Yamaha Fz 09 2014 Manual

							page 7-15. 
• Air  filter  case 
Refer  to 
GENERAL  CHASSIS on page  4-1. 
•Fue l tank 
Refe r 
to 
FUEL TANK  on  page  7-1. 
•R ide r seat 
Refe r to 
GENERAL  CHASSIS on page  4-1. 
,...,.., 
ADJUSTING THE VALVE CLEARANCE 
The following procedure  applies to all of the 
va lves. 
TIP--------------­
Va lve  clearance  adjustmen t should  be made  on 
a  cold  engine , a t  room  tempe ra ture. 
1.  Remove: 
•Ride r seat 
Refe r to 
GENERAL  CHASSIS on page  4-1. 
•Fue l tank 
Refe r 

to 
 FUEL TANK  on  page  7-1. 
• Air 

fil ter  case 
Refer  to 
GENERAL  CHASSIS on page  4-1. 
• Air  cut-off  valve 
Refer  to 
AIR  INDUCT ION  SYSTEM on 
page  7-15. 
• Rad iator 
Refer  to RADIATOR on page 6-1 . 
2.  Remove: 
• Ignit ion  coils 
• Spark plugs 
• Cylinder  head cover 
• Cylin der  head  cover  gasket 
Refer 
to  CAMSHAFTS  on page 5-9. 
3.  Remove: 
• Tim ing  mark  access ing  bolt 1  
• 
Crankshaft  end  cover 2 
4.  Measure: 
• Valve  clea ran ce 
Out of  specifica tion --+Ad just. 
3-5 
PERIODIC  MAINTENANCE 
Valve clearance (cold) 
Intake 
0.11--0.20 mm (0 .0043--0.0079 in) 
Exhaust 
0.26--0.30 mm (0.0102--0.0118 in ) 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a.  Turn  the crankshaft  counter clockw ise. 
b. When  piston  #1  is at TDC  on the  compres­
s ion  stroke , a
lign  the  TDC  mark a on  the 
generator  rotor wi th  t
he generator  rotor  cover 
mark b. 
TIP---------------
TDC on the  compression  stroke  can  be found 
when  the camshaft  lobes  are turned  away from 
each  other. 
c.  Measure  the valve  clearance  with  a th ickness 
gauge 
1 . 
Thickness gauge 
90890-03180 
Feeler  gauge set 
YU-26900-9 
TIP--------------~ 
• If th e  va lve clearance  is incorr ect,  reco rd  t he 
measured read ing. 
• Measure  the  valve  cleara nc e in  th e followi ng 
sequence. 
Valve  clearance 
measuring sequence 
Cylinder #1 --+ #2 --+ #3  
						

							000 
#1 #2  #3 
A. Front 
d.  To  measure  the 
va lve  clea rances o f the  oth er 
cy lin ders , starting  with cyl inder #1 at  TDC , 
tum  the cranks haf t  cou nterclockw ise 
as 
specified  in  th e follo wing  table. 
B o · 240·  4ao· 120· 
~~> l>----+-1 --+- I ____,I 
#1 D 
c #2 D 
#3 D 
B. Degrees that the c ranksha ft is  turned coun­
t
erclockwis e 
C. Cylinde r 
D. Com bustion cyc le 
Cyl in der 
#2  240° 
Cylind er #3 480° 
••••••••••••••••••\
•••••••••••••• 
5.  Remove: 
•Cam shaft 
TIP---------------
• Refer t o CAMSHA FTS  on  page  5-9. 
• When  removi ng  the  tim in g  cha in  and cam ­
shafts , faste n  th e tim ing  cha in  with  a wire  to re­
trieve  it if  it fa lls in to  the  crankcase. 
6. 
Adju st: 
• Va lve  clearance 
••••••••••••••••••\
•••••••••••••• 
a. Remove  the valve li fter 1  and  the valve pad 
2 with  a valve  lapper 3. 
3-6 
PERIODIC  MAINTENANCE 
1 
Valve lapper 
90890-04101 
Valve lapping  tool 
YM·A8998 
TIP---------------
• Cover  the tim ing  chain  opening with a rag  to 
prevent  the 
valve pad from falling in to  the 
crankcase. 
• Make  a note of th e pos it ion  of  each valve lifter 
1   and va lve pad  2 so that  they  can be in­
stalled 
i n  th e co rre ct place. 
1 3 
EX 
IN 
2 1 
b. Ca lculate the diffe ren ce  betwee n the speci · 
lied  valve  clearance 
and  the measured valve 
c learance. 
Examp le: 
Specified va lve  clearance = 0 .1 1-0.20 mm 
(0 .004-0.008 in) 
Measured 
va lve  clearance= 0.25  mm (0.01 O 
in) 
0 .2 5  mm 
(0.01 O  in)-0.20 mm (0 .008 in )  = 
0.05 mm (0.002 in) 
c .  Check  the thickness  of the 

