SUPPLEMENTARY

SERVICE MANUAL
 FAZER
SUPPLEMENTARY SERVICE MANUAL
YAMAHA MOTOR INDIA PVT. LIMITED
All rights reserved.
Any reprinting or unauthorised use without
the written permission of
YAMAHA MOTOR INDIA PVT. LIMITED
is expressly prohibited.
 FOREWORD

This Supplementary Service Manual has been prepared for use by the
Yamaha Motor India Private Ltd. Authorised Dealerships and their service
personnel to attend to servicing of Fazer Motorcycles. It is not possible to include
entire service education into this Manual. It is assumed that persons using this
book to perform maintenance and repairs on Fazer Deluxe/Flame Motorcycles
have a basic understanding of mechanical concepts and procedures inherent to
Motorcycle repair technology.

For complete Service information procedures of Fazer Deluxe/Flame it

is necessary to use this supplementary Service Manual together with following
manual.
FAZER 5YY2 - Service Manual

Service Department
Yamaha Motor India Private Ltd.
 HOW TO USE THIS MANUAL

MANUAL ORGANISATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1 : This is the Title of the Chapter with its symbol on the upper right corner of each page.
2nd title 2 : This title indicates the Section of the chapter and only appears on the first
page of each section. It is located in the centre of the page.
3rd title 3 : This title indicates a Subsection that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are Exploded Diagrams at start of
each Removal and Disassembly section.
1. An easy-to-see Exploded Diagram 4 is provided for Disassembly and Assembly jobs.
2. Numbers 5 are given in the order of jobs in the exploded diagram. A number that is en-
closed by a circle indicates a part.
3. An explanation of jobs and notes are presented in an easy-to-read way by the use of Symbol
Marks 6 . The meaning of the Symbol Marks are given on the next page.
4. For jobs requiring more information, the step-by-step format supplements 7 are given in
addition to the exploded diagram. 1
2
CHAS
4 FRONT BRAKE / CALIPER ASSEMBLY
CALIPER DIASSEMBLY
Á 1. Remove:
3
• Bolt ¿
• Copper Washers À
NOTE:
¿ Place the container under the caliper to catch
À the standing brake fluid.
2. Disconnet:
• Brake hose Á
3. Remove:
• Clip pin Â
• Retaining pin Ã
Ä • Brake pads Ä
• Pad spring
4. Remove
5 • Bolts Å
• Brake Caliper Body.
5. Remove:
• Piston Æ
Ã
• Piston seal Ç
Â
7
3. Remove
• C.D.I. Magneto ¿
¿ • Wood-ruff key
6
CAUTION:
WARNING
• Cover the crankshaft end with the spacer.

Magneto Puller :
YSST - 628
 ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as thumb tabs to indicate the chapter’s number
and content.

1. General GEN 2. Specifications SPEC

Information INFO

3. Periodic inspection
INSP 4. Engine ENG
and adjustment
ADJ

5. Carburetion CARB 6. Chassis CHAS

8. Troubleshooting
TRBL
7. Electrical ELEC SHTG
Illustrated symbols 9 to 15 are used to identify the specifications appearing in the text.

9. Filling fluid 10.Lubricant 11.Special Tool

12.Torque 13.Wear Limit, 14.Engine speed

Clearance

15.Resistance,
Voltage, Current

Illustrated symbols 16 to 21 in the exploded diagrams indicate the types of lubricants and
lubrication points.

16. Apply engine oil 17. Apply gear oil 18. Apply molybdenum
disulfide oil

19. Apply wheel 20.Apply lightweight 21. Apply molyb-

bearing grease lithium-soap base denum disulfide
grease grease

Illustrated symbols 22 and 23 in the exploded diagrams indicate where to apply locking
agent and when to install new parts

22. Apply locking

23. Use New One
agent (LOCKTITE*)
 INDEX GEN
INFO

GENERAL INFORMATION GEN

INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
INSP
ADJUSTMENTS ADJ 3
ENGINE ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
ELECTRICAL ELEC
7
TROUBLE SHOOTING TRBL
SHTG 8
 CHAPTER 1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER ..........................................................1-1
ENGINE SERIAL NUMBER .........................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY ........................................1-2
ALL REPLACEMENT PARTS .....................................................1-3
GASKETS, OIL SEALS, AND O-RINGS ......................................1-3
LOCK WASHERS/PLATES AND COTTER PINS .......................1-3
BEARINGS AND OIL SEALS ......................................................1-3
CIRCLIPS ....................................................................................1-3
SPECIAL TOOLS
SPECIAL SERVICE TOOLS .......................................................1-4
 GEN
MOTORCYCLE IDENTIFICATION INFO
MOTORCYCLE IDENTIFICATION

FRAME SERIAL NUMBER

The Frame Serial Number ¿ is stamped into the
right side of the Steering Head Pipe.

ENGINE SERIAL NUMBER

The Engine Serial Number À is stamped on the
top portion of RH Crankcase. ( Engine Serial
Number does not contain Year and Month of
production)

XX X 5YY 2XXXXX

YEAR OF MONTH MODEL UNIT PRODUCTION

PRODUCTION CODE CODE NUMBER

Year of Production : 2 Digits standing for last two digits of year

Month Code
Starting Serial Number
Eg. 0 0 - 2000, 0 1 - 2001 ......
: One alphabet standing for Month
Eg. A - January, B - February........
M - December ( I - Not Used for Month)
: 5YY 200001

WARNING
Do not tamper with any of these numbers. It
may lead to legal action.

NOTE :
Designs and sepecifications are subject to
change without notice.

1-1
 GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
PREPARATION FOR DISASSEMBLY
1. Remove all dirt, mud, dust and foreign ma-
terial before disassembly.

2. Use proper Tools and Cleaning Equipment.

Refer to “YAMAHA SPECIAL SERVICE
TOOLS”.

3. When disassembling the Motorcycle, keep

mated parts together. This includes gears,
Cylinder, Piston and other mated parts that
have been “mated” through normal wear.
Mated parts must be reused as an assem-
bly or replaced.

4. During the Motorcycle disassembly, clean

all parts and place them in trays in the or-
der of disassembly. This will speed up as-
sembly time and help assure that all parts
are correctly reinstalled.

5. Keep Motorcycle and its parts away from

any source of fire.

1-2
 GEN
IMPORTANT INFORMATION INFO
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use Yamalube Oil and
Grease recommended by Yamaha for
assembly and adjustment. Other brands
may be similar in function and appearance,
but inferior in quality.
GASKETS, OIL SEALS, AND O-RINGS
1. All Gaskets, Seals and O-rings should be
replaced when the Engine is overhauled.
2. All surfaces where Gasket, Oil Seal lips and
O-rings contact must be cleaned and
Lubricated.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All Lock Washers/plates ¿ and Cotter Pins
must be replaced when they are removed.
Lock tab (s) should be bent along the Bolt

BEARINGS AND OIL SEALS

1. Install the bearing (s) ¿ and Oil Seal (s)
À with their manufacturer’s marks or
numbers facing outward. (In other words,
the stamped letters must be on the side
exposed to view.) When installing Oil Seal
(s), lubricate a light coating of lightweight
lithium base grease to the seal lip(s). Oil the
Bearings liberally when installing.

CAUTION:
WARNING
Do not use compressed air to spin the
Bearings dry. This causes damage to the
Bearing surfaces.

CIRCLIPS
1. All Circlips should be inspected carefully
before reassembly. Always replace Piston
Pin Clips after one use. Replace distorted
Circlips. When installing a circlip ¿, make
sure that the sharp-edged corner À is
positioned opposite to the thrust Á it
receives. See the sectional view of shaft Â.
WARNING
If the Circlip is fitted the wrong way it would
cause it to jump off its groove and damage
related components.

1-3
 GEN
YAMAHA SPECIAL SERVICE TOOLS INFO
YAMAHA SPECIAL SERVICE TOOLS

The appropriate Yamaha Special Service Tools are necessary for proper maintenance of the Motorcycle.
Using the correct Yamaha Special Service Tool will help to prevent damage caused by the use of
improper tools or improvised techniques. The following is the detailed list of all Yamaha Special Service
Tools with their application for only 5YY2 model.
Refer to the list provided to avoid errors when placing an order for Yamaha Special service tools.

