Yamaha FZ8-NA User manual

SERVICE MANUAL
FZ8NA
FZ8SA
2011
1BD-28197-E0

EAS20040
FZ8NA
FZ8SA
SERVICE MANUAL
©2010 by Yamaha Motor Co., Ltd.
First edition, May 2010
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING

EAS20091
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described
sequentially.

EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine
mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOC-
TITE®).
Engine oil Replace the part with a new
one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

1
2
3
4
5
6
7
8
9
EAS20110 TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING

1
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.............................................................................................1-4
INSTRUMENT FUNCTIONS ..................................................................1-5
OUTLINE OF THE ABS..........................................................................1-8
ABS COMPONENT FUNCTIONS ........................................................1-14
ABS OPERATION.................................................................................1-19
ABS SELF-DIAGNOSIS FUNCTION ....................................................1-22
ABS WARNING LIGHT AND OPERATION...........................................1-25
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
BASIC SERVICE INFORMATION...............................................................1-28
QUICK FASTENERS ............................................................................1-28
ELECTRICAL SYSTEM........................................................................1-28
SPECIAL TOOLS........................................................................................1-33

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

FEATURES
1-2
EAS20170
FEATURES
EAS39P1101
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-
ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-
ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.

FEATURES
1-3
1. Engine trouble warning light
2. Intake air temperature sensor
3. ECU (engine control unit)
4. Intake air pressure sensor
5. Throttle position sensor
6. Sub-throttle position sensor
7. Air filter case
8. Fuel tank
9. Fuel pump
10.Battery
11.Atmospheric pressure sensor
12.Relay unit (fuel pump relay)
13.Lean angle sensor
14.Catalytic converter
15.O2sensor
16.Fuel hose
17.Fuel injector
18.Crankshaft position sensor
19.Coolant temperature sensor
20.Spark plug
21.Ignition coil
22.Cylinder identification sensor
23.Air cut-off valve
A. FZ8NA
B. FZ8SA

FEATURES
1-4
EAS39P1102
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus-
ing the fuel to be injected into the intake manifold only during the time the passage remain open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is ener-
gized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, sub-throttle position sensor, crankshaft position sensor, intake air pres-
sure sensor, atmospheric pressure sensor, intake air temperature sensor, coolant temperature sen-
sor, speed sensor and O2sensor enable the ECU to determine the injection duration. The injection
timing is determined through the signals from the crankshaft position sensor. As a result, the volume
of fuel that is required by the engine can be supplied at all times in accordance with the driving con-
ditions.
Illustration is for reference only.
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Intake air temperature sensor
6. Speed sensor
7. Throttle position sensor
8. Atmospheric pressure sensor
9. O2sensor
10.Catalytic converter
11.Coolant temperature sensor
12.Crankshaft position sensor
13.Intake air pressure sensor
14.Throttle body
15.Sub-throttle position sensor
16.Air filter case
A. Fuel system
B. Air system
C. Control system

FEATURES
1-5
EAS39P1103
INSTRUMENT FUNCTIONS
Multi-function meter unit
WARNING
EWA12422
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The multi-function meter unit is equipped with
the following:
• A speedometer
• A tachometer
• An odometer
• 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 left segment of
the fuel meter started flashing)
•Aclock
• A fuel meter
• A coolant temperature display
• A self-diagnosis device
TIP
• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.
• For the U.K. only: To switch the speedometer
and odometer/tripmeter displays between
kilometers and miles, press the “SELECT”
button for at least one second.
Tachometer
The electric tachometer allows the rider to
monitor the engine speed and keep it within
the ideal power range.
When the key is turned to “ON”, the tachome-
ter needle will sweep once across the r/min
range and then return to zero r/min in order to
test the electrical circuit.
ECA10031
Do not operate the engine in the tachome-
ter red zone.
Red zone: 11500 r/min and above
Clock
The clock displays when the key is turned to
“ON”. In addition, the clock can be displayed
for 10 seconds by pushing the “SELECT” but-
ton when the main switch is in the “OFF”,
“LOCK” or “ ” position.
To set the clock
1. Turn the key to “ON”.
2. Push the “SELECT” button and “RESET”
button together for at least two seconds.
3. When the hour digits start flashing, push
the “RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
1. Fuel meter
2. Coolant temperature display
3. Speedometer
4. Tachometer
5. Odometer/tripmeter/fuel reserve tripmeter
6. “SELECT” button
7. “RESET” button
8. Clock
1. Tachometer
2. Tachometer red zone
1. Clock