c u rren t 
valve pad. 
TIP--------------­
T he  th ick ness a  of eac h valve pad  is  marked  in 
h undred ths of 
millimeters on  the  sid e that touch· 
es the va lve  lifter. 
Examp le: 
I f 
the va lve pad  is marked 15 8, the  pad 
th ickn ess  is 1.58  mm 
(0.062 in ).  
						

							158 
~--~~ 
a 
d-Calculate the sum  of the values obta ined  in 
steps  (b) and  (c) to 
detenn ine  the  requ ired 
va lve pad  thickness  and the valve pad num ­
ber. 
Examp le: 
1 .58 mm (0.062 in) + 0 .05 mm (0.002 in)  = 
1 .63 mm (0.064 in) 
T he 
valve pad  numbe r is 163. 
e.  Round  off the valve pad  numbe r acco rding  to 
the 
follow ing table , and  the n selec t the suit­
able  va lve pad. 
Last  dig it  Rounded 
value 
0, 1,2 0 
3 ,4 ,5 ,6  5 
7,8,9 10 
TIP~~~~~~~~~~~~~~~ 
Refer to the follow ing  table for  the available 
va lve 
pads. 
Valv e pad  range  Nos. 120-240 
Valve pad thickness 1.20-2.40 mm 
(0.0 47---0.094 in ) 
25 thicknesses  in 
Availab le  valve pads 0.05 mm (0.002 in ) 
i ncremen ts 
Example: 
Valve pad number= 163 
Rounded 
value = 165 
New va lve pad  number  = 165 
f. Install the  new valve pad 1 and  the valve  li ft­
er  211• 
TIP~~~~~~~~~~~~~~-
• Lubr icate  the valve pad with molybde num di­
su lfide  oil. 
• 
Lubr icate  the valve  lifter (T op  side)  with mo lyb­
de num disul fide  oil. 
• 
Lubr icate  th e va lve  lifter (Ou te r side)  with en­
gine o il. 
•  Install 
the va lve  lifte r an d  the va lve pad  in the 
co rrec t 
place . 
3-7 
PERIODIC  MAINTENANCE 
• The va lve  lifter mus t t urn smoothly when  rota t­
ed 
by ha nd. 
g. Install the  exhaust  and in take  camshafts,  tim­
in g chain  and camshaft  caps. 
Camshaft cap bolt 
10 Nm (1 .0  m·kgf, 7.2 ft ·lbf) 
TIP~~~~~~~~~~~~~~~ 
• Refer  to CAMSHAFTS on  page 5-9. 
• Lub rica te  the  cams haft lobes and  cams haft 
journa ls. 
• 
First, i nstall the 

exhaust camshaft . 
• Align the 

camshafts marks with  the camshaft 
cap  marks . 
• Turn the crankshaft  counterclockwise several 
fu
ll turns to seat  the parts. 
h. Measure the valve  clearance again. 
1. If the valve  clearance is still out of specifica­
tion,  repeat all of the valve  clearance  adjust­
ment steps until the specified  clearance is 
obtained. 
••••••••••••••••••\
•••••••••••••• 
7. Install: 
•  All 
removed  parts 
TIP~~~~~~~~~~~~~~~ 
For installation, reve rse the removal procedu re . 
EAS1AC1311 
CHECKING THE ENGINE IDLING SPEED 
TIP~~~~~~~~~~~~~~~ 
Prior to ad justing  the engine i dling speed,  the 
throttle body synchronizat ion should be  adjusted 
proper ly, the  air filter  element  should be clean, 
and the engine should have  adequate compres­
sion. 
1. Start the e ngine  and let it  wann  up for several 
minutes. 
2. Check: 
• Eng ine i dling speed 
Out of specificat ion -+ Go to  nex t step.  
						