1. Magneto Holder 2. Magneto Puller with Spacer

YSST -601-B YSST-628

This tool is used to hold the Magneto when

removing or installing the Magneto Securing
Nut and Primary Drive Gear Nut This tool is used to remove the Magneto

1-4
 SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................... 2-1

GENERAL TORQUE SPECIFICATIONS
• ENGINE .................................................................................. 2-4
• CHASSIS ................................................................................2-4
MAINTENANCE SPECIFICATIONS

ELECTRICAL ............................................................................2-5

CABLE ROUTING ............................................................................2-7

 SPEC
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS

DESCRIPTION SPECIFICATION
Model : FAZER - Deluxe / Flame
Model Code : 5YY2
Engine model code: 5YY2
DIMENSIONS:
Overall length 2065 mm
Overall width 730 mm
Overall height 1060 mm
Seat height (Upto Rider) 800 mm
Seat height (Upto Pillion Rider) 870 mm
Wheelbase 1300 mm
Minimum ground clearance 160 mm
Minimum turning radius 2065 mm
Dry weight : 115 kg
Basic weight : 125 kg
(With Oil and full Fuel Tank)
ENGINE :
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined, single cylinder
Displacement 123.7 cm³
Bore X Stroke 54 X 54 mm
Compression ratio 10:1
Starting system Kick starter / Electrical Starter
Lubrication system Wet sump
Max power 11 BHP (8.0 KW) @ 8500 RPM
Torque 1.06 Kgm, 10.4 NM @ 6500 rpm
Oil type or grade :
Engine oil Yamalube 4-stroke Oil
(20W40 Type SG)
Oil capacity :
Engine oil
Periodic oil replacement 1.0 L
Total amount 1.2 L
Air filter : Washable, Dual Foam, Wet type
(Oil soaked)
FUEL :
Fuel Tank capacity 13 Ltrs.
Fuel reserve amount 1.2 Ltrs.
Carburetor :
Type BS-25

Spark plug :
Type/manufacturer R-CR7HSA / NGK
Spark Plug gap 0.6 ~ 0.7 mm

2-1
 SPEC
GENERAL SPECIFICATIONS

DESCRIPTION SPECIFICATION
Clutch type : Wet, Multiple disc
Transmission :
Primary reduction system Helical gear
Primary reduction ratio 68/19 (3.579 : 1)
Secondary reduction system Chain drive
Secondary reduction ratio 45/14 (3.214 : 1)
Transmission type Constant mesh 4-speed
Operation Left foot operation
Gear ratio 1st 33/12 (2.750)
2nd 27/16 (1.688)
3rd 24/20 (1.200)
4th 21/23 (0.913)
Primary Drive Grading Matching of Grades
DRIVEN GEAR ASSY. Gear Primary Primary Driven
GRADE
Drive Gear Assy.
•
B
• •A
GRADE C
• •B
D
• •C
E
• •D
GEAR PRIMARY DRIVE
F •E
Chassis :
Frame type Diamond
Caster angle 26.4º
Trail 83 mm

Tyre :
Type With tube
Size Front 2.75 - 18, 4 PR
Rear 3.00 - 18, 6 PR
Manufacturer Front LOCAL MADE
Rear LOCAL MADE
Type Front RIB TYPE / ZAPPER TYPE
Rear UNIVERSAL / ZAPPER TYPE

Tyre pressure (cold tyre) :

Front 25 PSI (1.75 kgf/cm²)

Rear 32 PSI (2.30 kgf/cm²)

2-2
 SPEC
GENERAL SPECIFICATIONS

DESCRIPTION SPECIFICATION
Brake :
Front brake Type Disc Brake
Operation Right hand lever operation
Oil Dot-3
Rear brake Type Drum brake (Dia 130 mm)
Operation Right foot operation
Suspension :
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorbser :
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel :
Front wheel travel 120 mm
Rear wheel travel 90 mm
Electrical :
Ignition system CDI (Digital)
Generator system Flywheel magneto
Battery type LOCAL MADE - LEAD ACID
Battery capacity 12V - 5 AH
Headlight type : Bulb type
Headlight bulb type S-1 Type Bulb
Bulb (voltage - wattage x quantity) :
Headlight 12V - 25W/25W x 2
Tail/Brake light 12V - 5W/21W x 1
Flasher light 12V - 10W x 4
Meter light 12V - 3.4W x 2
“NEUTRAL” indicator light 12V - 3.4W x 1
“HIGH BEAM” indicator light 12V - 3.4W x 1
“TURN” indicator light 12V - 1.7W x 2

HORN 12V - 1.5 Amp

FUSE 10 Amp.

2-3
 SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUE (ENGINE)

PARTS TO BE TIGHTENED PART THREAD QTY TIGHTENING TORQUE

NAME SIZE Nm m.kg ft.lb
Plate Idle Gear Screw M6 2 7 0.7 5
Starter Motor Assembly Bolt M6 2 10 1.0 7.2
Starter One Way Assembly Bolt Hex M8 3 30 3.0 21
Switch Handle- 2 Screw M6 2 4 0.4 3.0
Crank Case Cover-1 Bolt M6 7 10 1.0 7.2
Rotor Nut M 12 1 70 7.0 51

TIGHTENING TORQUE (CHASSIS)

PARTS TO BE TIGHTENED PART THREAD QTY TIGHTENING TORQUE

NAME SIZE Nm m.kg ft.lb
Bleed Screw Bolt M6 1 6 0.6 4.3
Front Wheel Axle Nut M14 1 80 8.0 58
Nipple - - 36 3 0.3 2.0
Brake Disc Allen M6 6 13 1.3 9.3
Union Bolt Bolt M8 2 25 2.5 18
Caliper Bracket Bolt M 10 2 28 2.8 20

2-4
 SPEC
MAINTENANCE SPECIFICATIONS
ELECTRICAL
DESCRIPTION SPECIFICATION
Voltage : 12V
Ignition system :
Ignition timing (B.T. D. C) 7º ± 2º BTDC at 1400 rpm.
Advancer Type Electrical type
CDI : Digitally Controlled
Magneto model/manufacturer 5YY/DENSO
Sensor Coil (Color) 240 Ω ± 20%
CDI Unit Model/manufacturer 5KA/ Denso
IgnitionCoil :
Model/Manufacturer 5YY/Wings Automobiles Pvt. Ltd.
Primary Coil Resistance 0.22 Ω ± 15%
Secondary Coil Resistance 3.0 KΩ ± 20%
Spark Plug Cap :
Type Resistance Type
Resistance 5 kΩ at 20 ºC (68ºF)
Charging System :
Type Flywheel Magneto
Flywheel Magneto :
Model/Manufacturer 5YY/DENSO
Charging Voltage 14 ~ 15V @ 5000 RPM
Charging Coil Resistance 0.75 Ω ± 20% (68ºF)
Lighting :
Lighting Voltage 14 V ± 0.5 @ 5000 RPM

Lighting Coil Resistance 0.62Ω ± 20 % (68ºF)

Rectifier/Regulator :
Type Semi conductor-Short Circuit Type
Model/Manufacturer 5YY / Nappino Auto
No load regulated voltage 14.5 ± 0.5 V at 5000 rpm
Capacity 8A
Withstand voltage 400 V
Battery :
Specific Gravity 1.280
Horn:
Type Plane type
Quantity 1 pc.
Model/Manufacturer 5YY/Local Made
Maximum Amperage 1.5 A
Flasher relay:
Type Semi transistor type
Model/Manufacturer Local Made
Self cancelling device No
Flasher frequency 85 ± 15 cycles/min
Wattage 10W X 2

2-5
 SPEC
MAINTENANCE SPECIFICATIONS

Circuit Breaker :
Type Fuse
Amperage for individual circuit X quantity :
Main 10A X 1pc.
Reserve 10A X 1pc.

