THE CYLINDER AND PISTON 5-69. . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 5-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BIG END BEARINGS 5-72. . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON (except for CAL) 5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON (for CAL) 5-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT5-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-84. . . . . . . . INSTALLING THE CRANKSHAFT 5-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION5-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION 5-94. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 5-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 5-95. . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 5-95. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 6 COOLING SYSTEM RADIATOR6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP 6-13. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE WATER PUMP 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU’S SELF-DIAGNOSTIC FUNCTION 7-3. . . . . . . . . . . . . . . . . . . . . . ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAIL-SAFE ACTIONS TABLE 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING CHART 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC MODE 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING DETAILS 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . THROTTLE BODIES7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INJECTORS 7-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE INJECTORS 7-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THROTTLE BODIES 7-28. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 7-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM7-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUT-OFF VALVE 7-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 7-33. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 7-34. . . . . . . . . . . . . . . . . . CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCH CONTINUITY8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWITCHES8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BULBS AND BULB SOCKETS8-5 . . . . . . . . . . . . . . . . . TYPES OF BULBS 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS 8-5. . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 8-6. . . . . . . CHECKING THE LED’s 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM8-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM8-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15. . . . . . . . . TROUBLESHOOTING 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR8-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR 8-21. . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . . CHARGING SYSTEM8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTING SYSTEM8-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM 8-31. . . . . . . . . . . . . . . . . . . . . . . . SIGNALING SYSTEM8-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 8-36. . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM8-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP SYSTEM8-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP SYSTEM 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 8-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELF-DIAGNOSIS8-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 9 TROUBLESHOOTING STARTING FAILURES9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCORRECT ENGINE IDLING SPEED9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE9-2 . . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULTY GEAR SHIFTING9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULTY CLUTCH9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHEATING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERCOOLING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POOR BRAKING PERFORMANCE9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULTY FRONT FORK LEGS9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNSTABLE HANDLING9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULTY LIGHTING OR SIGNALING SYSTEM9-6 . . . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL / BRAKE LIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . TAIL / BRAKE LIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS SLOWLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1 MOTORCYCLE IDENTIFICATION GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
1-2 FEATURES GEN INFO 7Intake air pressure sensor 8Throttle position sen- sor 9Fuel injector 10Catalytic converter 11Crankshaft position sensor 12Coolant temperature sensor 13Spark plug 14Pressure regulator 15Battery 16ECU 17Fuel injection system relay 18Engine trouble warn- ing light 19Lean angle cut-off switch 1Ignition coil 2Air filter case 3Intake air temperature sensor 4Fuel delivery hose 5Fuel tank 6Fuel pump EAS00896 FEATURES OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that me- ter the fuel through the use of jets have been provided with various auxiliary devices, so that an opti- mum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom- modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio re- quired by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI sys- tem) has been placed under computer control together with the FI system in order to realize cleaner exhaust gases.
1-3 FEATURES GEN INFO Illustration is for reference only. 6Throttle position sen- sor 7Intake air pressure sensor 8ECU 9Coolant temperature sensor 10Crankshaft position sensor A Fuel system B Control system1Fuel pump 2Pressure regulator 3Fuel injector 4Throttle body 5Intake air temperature sensor EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kPa (2.5 kg / cm 2). Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the injector is energized (injection duration), the greater the volume of fuel that is supplied. Con- versely, the shorter the length of time the injector is energized (injection duration), the lesser the vol- ume of fuel that is supplied. The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake temperature sensor and coolant temperature sensor enable the ECU to determine the injection duration. The injec- tion timing is determined through the signals from the crankshaft position sensor. As a result, the vol- ume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
1-4 FEATURES GEN INFO 1 Multi-function display 2 “SELECT” button 3 “RESET” button 4 Engine trouble warning light NOTE:INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: a speedometer (which shows the riding speed) an odometer (which shows the total distance traveled) two tripmeters (which show the distance traveled since they were last set to zero) a fuel reserve tripmeter (which shows the distance traveled since the bottom segment of the fuel meter started flashing) a tachometer (which shows the engine speed) a fuel meter a water temperature a clock a intake air temperature a self-diagnosis device Be sure to turn the key to “ON” before using the “SELECT” and ”RESET” buttons. For the U.K. only: To switch the speedometer and odometer / tripmeter display between kilometers and miles, press the “SELECT” button for at least two seconds. Odometer, tripmeter and tachometer modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip- meter modes “TRIP 1” and “TRIP 2” and the tachometer mode “E” is the following order: ODO TRIP 1 TRIP 2 (TRIP F) E ODO When approximately 3.6 L of fuel remain in the fuel tank, the bottom segment of the fuel meter will start flashing, and the odometer display will automatically change to the fuel reserve tripmeter mode “TRIP F” and start counting the distance traveled from that point. In that case, pushing the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: TRIP-F E ODO TRIP 1 TRIP 2 TRIP F To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3.1 mi). Tachometer mode Displays the digital indication of the engine speed on the odometer section. Air intake temperature indicator. When “ODO” is displayed, pressing the “RESET” for a long time allows the indicator to switch displays between Clock and Air intake temperature. (It activates the clock indication when the main switch is turned OFF.) In the Co adjustment mode, the indication automatically changes from clock (Air intake temperature) to the engine speed.