							3. Check: 
Engine idling speed 
1100-1300 r/min 
•  ISC  (id le speed contro l) learn ing value 
00 or 01 4 Check the  in ta ke  system. 
02 4 C lean the th rottle bodies. 
Refe r to CHECKING AND C LEANING THE 
THROTILE BODIES  on page 7·8 . 
••••••••••••••••••\
•••••••••••••• 
a.  Connec t th e Yamaha d iagnost ic tool. 
Use t h e d iagn ostic code number 67. 
Refe r  to S E LF-DIAGNOSTIC  FUNCTION 
AND DIAGNOS TIC CODE TABLE  on  page 
9-5. 
b.  Check  the ISC  (idle speed control) lean in g 
value. 
E AS1 AC1318 
SYNCHRONIZING THE THROTILE BODIES 
TIP~~~~~~~~~~~~~~~ 
Be fore synchron iz ing the thro ttle bodies , check 
the  following  it
ems: 
• Va lve  clearance 
• 
Spark pl ugs 
• Air filter  elemen t 
•  Th r
ottle body join ts 
• Fue l hose 
• Exhaust  system 
• Breather  hoses 
Checking the throttle body synchronization 
1. Stand the vehicle o n  a leve l su rface. 
TIP~~~~~~~~~~~~~~-
Place the  veh icle  on a suitable stand. 
2.  Remove: 
•R ide r seat 
Refer  to GENERAL  CHASSIS on page 4· 1. 
•Fue l tank 
Refer  to 
FUEL TANK on  page 7-1. 
• 
Air filter case 
Refer  to 
GENERAL  CHASSIS on page 4· 1. 
3. Remove: 
• Caps 1 
3-8 
PERIODIC  MAINTENANCE 
4. Install: 
• 
Vacuum gauge 1 
5. Install: 
Vacuum gauge 
90890-03094 
Vacuummate 
VU- 44456 
• 
Air filter case 
Re fe r to GENERAL CHASS IS  on  page  4-1. 
•Fue l tank 
Re f
er to FU EL TANK on  page  7-1 . 
6.  Check: 
•Throttle body  synchronization 
••••••••••••••••••\
•••••••••••••• 
a. Start the  engine,  warm  it up for sever a l min· 
u tes,  and  then let it  ru n  at  the specified en­
gine id ling speed. 
E
ngine idling speed 
1100-1300 r/min 
b.  Check  the vacuum  pressure. 
The difference In vacuum pressure 
between the throttle bodies should 
not exceed 1.33 kPa (10 mmHg). 
If ou t of specificat ion 4 Ad just  the thrott le 
body  synchroniza tion.  
						

							Adjusting the throttle body synchronization 
1. Adjust: 
•Throttle body  sy nch ro nizatio n 
••••••••••••••••••\
•••••••••••••• 
a. Start the  engine,  warm  it  up  for seve ra l m in -
u tes,  and  then 
let it run  at  th e  spec if ied  en ­
g in e 
idli ng sp eed . 
Engine idling speed 
1100-1300 r/mln 
b . Usin g the throttle b ody tha t has the  byp ass  air 
screw 1 wi th  a white pain t mark  as  th e stan­
dard , adj ust  the  othe r 
thrott le bodies b y  tu rn­
i n g  its  byp a
ss air screw in or ou t. 
ECA1ACl301 
NOTICE~~~~~~~~~~~~ 
Do not turn the bypass air screw (white paint 
mark) of the throttle body that is the stan­
dard. Otherwise, the engine may run roughly 
at idle and the throttle bodies may not oper­
ate properly. 
TIP~~~~~~~~~~~~~~~ 
•Turn th e bypass  air  sc rew usin g  th e carb ureto r 
angle dr iver. 
• Afte r each  step ,  rev  the  engine two or th ree 
ti m es,  each  time  for 
le ss tha n a 