2-6
 SPEC
CABLE ROUTING
CABLE ROUTING É Flasher light lead (left) B Pass the Throttle Cable Å,
¿ Handlebar switch (left) Ê Flasher Light and the Brake Hose Ä and
À Clutch cable Ë Flasher Light lead (right) the Front Brake switch lead
Á Starter Wire Ì Master Cylinder Æ through the Cable Guide of
 Speedometer Í Kill Switch the right side.
à Tachometer A Pass the Clutch Cable À, C Clamp Wireharness È and
Ä Brake Hose Starter wire Á and front fork.
Å Throttle cable Handle-bar Switch Lead D Pass the Wireharness È and
Æ Brake switch lead through the cable guide of Clutch Cable À.
Ç Speedometer cable the left side.
È Wireharness

 Ã
A
B
À Å
Ä
¿ Ì

Í
Á Æ

Ã
Â
Ì

Å Ê

Ê É

Á
Ë À
C

È
À D

2-7
 SPEC
CABLE ROUTING
¿ Headlight assembly Î Starter Relay D Connect the battery
À Handlebar switch lead Ï H.T. Coil negative (-) lead and
Á Speedometer cable Ð Air Induction system positive (+) lead with the
 Cable guide Ñ Relay Assembly wireharness.
à Clutch cable Ò Battery (+ve) lead E Pass the battery breather
Ä Horn Ó Battery (-ve) lead hose Ì through the hole
Å Fuse A Pass the wireharness through of the lower left side of
Æ CDI unit the cable guide. the Battery Box
Ç Clamp Battery B Pass the speedometer cable F Pass the magneto lead to
È Stop/tail light Á and front brake cable Î the outside of the flange of
É Flasher light lead (LH) through the Cable Guide. the chain cover.
Ê Flasher light C Align the white marking of
Ë Battery Wireharness with the frame
Ì Battery breather hose clamp
Í Starter Motor Lead Wire

À
Ã
Ï
¿
Æ

Ð
C
É
Ó Î Ñ
È
Å
Ä
Á
Ê
A Ò

Ë D

Á Â Ì
E F
Í

2-8
 SPEC
CABLE ROUTING

¿ Throttle cable È A.I.S. Unit A Pass the high tension cord À through the
À High tension cord É Starter wire cable guide and starter wire.
Á Ignition Coil Ê Carburettor Breather B Pass the throttle cable ¿ and starter wire
 Band - C.D.I. Pipe. É through cable guide.
à Brake Hose front Ë Caliper C Pass the clutch cable Æ through cable
Ä Speedometer Ì Disc guide.
Å Brake switch lead D Pass breather hose through upper right side
Æ Clutch cable hole of frame bracket engine.
Ç Rr Brake Switch E Clamp the hose front brake with front
mudguard.

Ä
Ã

Å
B
 É
È ¿

Á
Æ
C
Ã
Ç
Ê ¿
D
Ë
À
Ì

2-9
 SPEC
CABLE ROUTING

¿ C.D.I. Unit
À Rectifier regulator
Á Flasher relay
 Flasher light lead
A Clamp the Wire Harness lead.
B Pass the Wire Harness between Frame and Rear Fender

À
Å

Ã
Æ

2-10
 INSP
ADJ

CHAPTER 3

PERIODIC INSPECTION AND ADJUSTMENTS

FRONT BRAKE FLUID LEVEL ...................................................3-1

FRONT BRAKE PAD INSPECTION ............................................3-1
AIR BLEEDING (FRONT BRAKE SYSTEM ................................3-2
CABLE INSPECTION AND LUBRICATION .................................3-3
BATTERY INSPECTION .............................................................. 3-4
FUSE INSPECTION ....................................................................3-6
 INSP
FRONT BRAKE FLUID LEVEL ADJ
I
FRONT BRAKE FLUID LEVEL
INSPECTION
1. Place the motorcycle on a level place.
NOTE :
• Position the motorcycle straight up when
inspecting the brake fluid level.
• When inspecting the front brake fluid level
make sure the master cylinder top is
horizontal by turning the handlebars.

2. Inspect:
¿ • Brake fluid level
• Fluid level is under “LOWER”level line ¿
Ÿ Fill up.

Recommended brake fluid:

DOT - 3

CAUTION:
WARNING

Brake fluid may erode painted surfaces or

plastic parts. Always clean up spilled fluid
immediately.

WARNING
• Use only the designated quality brake fluid:
otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor
performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.

FRONT BRAKE PAD INSPECTION

1. Activate the brake lever
2. Inspect :
• Brake pad
¿ Wear indicator ¿ almost contacts brake
disc -> Replace brake pad as a set.
ç
Thickness : ç New 7.4 - 7.7 mm
Min - 3.8 mm

Refer to the “BRAKE PAD

REPLACEMENT” section on Page No.:

3-1
 INSP
AIR BLEEDING ADJ

AIR BLEEDING (FRONT BRAKE

SYSTEM)
WARNING
Bleed the brake system if :
• The system has been disassembled.
• A brake hose has been loosened or
removed.
• The brake fluid is very low.
• The brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not
properly bleed.

1. Bleed
• Brake system
ææææææææææææææææææææææææææææææææææ
Air bleeding steps :
a. Add proper brake fluid to the reservoir.
À b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect the clear plastic tube ¿ tightly to
the caliper bleed screw À.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
À
h. Tighten the bleed screw when the lever limit
has been reached; then release the lever.

Bleed screw:
6 Nm (0.6 m.kg., 4.0 ft.lb)

¿ i. Repeat steps (e) to (h) untill all of the air

bubles have been removed from the
system.
NOTE:
If the bleeding is difficult, it may be necessary
to let the brake fluid system stablize for a few
hours. Repeat the bleeding procedure when the
tiny bubles in the system have disappeared.

j. Add brake fluid to proper level

Recommended brake fluid:
DOT - 3

3-2
 INSP
CABLE INSPECTION AND LUBRICATION ADJ
CABLE INSPECTION AND
LUBRICATION

WARNING
Damaged cable sheth may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace such
cable as soon as possible.

1. Inspect:
¿ • Cable sheath ¿
Damage Ÿ Replace.

2. Check:
• Cable operation
Unsmooth operation Ÿ Lubricate.

Recommended lubricant:
Yamaha Chain and Cable Lube
or motor oil SAE 20W40
¿
NOTE:
Hold cable end high and apply several drops of
lubricant to cable.

LEVER LUBRICATION
Lubricate the lever ¿ at their pivoting points.

Recommended lubricant:
Yamaha Chain and Cable Lube
or motor oil SAE 20W40

3-3
 INSP
BATTERY INSPECTION ADJ
BATTERY INSPECTION
1. Remove:
• Side Cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 Fazer
Manual.
2. Inspect:
• Electrolyte level
Electrolyte level should be between the
upper ¿ and lower À level marks.
Electrolyte level is too low Ÿ Add
distilled Water to proper level.
WARNING
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.

3. Inspect:
• Battery terminals
Dirt Ÿ Clean with a wire brush.
Poor connection Ÿ Correct
NOTE :
¿
After cleaning the terminals, apply a light coat
À
of grease to the terminals.

4. Inspect:
Á • Breather hose Á
Obstruction Ÿ Remove
Damage Ÿ Replace
CAUTION:
When inspecting the battery, make sure that
the breather hose is routed correctly. If the
breather hose is positioned in such a way
as to allow battery electrolyte or gas to
come into contact with the frame, this could
damage the motorcycle and ruin its finish.
5. Connect:
• Breather hose Á
Make sure tha the hose is properly
attached and routed.
6. Check:
• Specific gravity
Less than 1.280 g/dm3 Ÿ Recharge the
battery.
Charging Current : 0.50 amp.
Specific Gravity: 1.280 g/dm3 to 20o C

3-4
 INSP
BATTERY INSPECTION ADJ
ææææææææææææææææææææææææææææææææææ
Replace the battery if:
• Battery voltage will not rise to a specific
value or bubbles fail to rise during
charging.
• Sulphation of one or more cells occurs,
(as indicated by the plates turning
white, or material accumulating in the
bottom of the cell).
• Specific gravity readings after a long,
slow charge indicate that one cell is
charged lower than the rest.
• Warpage or buckling of plates or
insulators is evident.
ææææææææææææææææææææææææææææææææææ
CAUTION:
Always charge a new battery before using
it to ensure maximum performance.

WARNING
Battery electrolyte is dangerous. It contains
sulfuric acid which is poisonous and highly
caustic. always follow these preventive
measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
• Wear protective eye wear when handling
or working near batteries.
• Antidote (EXTERNAL):
• SKIN - Flush with water.
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
• Antidote (INTERNAL):
• Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg or vegitable oil. Get immediate
medical attention.
• Batteries generate explosive hydrogen
gas.
• Always follow these preventive measures:
• Charge batteries in a well - ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g. welding equipment,
lighted cigarettes, etc.)
• DO NOT SMOKE when charging or
handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

3-5
 INSP
BATTERY CHARGING / FUSE INSPECTION ADJ
7. Install:
• Battery
8. Connect:
• Battery leads
CAUTION:
Connect the positive lead ¿ first and then
¿
À connect the negative lead À.

9. Connect:
• Breather hose
Be sure the hose is propely attached and
routed.
Refer to “CABLE ROUTING” Chapter 2
Page 2-8.
10. Install:
• Side cover (left)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 Fazer
Service Manual.