FEATURES
1-6
5. Push the “RESET” button to set the min-
utes.
6. Push the “SELECT” button and then
release it to start the clock.
Odometer and tripmeter modes
Push the “SELECT” button to switch the dis-
play between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
the following order:
TRIP A →TRIP B →ODO →TRIP A
When the fuel amount in the fuel tank
decreases to 3.4 L (0.90 US gal, 0.75 Imp.gal),
the left segment of the fuel meter will start
flashing, and the odometer display will auto-
matically change to the fuel reserve tripmeter
mode “F-TRIP” and start counting the distance
traveled from that point. In that case, push the
“SELECT” button to switch the display between
the various tripmeter and odometer modes in
the following order:
F-TRIP →TRIP A →TRIP B →ODO →F-
TRIP
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 mi).
Fuel meter
The fuel meter indicates the amount of fuel in
the fuel tank. The display segments of the fuel
meter disappear towards “E” (Empty) as the
fuel level decreases. When the last segment
on the left starts flashing, refuel as soon as
possible.
TIP
This fuel meter is equipped with a self-diagno-
sis system. If a problem is detected in the elec-
trical circuit, the following cycle is repeated
until the malfunction is corrected: fuel level
segments and symbol “ ” flash eight times,
then go off for approximately 3 seconds. If this
occurs, have a Yamaha dealer check the elec-
trical circuit.
Coolant temperature display
The coolant temperature display indicates the
temperature of the coolant.
ECA10021
Do not continue to operate the engine if it is
overheating.
1. Odometer/tripmeter/fuel reserve tripmeter
1. Fuel meter
1. Coolant temperature display

FEATURES
1-7
Self-diagnosis device
This model is equipped with a self-diagnosis
device for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light will come on
and the display will indicate an error code.
The self-diagnosis device also detects prob-
lems in the immobilizer system circuits.
If a problem is detected in the immobilizer sys-
tem circuits, the immobilizer system indicator
light will flash and the display will indicate an
error code.
TIP
If the display indicates error code 52, this could
be caused by transponder interference. If this
error code appears, try the following.
1. Use the code re-registering key to start the
engine.
TIP
Make sure there are no other immobilizer keys
close to the main switch, and do not keep more
than one immobilizer key on the same key ring!
Immobilizer system keys may cause signal
interference, which may prevent the engine
from starting.
2. If the engine starts, turn it off and try start-
ing the engine with the standard keys.
3. If one or both of the standard keys do not
start the engine, take the vehicle, the code
re-registering key and both standard keys
to a Yamaha dealer and have the standard
keys re-registered.
If the display indicates any error codes, note
the code number, and then have a Yamaha
dealer check the vehicle.
ECA11590
If the display indicates an error code, the
vehicle should be checked as soon as pos-
sible in order to avoid engine damage.
1. Error code display

FEATURES
1-8
EAS4B56001
OUTLINE OF THE ABS
1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on
the front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability
of the vehicle.
3. The hydraulic unit assembly, which is the main component of the ABS, is centrally located on the
vehicle to increase mass centralization.
ABS layout
1. Hydraulic unit assembly (ABS ECU)
2. ABS warning light
3. Rear wheel sensor rotor
4. Rear wheel sensor
5. Front wheel sensor
6. Front wheel sensor rotor
7. ABS test coupler
8. Fuse box 1

FEATURES
1-9
ABS
The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with
a front brake lever for operating the front brake and a rear brake pedal for operating the rear brake.
When wheel lock is detected during emergency braking, hydraulic control is performed by the
hydraulic system on the front and rear brakes independently.
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.
• Brake force:
The force applied by braking to reduce the wheel speed.
• Wheel lock:
A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle
continues to travel.
• Side force:
The force on the tires which supports the vehicle when cornering.
• Slip ratio:
When the brakes are applied, slipping occurs between the tires and the road surface. This causes
a difference between the wheel speed and the chassis speed.
Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
0%: There is no slipping between the wheel and the road surface. The chassis speed is equal to
the wheel speed.
100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock).
Slip ratio =
Chassis speed –
Wheel speed ×100 (%)
Chassis speed

FEATURES
1-10
Brake force and vehicle stability
When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire
and the road surface and brake force is generated. The limit of this brake force is determined by the
friction force between the tire and the road surface and is closely related to wheel slippage. Wheel
slippage is represented by the slip ratio.
Side force is also closely related to wheel slippage. See figure “A”. If the brakes are applied while
keeping the proper slip ratio, it is possible to obtain the maximum brake force without losing much
side force.
ABS allows full use of the tires’ capabilities even on slippery road surfaces or less slippery road sur-
faces. See figure “B”.
a. Friction force between the tire and road sur-
face
b. Brake force
c. Side force
d. Slip ratio (%)
e. Less slippery road surface
f. Controlling zone
g. Slippery road surface

FEATURES
1-11
Wheel slip and hydraulic control
The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received
from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis
speed and the rate of speed reduction based on the wheel speed values.
The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is
equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to
lock. When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS
ECU determines that the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point A in the following figure), the ABS
ECU reduces the brake fluid pressure in the brake caliper. Once the ABS ECU determines that the
tendency of the wheel to lock has diminished after the brake fluid pressure is reduced, it increases
the hydraulic pressure (point B in the following figure). The hydraulic pressure is initially increased
quickly, and then it is increased gradually.
a. Chassis speed
b. Wheel speed
c. Brake force
d. Depressurizing phase
e. Pressurizing phase