s
econd, an d 
ch eck  the  synchron iz
ation  aga in . 
•  If a  byp ass  air screw was  remove d, tu rn  the 
screw  in 
f u lly and  be sure  to sync hron ize  the 
thrott le bod ies. 
•  If the th rottle body  synchr onizat ion  can  not be 
ad justed  using  t
he bypass  air screw , clean or 
rep lace the throttle bod ies. 
• T he  difference in vacuum  press ure betwee n 
the 
th ro ttle bod ies should no t exceed  1.33 kPa 
(10 mmHg). 
Carburetor angle driver 2 
90890-03173 
3-9 
PERIODIC  MAINTENANCE 
2. Sto p the  engine  and remov e th e  m easu ring 
e quipme n
t. 
3. Install: 
•Caps 
4. Install: 
• 
Air fil te r case 
Re fe r  to 
 GENERA L CHASSIS  on  pag e  4-1. 
•Fue l ta nk 
Re fe r  to 
FU E L TA NK on page  7-1 . 
•Ri der seat 
Re fe r 

t o 
GE NER AL 

C HA SSIS 
o n  page  4-1. 
5. Adj ust: 
•  Th rottle grip  free play 
Re fe r  to CHECKI NG THE  TH ROTTLE 
GRIP on  page 3-28. 
Throttle grip free play 
3.0-5.0 mm (0 .12-0.20 in) 
CHECKING THE  THROTTLE BODY  JOINTS 
1. Rem ove : 
•  Th rottle bodie s 
Reier to  TH ROTT LE BOD IES on page 

7-
5. 
2.  Check: 
• Th rottle bod y join ts 1 
Cra cks/d am ag e ~ Rep lace. 
3. Inst all: 
•  Th rottle 
bodi es 
R efe r 

t o  T HROTT LE 
BOD IES  on  page  7-5. 
 CHECKING THE CANISTER (for California 
only) 
1 .  Remove: 
•Rid er seat 
R efe r 
to 
GE NERA L CH ASS IS o n  page  4-1. 
• Fue l ta nk 
Reier to FU EL T AN K on pag e  7- 1 . 
2.  Check: 
•Canis ter 
• 
Can is ter  purge  hose 
• Fue l ta nk  bre ath er hose 
• Can ist er  breat he r  hos e  
						

							Crac ks/d amage -> Rep lace . 
3. Install: 
• Fue l 
ta n k 
Refe r 

t o 
 FUEL TA NK  on  page  7-1. 
• R ide r sea t 
Refe r to 
 G ENE RAL  CHASSIS  on page  4-1. 
EAS 1A C130& 
CHECKING THE AIR  INDUCTION  SYSTEM 
Refer  to C HECKING THE AIR  INDUCTION 
SYSTEM 
on  page  7-18. 
EA~IO:icl 
CHECKING THE CYLINDER HEAD 
BREATHER 
HOSE 
1.  Remove : 
•A ir  filter ca se 
Refe r to 
G EN ERAL  CHASSIS  on  page  4-1. 
2.  Chec
k: 
• Cy lin de r hea d breat her  hose  1 
Cracks/damage 
-> Replace. 
Loose  connectio n -> Conn ect  properly. 
ECA14920 
NOTICE ----------­
Make sure the cylinder head breather hose is 
routed  correctly. 
3. 
Ins tall: 
• A ir  filter 
ca se 
Refe r to 
 G ENE RAL  CHASSIS  on page  4-1. 
EAS20!ir01 
REPLACING THE AIR  FILT ER E LEMENT 
1.  Remove: 
•R ider seat 
Re f
er to GE NERAL  CHASSIS  on pag e 4-1. 
•Fue l ta nk 
Re f
er to  FUEL TA NK on  page  7-1. 
2.  Remove : 
• E C U (engine cont ro l u nit ) 1 
• 
A ir fi lter c ase  cover 2 
Refe r to GE NERAL  CHASSIS  on page  4-1. 
PERIODIC  MAINTENANCE 
3. Check: 
• Air fil te r elemen t 1 
• 
A ir fil ter seal 
Damage 
-> Rep lace. 
TIP
--------------
•  Replace th e air fil t er  eleme nt every 37000 km 
(24000 mi)  of opera tion. 
• The  air fil ter needs  more freq ue nt  serv ice  if  yo u 
a re  rid
ing in u nu sually  we t or dusty  areas. 
4. 
Install: 
• 
Air filte r elemen t 
• 
A ir filter case  cover 
• ECU (eng in e co ntr ol unit) 
EC.A.14401 
NOTICE 
Never  operate the engine without the air filter 
element Installed . Unfiltered air wlll cau se 
rapid 
wear of engine parts and may damage 
the engine.  Operating the engine without the 
air filter element will also affect throttle bod· 
ies synchronization,  leading to poor engine 
performance and possible overheating. 
TIP------------­
W he n installing  the  air fil ter e lemen t in to  the air 
filter case 