FUSE INSPECTION
CAUTION:
Always turn off the main switch when
checking or replacing the fuse. Otherwise,
a short circuit may occur
1. Remove:
• Side Cover (LH)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 Fazer
Service Manual.
• Fuse Holder ¿
2. Inspect:
• Fuse
¿ ææææææææææææææææææææææææææææææææææ
Inspection steps :
• Connect the Multimeter to the fuse and
check it for continuity.
NOTE :
Set the Multimeter selector to “Ω x 1” position

Multimeter.

• If the Multimeter is indicated at ∝ ,

replace the fuse.
ææææææææææææææææææææææææææææææææææ

3-6
 INSP
FUSE INSPECTION ADJ
3. Replace:
• Blown fuse
ææææææææææææææææææææææææææææææææææ
Replacement steps:
• Turn off the main switch.
• Install a new fuse with the proper current
rating.
• Turn on switches to verify operation of related
electrical devices.
• If the fuse blows again immediately, check the
electrical circuit.

WARNING
Never use a fuse with a rating other than
that specified. Never use other materials in
place of a fuse. An improper fuse may
cause extensive damage to the electrical
system, malfunction of lighting and ignition
systems and could possibly cause a fire.

4. Install:
• Fuse holder
• Side cover (LH)
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” section in 5YY1 “Fazer”
Service Manual.

3-7
 ENG

CHAPTER 4

ENGINE

C.D.I. MAGNETO ........................................................................4-1

C.D.I. MAGNETO REMOVAL ...................................................... 4-2
STARTER IDLE GEAR INSPECTION.......................................... 4-3
ROTOR & STARTER GEAR INSTALLATION ...............................4-3
 ENG
ENGINE

CDI MAGNETO
¿ Starter idle gear 1 Ä Stator assembly
À Plate Å Gasket
Á Washer Æ Dowel pin
 Starter wheel gear 2 Ç Crankcase cover
à CDI Magneto rotor

Á
Â
Ã

¿
À
Ä
Ç

4-1
 ENG
ENGINE
CDI MAGNETO REMOVAL
1. Remove :
• Screw - 2 Nos. ¿
¿
• Chain cover (Half) À
À
NOTE :
The CDI magneto can be removed while the
engine is mounted by removing the shift pedal.

Magneto Holder :
YSST - 601 - B

2. Remove
Á
• Crank case cover #1
• Neutral switch lead ¿
• Gasket À
• Dowel Á
À • Nut (magneto) Â
Ã
 • Plain washer Ã
¿
3. Remove
• C.D.I. Magneto ¿
• Wood-ruff key
¿
CAUTION:
WARNING
• Cover the crankshaft end with the spacer.

Magneto Puller :
YSST - 628

NOTE :
• Remove the magneto using the flywheel
Á puller À with spacer Á.
• Center the flywheel puller over the magneto.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the magneto is the same every-
where. If necessary, one holding bolt may
be turned out slightly to adjust the flywheel
À
puller’s position.

Ã
4. Remove :
 • Starter idler gear ¿
À
• Washer À
5. Remove
• Screw - 2 Nos. Á
• Plate Â
¿ Á
• Starter idler gear Ã

4-2
 ENG
ENGINE

è STARTER IDLE GEAR INSPECTION

1. Inspect:
• Gear teeth ç, è and é
Burrs/chips/roughness/wear Ÿ Replace

2. Check
• Starter clutch operation
é
ç
ææææææææææææææææææææææææææææææææææææ
Checking steps :
À • Install the starter wheel gear ¿ to the
B
starter clutch À, and hold the starter
clutch.
• When turning the starter wheel gear
A clockwise A , the starter clutch and the
wheel gear should be engaged. If not, the
starter clutch is faulty. Replace it.
¿
• When turning the starter wheel gear
counter closckwise B , the starter clutch
gear should turn freely. If not, the starter
Á
clutch is faulty. Replace it.
ææææææææææææææææææææææææææææææææææææ
¿

ROTOR AND STARTER IDLE GEAR

INSTALLATION
1. Install
À • Starter idle gear ¿.
• Plate À
• Screw - 2 Nos. Á

¿
2. Apply
• 4-stroke engine oil.
(onto journal and starter drives)

3. Install
• Washer ¿
• Starter idle gear À
4. Install:
• Wood-ruff key
• Magneto rotor Á
NOTE :
Temporarily install the rotor aligning the key way
of the rotor with the wood-ruff key. Turn the
starter wheel gear clockwise and install the
À Á Á rotor to the start wheel gear.

4-3
 ENG
ENGINE
5. Tighten :
• Nut (rotor) ¿

¿ Nut (rotor):
70 Nm ( 7.0 m. kg., 51 ft.lb)
À

Á NOTE :
• Tighten the nut (rotor) ¿ while holding the ro-
tor À with the magneto holder Á.

Magneto Holder :
YSST 601 - B

6. Install:
• Dowl pin ¿
• Gasket À
À • Crankcase cover (LH)
• Bolts - Seven Nos.

¿
Bolt (left crankcase cover):
10 Nm (1.0 m.kg, 7.2 ft.lb)
Á

7. Connect:
• Neutral switch lead Á
¿
8. Install
À
• Cover (Half) chain ¿

9. Tighten
Screw - 2 Nos. À

4-4
 CARB
CARBURETION

CHAPTER 5

CARBURETION

REFER CHAPTER-5

FROM

5YY1 - FAZER

SERVICE MANUAL
 CHAS
FRONT WHEEL AND FRONT BRAKES

CHAPTER 6

CHASSIS

FRONT WHEEL .......................................................................... 6-1

REMOVAL ...................................................................................6-2
FRONT WHEEL INSPECTION ....................................................6-3
INSTALLATION ............................................................................6-5
FRONT BRAKE ...........................................................................6-7
BRAKE PAD REPLACEMENT ...................................................6-8
CALIPPER DISASSEMBLY ........................................................6-10
MASTER CYULINDER DISASSEMBLY ...................................... 6-11
INSPECTION AND REPAIR ......................................................... 6-12
CALIPER ASSEMBLY ................................................................. 6-14
 CHAS
FRONT WHEEL AND FRONT BRAKES
FRONT WHEEL
¿ Wheel axle Ç Gear Unit (Speedometer)
À Collar È Axle Nut
Á Dust Cover É Split Pin
 Oil Seal
à Bearing
Ä Spacer Collar
Å Front Wheel
Æ Bearing

À
Á
Â
Ã
Ä

Æ
Ç
È
É
Å

6-1
 CHAS
FRONT WHEEL AND FRONT BRAKES
REMOVAL

WARNING
Securely support the motorcycle so there is
no danger of it falling over.
¿

1. Place the motorcycle on a level place.

2. Elevate the front wheel by placing suitable
stand under the frame and engine.
3. Remove:
Á • Speedometer Cable ¿
• Split pin À
• Nut Á
À

4. Remove:
 • Wheel axle Â
• Front Wheel Ã

NOTE:
Do not depress the brake level when the wheel
is off the motorcycle otherwise the brake pads
à will be forced shut.

5. Remove:
• Collar ¿
• Dust Cover À
• Gear Unit (Speedometer) Á

B A

Á
A Right side
B Left Side
À

6-2
 CHAS
FRONT WHEEL AND FRONT BRAKES
INSPECTION
1. Eliminate any corrosion from parts.
2. Inspect:
ò Wheel axle
Roll the axle on a flat surface.
Bends Ÿ Bends

WARNING
Do not attempt to straighten a bent axle.

3. Inspect:
• Tyre
Wear/Damage Ÿ Replace.

• Wheel
Bends/Damage Ÿ Replace.

4. Check:
• Spoke(s)
Bend/Damage Ÿ Replace.
Loose spoke(s) ŸRetighten.
Turn the wheel and tap the spokes with
a screw driver.

NOTE:
A tight spoke will emit a clear, ringing tone; a
lookse spoke will sound flat.

5. Tighten:
• Loose spokes

Nipple :
3 Nm (0.3 m.kg. -2.0 lbft)
NOTE:
Check the wheel runout after tightening spoke.

6. Measure:
• Wheel runout
Out of specification Ÿ check the wheel
and bearing play.

Rim runout limits:

Vertical ¿ : 1.0 mm
Lateral À : 0.5 mm

6-3
 CHAS
FRONT WHEEL AND FRONT BRAKES

WARNING
After mounting a tyre, ride conservatively to
allow proper tyre to rim seating. Failure to
do so may cause an accident resulting in
motorcycle damage and possible operator
injury.
After a tyre repair or replacement, be sure to
torque tighten the valve stem locknut ¿ to
specification

Valve stem locknut:

3 Nm (0.3 m.kg. - 2 ft.lb)

7. Check
• Wheel bearings ¿
• Abnormal noise/turn roughly/free play
Ÿ replace.
• Oil seal À
Wear/damage Ÿ replace.

A Free Play

ææææææææææææææææææææææææææææææææææ

Oil seal and wheel bearing replacement steps:

• Clean the outside of the wheel hub.
• Remove the oil seals ¿.
• Remove the bearing À .
¿ • Install the new bearing and new oil seal.

6-4
 CHAS
FRONT WHEEL AND FRONT BRAKES

Ä NOTE:
Use a socket Ä that matches the outside
diameter of the race of the bearing and oil seal.
Ã
Á
Â

CAUTION:
WARNING
Do not strike the centre race Á or balls  of the
bearing. Contact should be made only with the
outer race Ã.

ææææææææææææææææææææææææææææææææææ

INSTALLATION

Reverse the “Removal” procedure.

1. Lubricate:
• Wheel Axle ¿
• Oil Seal (Lip) À
• Bearings Á
• Driven Gear  (speedometer)

Lithium Soap base grease

2. Install:
• Gear unit assembly ¿.
è

¿ NOTE:
WARNING
Make sure the projections on the meter clutch
ç and meshed with the flats in the wheel hub è

6-5
 CHAS
FRONT WHEEL AND FRONT BRAKES
3. Install :
• Collar ¿
• Dust Cover À

NOTE :
À
Install the oil seal taking care not to damage or
reverse the lips.

ç 4. Install :
• Front wheel assembly

NOTE :
Be sure the boss on the outer fork tube ç
è
correctly engages with the locating slot on the
gear unit assembly è.

5. Install :
¿ • Wheel axle ¿
• Axle nut À

6. Tighten
• Nut À

Nut (wheel axle) :

80 Nm (8.0m.kg, 58 ft.lb)

7. Install:
• Split Pin Á
À • Speedometer cable Â
À

CAUTION:
WARNING
 Make sure that the speedometer cable  is
Á
routed properly.

6-6
 CHAS
FRONT BRAKE
FRONT BRAKE
¿ Master cylinder cap ÇRubber boot
À Diaphragm ÈBrake caliper body
Á Master cylinder kit ÉBleed Screw
 Master cylinder ÊPad spring
à Brake hose ËBrake pads
Ä Holder (brake hose and meter cable) ÌPiston seal
Å Caliper bracket ÍPiston
Æ Retaining bolt ÎBrake disc

¿
À
Á

Å Æ
Ç É

Ê
Ë

Î Ì
Í

6-7
 CHAS
FRONT BRAKE
CAUTION:
WARNING
Disc brake components rarely require
disassembly. DO NOT:
• Disassembly components unless
absolutely necessary.
• Use solvents on internal brake
component.
• Allow brake fluid to come in contact with
the eyes otherwise eye injury may occur.
• Allow brake fluid to contact painted
surfaces or plastic parts otherwise
damage may occur.
• Disconnect any hydraulic connection
otherwise the entire system must be
disassembly, drained, cleaned, and then
properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

¿
NOTE :
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
• Front wheel ¿ - Refer Chapter-6 Page
No. 6-2.

WARNING
Securely support the motorcycle there is no
danger of falling over.
¿

2. Remove:
¿ • Clip Pins - 2 Nos ¿.
À • Retaining Pin À.

Á 3. Remove:
• Brake Pads Á.
• Pad Spring Â.

À
¿ Â

6-8
 CHAS
FRONT BRAKE
NOTE:
WARNING
• Replace the pad spring if the pad replacement
¿ is required.
• Replace the pads as a set if either is found
ç to be worn to the wear limit.

Thickness : ç New 7.4 - 7.7 mm

Min - 3.8 mm

3. Install:
À • Pad Spring ¿
• Brake pads À

4. Install / Lubricate:
• Retaining pin Á
Á • Clip pin - 2 Nos. Â
 ¿
Recommended lubricant :
Lithium soap base grease
ææææææææææææææææææææææææææææææææææ
ç
Installation steps:
è • Connect the clear plastic tube ç tightly to
the caliper bleedscrew è. Then, place the
other end of this hose into an open con-
tainer.
• Loosen the caliper bleed screw and push the
piston into the caliper by your finger.
• Tighten the caliper bleed screw.
ç • Install pad spring and brake pads.
ææææææææææææææææææææææææææææææææææ
Caliper bleed screw :
6 Nm (0.6m.kg, 4 ft.lb)

5. Install:
• Retaining pin
6. Inspect:
• Brake fluid level ç
Refer to the Brake Fluid Inspection
on Chapter 3 Page No.: 3-1
¿ “LOWER” level line.
¿
7. Check:
• Brake lever operation ¿
A softy or spongy feeling Ÿ Bleed
brake system.
Refer to the Air Bleeding section on
Chapte 3Page No.: 3-2

6-9
 CHAS
FRONT BRAKE / CALIPER ASSEMBLY
CALIPER DIASSEMBLY
À NOTE:
Before disassembling the front brake caliper,
drain the brake system of its brake fluid.

¿ WARNING
Á Securely support the motorcycle there is no
Á danger of falling over.

1. Remove:
Á • Bolt ¿
• Copper Washers 2 Nos. À
NOTE:
¿ Place the container under the caliper to catch
À the standing brake fluid.

 2. Disconnet:
• Brake hose Á
3. Remove:
• Clip pin Â
Ä • Retaining pin Ã
• Brake pads Ä
• Pad spring
4. Remove
• Bolts Å
à • Brake Caliper Body.
 5. Remove:
• Piston Æ
• Piston seal Ç
ææææææææææææææææææææææææææææææææææ
Removal steps:
• Blow compressed air into the Bleeding Bolt
Å opening to force out the piston from the
caliper body.

WARNING
• Never try to pull out the piston.
• Cover the piston with a rag. Use care so
Ç that piston does not cause injury as it is
come out from the CaIiper Body.

CAUTION:
WARNING
Æ Remove the piston seal by pushing it in with
finger. Do not use a screwdriver.

ææææææææææææææææææææææææææææææææææ

6-10
 CHAS
FRONT BRAKE / MASTER CYLINDER
MASTER CYLINDER DISASSEMBLY
¿
NOTE:
WARNING
Before disassembling the front brake master
cylinder, drain the brake system of the brake
fluid.

WARNING
Securely support the motorcycle so there is
no danger of it falling over.
À Á
1. Remove:
• Mirror (right) ¿
• Brake lever cover
• Brake switch À

Á 2. Loosen:
• Union bolt Á

¿ 3. Remove:
Á • Master cylinder ¿
• Union bolt À
• Copper washer - 2 Nos. Á
À

NOTE:
WARNING
Place a container under the master cylinder to
catch the standing brake fluid.

¿ 4. Remove
À
Á • Screw ¿
• Cover master cylinder À
• Diaphragm Á

¿ À 5. Remove
• Bolt ¿
• Brake Lever À
• Brake Lever Pin with spring, boot Á
• Circlip Lock Â
Á • Master Cylinder Kit Ã
à Â

6-11
 CHAS
FRONT BRAKE / NSPECTION
INSPECTION AND REPAIR
¿
WARNING
All internal parts should be cleaned in new
brake fluid only. Do not use solvents will
cause seals to swell and distort.

1. Inspect:
• Caliper cylinder
Wear / scratches Ÿ Replace caliper
Á
À assembly.
• Caliper piston À
Scratches/rust/wearŸReplace
À caliper assembly
• Caliper body Á
Cracks/damage ŸReplace brake
caliper assembly.
• Rubber boots
• Cracks/wear/damageŸReplace
Á • Oil delivery passage (caliper body) Â
Blow out with compressed air.

WARNING
Â
Replace the piston seal and dust boot when-
ever a caliper is disassembled.

2. Inspect :
• Caliper bracket
Cracks / damage ŸReplace brake
caliper assembly
¿

3. Inspect :
• Master cylinder ¿
¿ Wear/ScratchesŸReplace master cylinder
assembly.
• Oil delivery passage (master cylinder
body)
Blow out with compressed air.

6-12
 CHAS
FRONT BRAKE / INSPECTION
4. Inspect :
Á
• Diaphragm ¿
• Master Cylinder Kit À
¿ • Spring Á
Wear/damage Ÿ Replace

5. Inspect :
• Brake hoses ¿
¿ Cracks/wear/damage ŸReplace

6. Measure :
• Brake pad thickness ç
Out of specification ŸReplace
¿

Thickness : ç New 7.4 - 7.7 mm

ç
Min - 3.8 mm

¿ NOTE:
WARNING
Replace the pads ¿ as a set either if found to
be worn to the wear limit.