cover, 
mak e  sur e that the sea lin g sur­
faces  are alig n ed to  preve nt  any  air leaks. 
5. 
Install: 
• Fue l 
ta nk 
Re fer  to 
FU EL TANK  on page  7 -1 . 
•Rider seat 
Re fe r 

t o 
 GENERA L CHASS

I S  
on  page  4-1 . 
3-10  
						

							,..,,.,. 
ADJUSTING THE CLUTCH LEVER FREE 
PLAY 
1. Check: 
• C lut ch  leve r free pla y  a 
Out of speci fica tion -> Ad just. 
Clutch lever free play 
10.0-15.0 mm (0 .39-0.59 In) 
2.  Adjust: 
• C lu tc h  lever free p la y 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
Handlebar side 
a.  Turn  the adjusting bo lt  1 in  directio n a or 
b until the specified Clutch  lever free play i s 
obtain ed. 
Direction a 
Clutch lever free play Is Increased. 
Direction b  
Clutch lever free play is decreased. 
1 
TIP--------------­
lf the  specified clu tc h  lever free play cannot  be 
obtained  on the 
handlebar side  of the cab le, use 
the  adjusting nut on the engine  side. 
••••••••••••••••••\
•••••••••••••• 
••••••••••••••••••\
•••••••••••••• 
Engine side 
a. Loose n the lockn ut 1 . 
b. 
Tum t h e  adjus ti n g n ut 2 in  direct ion a or  b  
u n til 
the  specified clutch  lever free p la y i

s 
ob-
3-11 
PERIODIC  MAINTENANCE 
tained. 
Direction a 
Clutch lever free play Is Increased. 
Direction b 
Clutch lever free play is decreased. 
c.  Tighte n the locknut 1 . 
Locknut 
7 Nm (0.7 m ·kgf, 5.1 ft·lbf) 
E.ASIFOC1307 
CHECKING THE BRAKE OPERATION 
1. Check: 
• Brake  operat ion 
Brake  not work i
ng prope rly -> Check the 
brake  system. 
Refer  to 
FRONT B R AKE  on page 4-20 and 
REAR 

BRAKE 
on  page  4-32. 
TIP
--------------­
D rive  on the dry road,  operate  the fron t and  rear 
b ra kes 
separate ly and  check  to see  if the  brakes 
a re  operating 
prope rly. 
CHECKING 
THE BRAKE FLUID LEVEL 
1. Stand  the vehicle on a level surface. 
TIP--------------
•  Pla ce the v e hicl e on a suit able s ta nd. 
• Make  su re  the veh icle is  up right. 
2.  Check: 
• Brake fluid  level 
Be l
ow the  minimum level mark   a -> Add the 
specified  brak e fluid to  the prope r level. 
Front brake 
Specified brake fluid 
DOT4 
Rear brake 
Specified brake fluid 
DOT4  
						

							A. Front brake 
B. Rear brake 
EWA \3000 
AwARNING 
•  Use only the  designated  brake fluid. Other 
brake fluids may cause  the rubber  seals to 
deteriorate,  causing leakage and poor 
brake performance. 
• Refill with  the same type of brake  fluid that 
is already in the system.  Mixing brake fluids 
may result in a harmful  chemical  reaction, 
leading 
to poor brake  performance . 
• When refilllng, be careful  that water does 
not enter the brake  fluid reservoir.  Water 
will significantly  lower the boiling point of 
the brake  fluid and could  cause  vapor lock. 
ECAI~ 
NOTICE ~~~~~~~~~~~~-
Br a k e  fluid  may damage  painted surfaces 
and  plastic  parts. Therefore,  always clean 
up 
any spilt brake fluid immediately. 
TIP--------------­
ln order  to  ensure  a correct  reading  of the  brake 
fluid leve l, make  sure the top of the  brake fluid 
reservo ir  is  horizonta l. 
EA$?1U50 
ADJUSTING THE FRONT DISC BRAKE 
1.  Adjus
t: 
• Brake lever pos it ion 
(d istance 
a from 

the 
throttle  grip to the brake 
lever) 
PERIODIC  MAINTENANCE 
TIP~--------------
• While pushing  the brake  leve r forward, turn  the 
ad just i
ng dia l 1   un til the  brak e lever  is in  the 
desired  posit io
n. 
• Be sure to al ign  the  setting on  the  adjusting dial 
with  the arrow mark 2  on the  bra ke lever  hold­
er. 
Position 
#1 
Distanc e a is the largest. 
Position #5 
Distance a is the smallest. 
A WARNING 
• After adjusting the brake  lever position , 
make  sure 
the pin on the  brake lever holder 
is firmly  inserted in the hole in the adjusting 
dial. 
• A soft or spongy feeling in the  brake  lever 
can 
Indicate the  presence of air In the brake 
system.  Before 
the vehicle is operated , the 
air must be removed by bleeding  the brake 
system.  Air 
in the brake system will consid­
erably  reduce  brake performance  resulting 
in loss of control and possibly cause an ac­
cident.  Therefore , check  and if necessary , 
bleed 
the brake  system. 
NOTICE 
After  adjusting the brake  lever position , 
make  sure there  is 
no brake  drag. 
EA$212$0 
CHECKING  THE FRONT BRAKE PADS 
The following proc edure applies to all of  the 
brake  pads. 
1 . 
Operate the  brake. 
2.  Check: 
• Front brake  pad 
3-12 
Wear  in d ica tors 1  almost touch  the brake 
d isc 
~ Replace the  brake  pads as a set. 
Refer 
to  FRONT  BRAKE on page 4-20.  
						

							1 1 
EA$Zllll0 
ADJUSTING THE REAR DISC BRAKE 
1. 
Adjust: 
• Brake  pedal pos itio n 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a.  Loosen  the loc kn u t 1 . 
b.  Tum  the adjus ting bo lt  2  in  directio n a or 
b  until the  spec ified  brake peda l pos it ion is 
obt a ined. 
Direction 
 a  
Brake  pedal is raised. 
Direction 
 b  
Brake  pedal is lowered. 
EWA\3010 
AwARNING 
After  adjusting the brake  pedal position, 
check that the end  of the  adjusting bolt c  is 
visible through the hole d . 
c. T ig hten th e locknut 1 to specificat ion. 
Locknut 
18 Nm (1.8 m ·kgf, 13 ft· lbf) 
EWAI A C l300 
A WARNING 
A soft or spongy feeling in the  brake  pedal 
can  indicate  the presence 
of air in the brake 
system.  Before 
the vehicle is operated , the 
air 
must be  removed by bleeding  the brake 
system. 
Air in the brake  system will consid­
erably  reduce  braking  performance . 
NOTICE ------------­
After adjusting the brake  pedal position, 
make  sure there 
is no brake  drag. 
PERIODIC  MAINTENANCE 
••••••••••••••••••\
•••••••••••••• 
2. Adjust: 
• Rear brake li gh t sw itch 
Ref er  to ADJUSTI NG THE REAR BRAKE 
LIGH T  SWITCH  on page 3-27. 
EA$212&0 
CHECKING THE  REAR  BRAKE PADS 
The follow ing p rocedure applies to all of  the 
brake  pads. 
1. Op erate the  brake. 
2 . C heck: 
• Rea r brake pad 
Wea r  ind ic ato r  groo ves 
1  a lmost  disap ­
peared ~ Replace the  brake  pads as a set. 
Refe r to REA R BRAKE on page 4-32 . 
1 
  BLEEDING THE HYDRAULIC BRAKE 
SYSTEM 
A WARN ING 
Bleed the hydraulic  brake system  whenever: 
• the system is disassembled . 
• a brake hose is loosened,  disconnected or 
replaced . 
•the brake fluid level is very low. 
• brake operation  is  faulty. 
TIP---------------
• Be  ca reful  not to spill any  brake fluid o r allow 
the  brak e mast er cylinde r reservo ir  or  brak e 
fluid re se rvoir to overf low. 
• When bleed in g the hyd ra ulic brake  system, 
make sure  the re  is a lways enoug h brak e fluid 
3-13  
						