7. Inspect :
• Brake disc ¿
¿ Galling/damage ŸReplace

6-13
 CHAS
FRONT BRAKE / CALIPER ASSEMBLY
9. Measure :
• Brake disc deflection
Out of specificationŸInspect wheel runout.
DeflectionŸreplace.

Maximum deflection
0.3 mm
¿ Dial gauge
• Brake disc thickness ç
Out of specification Ÿ replace.
ç Brake Disc thickness ç
5.0 mm
<Wear Limit:3.5 mm>
NOTE:
WARNING
Tighten the bolts (brake disc) in stage using
a crissross pattern.

Bolt (brake disc):

13 Nm (1.3 m.kg, 9 ft.lb)

¿ CALIPER ASSEMBLY
WARNING
• All internal parts should be cleaned in
new brake fluid only.

Brake Fluid :
DOT # 3
• Internal parts should be lubricated with
brake fluid when installed.
• Replace the piston seal and dust boot
whenever a caliper is disassembled.
À
1. Install:
• Piston seal ¿
• Piston À
• Dust boot Á

NOTE:
WARNING
Always use new piston seal.

2. Install:
 • Caliper bracket Â
• Brake caliper body Ã
Á
Ä • Bolt Ä
à • Brake hose
• Union bolt with Copper washer

Bolt (Caliper bracket):

28 Nm(2.8 m.kg., 20 ft.lb)
Union Bolt:
25 Nm (2.5 m.kg., 18 ft.lb)
6-14
 CHAS
FRONT BRAKE / CALIPER ASSEMBLY

WARNING
• Proper hose routing is essential to insure
safe motorcycle operation.
• Always use new copper washers.

3. Install:
• Pad spring ¿
• Brake pads À
• Retaining pin Á
• Clip Â
4. Fill:
• Brake fluid

¿ Brake Fluid :
DOT # 3

CAUTION:
WARNING
À Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.

WARNING
• Use only the designated quality brake
Á Â fluid: otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemcial reaction and lead to poor
performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.

5. Air bleed:
• Brake system
Refer to the Air Bleeding section on
Chapter-3, Page No. 3-2
6. Install:
• Brake fluid level
Refer to the Brake Fluid Inspection
section on Chapter 3, Page No. 3-1

6-15
 CHAS
FRONT BRAKE / MASTER CYLINDER

WARNING
• All internal parts should be cleaned in new
brake fluid only.
• Internal parts should be lubricated with
brake fluid when installed.

Brake fluid :
DOT # 3

1. Install:
• Master cylinder kit ¿
• Circlip À
Á
• Brake lever with spring & Pin, Boot Á
• Master cylinder
¿ À 2. Install:
• Brake switch ¿
• Mirror (right) À

À Bolt (master cylinder bracket) :

¿ 10 Nm(1.0 m.kg. 7.2 lbft)

3. Tighten
• Bolt Á
 • Nut
4. Install:
Ã
Á • Copper washers
• Brake hose Â
• Copper washers
• Union bolt Ã
Union bolt:
25 Nm(2.5 m.kg. - 18 lbft)

NOTE:
WARNING
Always use new copper washers.

WARNING
Proper hose routing is essential t insure safe
motorcycle operation. Refer to the Cable
Routing section in the Chapter 2, Page No.

5. Fill:
• Brake fluid

6-16
 CHAS
FRONT BRAKE / MASTER CYLINDER

6. Install:
• Brake system
Refer to the Air Bleeding section in
the Chapter 3 Page No. 3-2.

7. Inspect:
• Brake fluid level ¿

6-17
 ELEC

CHAPTER 7

ELECTRICAL

CIRCUIT DIAGRAM .....................................................................7-1

LOCATION OF ELECTRICAL COMPONENTS ........................... 7-2

CHECKING OF CONNECTIONS ................................................ 7-3

CHECKING OF SWITCHES ........................................................ 7-4

STARTING CIRCUIT CUT OFF SYSTEM .................................... 7-5

IGNITION SYSTEM / CHARGING SYSTEM

• CIRCUIT DIAGRAM .............................................................. 7-6

• TROUBLE SHOOTING .......................................................... 7-7

STARTER MOTOR COMPONENTS ........................................... 7-15

REMOVAL OF STARTER MOTOR .............................................. 7-16

INSPECTION OF STARTER MOTOR .......................................... 7-16

ASSEMBLY OF STARTER MOTOR ............................................ 7-18

 ELEC
CIRCUIT DIAGRAM
ELECTRICAL WIRING CIRCUIT

7-1
 ELEC
ELECTRICAL COMPONENTS
LOCATION OF ELECTRICAL COMPONENTS
¿ Main Switch Æ Battery
À Horn Ç Starter Relay
Á Ignition Coil Assy. È Relay - A
 Spark Plug Cap É Flasher Relay Assy.
à Stop Switch Rear Ê CDI Unit Assy.
Ä Neutral Switch Assy. Ë Rectifier / Regulator Assy.
Å Fuse Ì Throttle Position Sensor (TPS)

Ë
¿
Ê

Ì É
À

 Æ
Ã

7-2
 ELEC
CHECKING OF CONNECTIONS
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on
the connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector
two or three.
4. Pull the lead to check that it will not
come off.
5. If the terminal comes off, bend up the
pin ¿ and re-insert the terminal into
the connector.

Multitester:

6. Connect:
• Connector
NOTE:
The two connectors “click” together.

7. Check for continuity with a tester.

NOTE:
• If there is no continuity, clean the
terminals.
• Be sure to perform the steps 1 to 7
listed above when checking the
wireharness.
• For a field remedy, use a contact
revitalizer available on the market.
• Use the tester on the connector as
shown.

7-3
 ELEC
CHECKING OF SWITCHES
CHECKING OF SWITCHES
CHECKING STEPS
Use a pocket tester to check the terminals
for continuity. If the continuity is faulty at
any point, replace the switch.

NOTE:
• Turn the switch key to the “ON” and “OFF”
several times.
• Set the pocket tester selector to the
“Ohm x 1
• Set the pocket tester to “0” before starting
the test.

SWITCH CONNECTION AS SHOWN

IN MANUAL

The manual contains a connection chart as

shown left showing the terminal
connections of the switches (e.g., main
switch, handlebar switch, bracket switch,
lighting switch etc.)

The extreme left column indicates the

switch positions and the top line indicates
the colors of leads of connectes with the
terminals in the switch component.

“ ” indicates the terminals between

which there is a continuity of electricity;
i.e.,a closed circuit at the respective switch
positions.

In this chart:
“Br” and “R” are continuous with the “ON”
switch position.

7-4
 ELEC
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUTOFF SYSTEM
OPERATION

à Ä
¿ Battery
Æ À Fuse(main)
Á Main Switch
 Kill Switch
à Neutral Light Switch
Ä Clutch Switch
 ŠStarter Switch
Å Æ Relay-1
Ç Starter Relay
È Starter Motor
Ç È
Conition-1
Vehicle in Neutral Gear
The main switch Á and kill switch  is
set to “ON” position then Press the
starter switch Å to operate the starter
motor È.

Á Condition-2
À Vehicle in Gear
¿
The main switch Á and kill switch  set
“ON” position and press the clutch lever
to operate the clutch switch Ä then
press the starter switch Å simultaniously
to operate the starter motor È.
COLOUR CODE

R Red
B/L Brown/Blue
Br Brown
LB Blue/Black
RW Red/White
LW Blue/White
Sb Sky Blue
RB Red/Blue

7-5
 ELEC
IGNITION SYSTEM / CHARGING SYSTEM
CIRCUIT DIAGRAM Å Ignition coil and Spark plug
¿ Magneto Æ Fuse
À Rectifier / Regulator Ç Starter Relay Assy.
Á Battery È Relay-A
 Main switch É Clutch Switch
à “Engine Stop” switch Ê Neutral Switch
Ä C.D.I. unit Ë Starter Motor
Ì Starter Switch
IGNITION SYSTEM, CHARGING SYSTEM AND TACHOMETER CIRCUIT

Ë
Ç

Æ Á

¿ À

7-6
 ELEC
IGNTION SYSTEM / CHARGING SYSTEM

IF THE IGNITION SYSTEM FAILS TO OPERATE.