							before apply in g the  brake. Ignor ing this  pre ­
cautio n could  allow air  to  ente r the hydr aulic 
brake  system, consi derably lengt he ning the 
b leed ing procedu re. 
• If  bleeding i

s 
diffi cult , it may b e  necessary  to let 
the  brak e fluid sett le for  a few  hours . Repeat 
the 
b leeding p rocedure w hen  the tiny bubb les 
in  th e  hose  have  di

sappeared. 
1. B leed: 
• 
Hydr a ulic brake  system 
••••••••••••••••••\
•••••••••••••• 
a. Fill th e  brake  master cylin der reservoir  or 
b ra
ke flu id reservoir  to the  proper leve l with 
the  speci fied  brake 
fluid. 
b. Inst all th e d iaphr agm  (bra ke master cylinder 
rese rvoir  or  bra ke fluid r eservo ir). 
c.  Connec t a clear  pla sti c h ose 1  tightly to  the 
bleed screw 2. 
1 
2 
A. Front 
B . Rear 
d. 
P lace the other end of the  hose  into a con­
ta iner. 
e. 
S lowly apply the  brake severa l times. 
f. Fully  pull the brake lever or fully press dow n 
the  brake 
peda l and hold i t  in posi t ion . 
g.  Loose n the 
blee d screw. 
TIP~~~~~~~~~~~~~~ 
Loosening  the bleed screw w ill  re lease the  pres­
sure  and  cause 
the  brake leve r to  contact  the 
thro ttle grip or the  brake peda l to fully extend. 
h. Tig hten  the bleed screw  and  the n release the 
brake 
leve r or brake pedal. 
PERIODIC  MAINTENANCE 
1. Repeat steps  (e) to  (h) un til  all of the  air  bub­
b les have  di

sappeared  from t
he brake fl u id in 
the 
p la sti c hose. 
J. T ighten  the bleed screw  to specifica tion. 
Brake caliper bleed screw 
5 Nm (0. 5 m·kgf, 3 .6 ft·lbf) 
k. F ill the bra ke master cyli nde r reservo ir  or 
brake 
fl ui d reservo ir  to  the  proper level w ith 
the  spec if ied  brake 
fluid . 
Re fe r  to  CHECKING THE BRAKE FLUID 
LEVE L  on  page 3-11. 
EWA13110 
,A WARN ING 
After bleeding the hydraulic brake system, 
check the brake operation. 
CHECKING THE FRONT BRAKE HOSES 
The following procedure applies t o all of the 
b rake  hoses  and brake  hose 
holde rs. 
1. Check: 
•Brake hose 
Cracks/damage
/wear -> Replace. 
2. Check: 
• Brake hose hol de r 
Loose -> Tig hte n the holder bolt. 
3. Hold th e vehicle upright a nd apply th e  brake 
severa l ti mes. 
4 . Check: 
• Bra ke hose 
B ra ke 
flui d leakage -> Replace the damaged 
hose.  Re f
er to FRONT BRAKE  on  page 4-20. 
EA$21290 
CHECKING THE REAR BRAKE HOSE 
1. Check: 
• Brake hose 
Cracks/damage
/wear -> Replace. 
2. Check: 
• Brake  hose holde r 
Loose  Connect ion 
-> T igh ten  the hol de r bol t. 
3. Hold the veh icle u prigh t and apply the  rear 
brake 
seve ral times. 
4. Check : 
•Bra ke hose 
3-14 
Brake flui d  leakage -> Rep lace the damaged 
hose . 
Re f
er to REAR BRAKE on  page  4-32.