(NO SPARK OR INTERMITTENT SPARK)

Procedure
Check: 7. Sensor coil resistance
1. Fuse 8. Charging coil resistance
2. Battery 9. Rectivier cum Regulator Unit
3. Spark plug 10. Wiring connection
4. Spark plug cap resistance (entire ignition system)
5. Ignition coil resistance 11. CDI Unit
6. Main switch 12. Tachometer
13. Engine stop switch
NOTE:
• Remove the following parts before troubleshooting:
1) Side covers (LH/RH)
2) Saddle
3) Fuel Tank
• Use the special tools specified in this troubleshooting

Multemeter

1. FUSE
• Remove the fuse. NON CONTINUITY
Ω x1) to the
• Connect the pocket tester (Ω
fuse.
• Check the fuse for continuity.
Refer to the Fuse inspection section in
Chapter 3 Page No. 3-6.
Fuse is faulty, replace it.

CONTINUITY

2.BATTERY
• Check the battery condition.
INCORRECT
Voltage:12.8V
Specifc gravity: 1.280 g/dm³
Electrolyte level

CORRECT
• Clean battery terminals.
• Recharge or replace battery.
• Refil with distilled water.

7-7
 ELEC
IGNITION SYSTEM

Standard spark plug:

CR7HSA/NGK
3. SPARK PLUG
• Check the spark plug condition.
• Check the spark plug type. OUT OF SPECIFICATION
• Check the spark plug gap.
Refer to the “SPARK PLUG INSPECTION”
section in the Fazer 5YY Service Manual
Spark pulg gap:
0.6 ~ 0.7 mm Adjust or replace the Spark Plug

CORRECT

Multimeter (+) lead → Spark Plug side ¿

Multimeter (-) lead → High Tension Cord
side À

4. SPARK PLUG CAP RESISTANCE

• Remove the spark plug cap.
Ωx1K) to the
• Connect the pocket tester (Ω
spark plug cap.. À
NOTE:
¿
• When removing the spark plug cap, do not
pull the spark plug cap from high tension
cord.
Remove → Turning counterclockwise.
Connect → Turning clockwise.
• Check the high tension cord when
connecting the spark plug cap.
• When connecting the spark plug cap, cut OUT OF SPECIFICATION
the high tension cord about 5 mm.
Spark pulg cap resistance:
5 KΩΩ ± 20% a 20o C

Replace the spark plug cap.

MEETS
SPECIFICATION

7-8
 ELEC
IGNITION SYSTEM / CHARGING SYSTEM

æ Multimeter (+) lead Ÿ Black/Blue Terminal ¿

Multimeter (-) lead Ÿ Green Terminal À
5A. IGNITION COIL RESISTANCE (Primary)

• Disconnect the Ignition Coil Connector From

the Wire harness
• Connect the Multimeter to the Ignition Coil.
• Check the primary Coil resistance

¿
Primary coil resistance :
À
0.22 Ω ± 15 %

5B. IGNITION COIL RESISTANCE (Second-
ary)
• Connect the Multimeter to the Ignition Coil
• Check the secondary coil resistance
Multimeter (+) lead Ÿ High Tension lead ¿
Multimeter (-) lead Ÿ Green Terminal À
À

Secondary coil resistance :

Ω ± 20% (at 20 º C)
3.0 kΩ

OUT OF SPECIFICATION

BOTH MEET
SPECIFICATIONS
Ignition Coil OK Replace the Ignition Coil

6. MAIN SWITCH

• Check for Continuity of Switch ON position

Multimeter (+) R NO CONTINUITY
Multimeter (-) BR/L

• Check for ignition “ON” “OFF” position

Replace the Main Switch
CONTINUITY

Main Switch OK

7-9
 ELEC
IGNITION SYSTEM/ CHARGING SYSTEM

7. SENSOR COIL RESISTANCE Mutimeter (+) lead ŸWhite/Blue terminal ¿

Multimeter (-) lead Ÿ Earth À
• Disconnect the sensor Coil Coupler from the
Wiring Harness
• Connect the Multimeter (Ω X 100) to the À
sensor coil coupler ¿
• Check the sensor coil resistance

Sensor coil resistance :

240 Ω ± 20 % (at 20ºC) OUT OF SPECIFICATION

MEETS
SPECIFICATION

Sensor coil is OK Replace the Sensor Coil Assembly

8. CHARGING COIL RESISTANCE Multimeter (+) lead Ÿ White Terminal ¿

Multimeter (-) lead Ÿ Black Terminal À
• Remove the Charging Coil coupler from the
Wire Harness
• Connect the Multimeter to the charging coil
À
• Measure the charging coil resistance

Charging coil resistance

0.75 Ω ± 20 % (at 20ºC)

OUT OF SPECIFICATION

MEETS
SPECIFICATIONS
Charging coil is OK Replace the Charging CoiL

7-10
 ELEC
IGNITION SYSTEM / CHARGING SYSTEM

9. RECTIFIER CUM REGULATOR UNIT Multimeter (+) lead Ÿ Battery (+) terminal ¿
Multimeter (-) lead Ÿ Battery (-) terminal À
• Check the Charging Voltage
À
Procedure Steps ¿
• Connect the Tachometer to Spark plug lead
• Connect the Multimeter ( DC 20V) to Bat-
tery Red Wire.
Measure the Battery Voltage : 12.8 V
If less than specifications, charge the
Battery
• Start the engine and accelearte the Engine
up to 5000 RPM .
• Check the Charging voltage :

Charging voltage :
14 ~ 15 V at 5000RPM MEETS SPECIFICATIONS

OUT OF
SPECIFICATION

Rectifier cum Regulator unit is faulty. Charging Circuit and Rectifier cum Regula-
• Replace RR unit tor are OK

10. WIRING CONNECTIONS

• Check the connection for entire Ignition and

Charging System “REFER TO CIRCUIT
DIAGRAM” Page 7-6
POOR CONNECTIONS

IF CORRECT

11. CDI UNIT Repair/ Replace the Harness

• Check CDI unit “REFER IGNITION

TIMING PROCEDURE Chapter 3,
Page 5YY1 - FAZER SERVICE MANUAL
IF NOT WORKING
12. TACHOMETER
• Check Tachometer Operation and entire
connection Replace Tachometer

7-11
 ELEC
IGNITION SYSTEM / CHARGING SYSTEM

13. ENGINE STOP SWITCH

• Check the Engine Stop Switch for
continuity.

• Is the Engine Stop Switch OK?

YES NO
Replace the Right
Handlebar Switch

TROUBLE SHOOTING

The Starter motor fails to turn ON.

1. FUSE

Check:
• Check the fuse for continuity.
1. Main fuse
Refer to Fuse inspection section in
2. Battery
Chapter-3 Page No. 3-6.
3. Starter motor
4. Relay -A
5. Starter relay
6. Main switch
7. Engine Stop switch
8. Starter Switch YES NO
9. Wiring connections
Replace the fuse
(Entire starting system)

NOTE:
2. BATTERY
• Before troubleshooting, remove the
• Check the condition of the battery.
following part(s):
Refer to Checking and charging the battery
1. Side panel (LH/RH)
in chapter 3 Page No. 3-4.
2. Saddle
3. Fuel Tank Minimum open-circuit voltae :
• Troubleshoot with the following special 12.8V or more at 20o C
tools(s) • Is the battery OK?

Multemeter :
YES NO
• Clean the battery
terminals.
• Recharge or replace
the battery.

7-12
 ELEC
IGNITION SYSTEM / CHARGING SYSTEM

3. STARTER MOTOR 4. RELAY - A

• Connect the positive battery terminal ¿ and
starter motor lead À with a jumper lead Á.
• Disconnect the Relay-A coupler from the
wire harness.
• Connect the pocket tester (ΩΩ x 1) and
battery (12 V) to the Relay-A coupler as
shown.
Positive Battery Terminal Ÿ blue/black ¿
Negative Battery Terminal Ÿ red/black À

Multimeter (+) Ÿ blue/black Á

Multimeter (-) Ÿ red/white Â

RW RB
WARNING
LB SB
• A wire that is used as a jumper lead must
have atleast the same capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.
• Does the Relay-A have continuity between
• This check is likely to produce sparks, blue/black and red/white
therefore, make sure nothing flammable
is in the vicinity.
• Does the starter motor turn?
YES NO

YES NO Replace the Relay-A

Repair or replace the

starter motor.
5. STARTER RELAY
• Disconnect the starter relay coupler from
the harness.
• Connect the Multimeter (Ω Ω x 1) and battery
(12 V) to the starter relay coupler as
shown.
Positive Battery Terminal Ÿ blue/white ¿
Negative Battery Terminal Ÿ red/white À

Multimeter (+) Ÿ red Á

Multimeter (-) Ÿ red Â

7-13
 ELEC
IGNITION SYSTEM / CHARGING SYSTEM
8. START SWITCH

• Check the Start Switch for continuity.

• Is the Start Switch OK?

YES NO

• Does the starter relay have continuity Replace the Right

between red Á and red  ? Handlebar Switch

YES NO

Replace the starter

relay.

6. MAIN SWITCH 9. WIRING

• Check the entire starting system’s wiring.
• Check the main switch for continuity.
Refer to “CIRCUIT DIAGRAM”. Page 7-6.
Refer to Fazer 5YY1 Service Manual
• Is the starting system’s wiring properly
• Is the Main Switch OK? connected and without defects?

YES NO
YES NO
The starting system Properly connect or
Replace the Main circuit is OK. repair/replace the
Switch. Wiring Harness.

7. ENGINE STOP SWITCH

• Check the Engine Stop Switch for
continuity.

• Is the Engine Stop Switch OK?

YES NO
Replace the Right
Handlebar Switch

7-14
 ELEC
STARTER MOTOR COMPONENTS
¿ Starter motor assembly Æ Oil Seal
À Rear bracket Ç Bearing
Á Brush set È Front bracket
 O-ring É O-ring
à Yoke Ê Bolt
Ä Armature Ë Harness
Å Shim

6 1

7
8
9
4

10 12

11

13

7-15
 ELEC
STARTER MOTOR
REMOVAL
1. Remove
• Starter Motor lead ¿

À Á 2. Remove
• Bolts À
¿ • Starter Motor Á

DISASSEMBLY
Á Â Ã 1. Put identifying marks on the
brackets for reassembly.

2. Remove:
¿ À • Bolts - 2 Nos. ¿
• Front bracket À
Ä Å • Shim Á
• Washer Â

3. Remove:
• Armature Ã
• Yoke Ä
• Rear bracket Å
¿

4. Remove:
• Screw - 2 Nos ¿
• Brush spring set À

À INSPECTION AND REPAIR

1. Inspect:
• Commutator ¿
Dirty Ÿ Clean ith with # 600 grit
sandpaper.

2. Measure:
• Commutator diameter ç
Out of specification Ÿ Replace
¿
starter motor

ç Commutator wear limit :

21 mm

7-16
 ELEC
STARTER MOTOR
3. Measure:
• Mica undercut ç
Out of specification Ÿ Scrape the
mica to proper value use a hacksaw
blade can be ground to fit.

Mica Undercut
0.7 mm

4. Inspect:
• Armature coil (insulation/continuity)
Defects Ÿ Replace starte motor.
ææææææææææææææææææææææææææææææææææ

Inspecting steps :
• Connect the Multimeter for continuity
check ¿ and insulation check À.
• Measure the armature resistances.
• If the resistance is incorect, replace the
starter motor.

Armature coil resistance:

Continuity check ¿:
0.017 ~ 0.021 Ω at 20oC
Insulation check À:
More than 1 M Ω at 20oC

ææææææææææææææææææææææææææææææææææ

5. Armature Insulation Test

Use 110 Volts AC mains and a 15W
bulb with two probes and check as
shown in figure. Bulb must not glow
when the probes are connected
between any one of the commutator
segments and Armature core. If the
bulb glows the fault is with the
insulation.

NOTE:
The brush dust in the armature should be
throughly cleaned before this test.

7-17
 ELEC
STARTER MOTOR
6. Measure:
ç • Brush length ç
Out of specification Ÿ Replace as a
set
Brush length limit :
New Length - 7 mm
Minimum Length - 3 mm

NOTE:
When replacing the brush, take care as
one side soldered.

7. Measure:
• Brush spring force
Fatigue/Out of specification Ÿ
Replace as a set.

Brush spring force:

560 ~ 840 g

8. Inspect:
¿ • Bearing ¿
• Oil Seal À
• Bush Á
Damage ŸReplace the bracket.
À • O-Ring Â
 Á Wear/damageŸReplace

ASSEMBLY
Reverse the “REMOVAL”procedure.
¿ 1. Install:
• Brush springs ¿
• Brush set À
À

7-18
 ELEC
STARTER MOTOR
2. Install:
• Screw ¿
• Nut À
¿
À
3. Install:
• Armature ¿

NOTE:
When installing the brush, pass the brush
lead outside of the projection on the brush
¿ spring holder. During installing the brush,
install the brush lead terminal to the
projection on the side of brush spring
holder.

NOTE:
When installing the armature, press the
brush with thin screwdriver, etc. to avoid
damage to the brush and install.

3. Install:
• O-ring

CAUTION:
Always use O-rings.

4. Install:
¿
• Yoke ¿

NOTE:
Align the match mark on the yoke with the
match mark on the rear bracket.

7-19
 ELEC
STARTER MOTOR
5. Install
 À ¿ • Washer ¿
• Shim À
• Front bracket Á
• Bolt 2 Nos - Â

NOTE:
• Align the projection of the washer with
the slot of the front bracket and install.
• Align the match mark ç on to yoke with
the match mark è on the front bracket.

Bolt :
5 Nm (0.5 m.kg. --- lbft)

INSTALLATION

1. Install:
• Starter motor - ¿
ç
è NOTE:
Apply a lightly grease to the O-ring.

2. Install:
• Starter motor bolts À
¿ • Starter motor lead Á
À

Bolt (Starter Motor) :

Á 7 Nm (0.7 m.kg.)

7-20
 TRBL
SHTG

CHAPTER 8

TROUBLE SHOOTING

BRAKE ........................................................................................8-1
• NOISY
• POOR BRAKE EFFICIENCY
• PADS NOT RETURN TO ORIGINAL POSITION

STARTER MOTOR ...................................................................... 8-2

• NOT WORKING
• MOVEMENT SLOW
• DO NOT ROTATE ENGINE EFFICTIVELY
 TRBL
STARTING FAILURE / HARD STARTING SHTG
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the related procedure in this manual for inspection,
adjustment and replacement of parts.

BRAKE

BRAKE NOISY BRAKE PADS NOT RETURN TO

ORIGINAL POSITION
• Glazed brake pads
• Week Return Spring (Master Cylinder).
• Excessive brake disc run out
• Blocked-Vent Hole / Return Port / cylinder
• Barke caliper incorrectly installed
Outlet / Inlet Port (Master Cylinder).
• Pad Worn out.
• Piston (Master Cylinder) movement
sticky.

POOR BRAKE EFICIENCY

• Low level of Brake Fluid.

• Leakage of Brake fluid thru hose pipe &

joints.

• Oily Brake Disc.

• Leakage of Brake fluid due to damaged

seal position & seal wiper (Brake Caliper).

• Air entrapped in the system.

• Damaged Primary Cup / O-ring (Master

Cylinder)

• Blocked-Air Vent, Return Port, Intake Port

and Cylinder Outlet (Master Cylinder).

• Excessive free play at Brake lever.

• Improper grde of Brake fluid.

• Worn out pads.

• Pistons (Brake caliper) - Movement

Sticky

• Glazed Pads.

8-1
 TRBL
POOR IDLE SPEED PERFORMANCE SHTG

STARTER MOTOR

STARTER MOTOR NOT WORKING STARTER MOTOR DO NOT ROTATE

ENGINE EFFECTIVELY
• Battery discharged
• Teeth damaged
• Fuse blown off
- Gear Idle-1
• Main switch defective
- Gear Idle-2
• Kill switch defective
- Motor shaft
• Start switch defective

• Neutral switch defective

• Crank shaft rotation sticky
• Clutch switch defective (if engine is in gear)
• Battery not fully charged
• Relay-A defective
• Carbon deposite in switches
• Starter Relay - defective
- Main Switch
• Starter motor defective
- Kill Switch
• Improper earthing / loose connections
- Start Switch

STARTER MOTOR MOVEMENT-SLOW - Neutral Switch

• Battery not fully charged - Clutch Switch

• Carbon deposite in switches

- Main Switch • Motor defective

- Kill Switch - Carbon bushes worn out

- Start Switch - Motor-shot

- Neutral Switch - Armature weak

- Clutch Switch - Damaged bearing/bush

• Motor defective

- Carbon bushes worn out • Improper earthing / loose connections

- Motor-shot
- Armature weak
- Damaged bearing/bush
• Improper earthing / loose connections

8-2
YAMAHA MOTOR INDIA PVT. LIMITED
19/6, Mathura Road, Faridabad - 121 006 INDIA

PRINTED IN INDIA
5YY (FAZER)
1Y16(WM-01)-213-03-05-E
SUPPLIMNTARY SERVICE MANUAL MARCH’05

E
IN
SP