2019

SUPPLEMENTARY

FZN250-A
FZF250-A

BC4-F8197-E1
 FORWARD
This supplementary service manual has been prepared to introduce new service and data for the
FZN250A & FZF250 2019 For complete information procedures it is necessary to use this
supplementary service manual together with the following manual.

FZN250 2017 SERVICE MANUAL: B97-F8197-E0

FZN250-A
FZF250-A
SUPPLEMENTARY SERVICE MANUAL
©2019 by India Yamaha Motor Pvt. Ltd.
First edition, April 2019
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
EAS20071

IMPORTANT
This manual was produced by the India Yamaha Motor Pvt. 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.
India Yamaha Motor Pvt. 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,

WARNING could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

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.
l The manual is divided into chapters and each chapter is divided into sections. The current sec-
tion title “1” is shown at the top of each page.
l Sub-section titles “2” appear in smaller print than the section title.
l To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
l Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step.
l Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.
l A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
l Jobs “7” requiring more information (such as special tools and technical data) are described
sequentially.

2
4

5
6 7

G088877
EAS20101

SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.

SYMBOL DEFINTION SYMBOL DEFINTION

Serviceable with engine mounted Molybdenum disulfide oil

M

Filling fluid Brake fluid

BF

Lubricant B Wheel bearing grease

Special tool LS Lithium-soap-based grease

Tightening torque M Molybdenum disulfide grease

T.
R.

Wear limit, clearance S Silicone grease

Engine speed Apply locking agent (LOCTITE®).

LT

Electrical data Replace the part with a new one.

Engine oil
E
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
FUEL SYSTEM 6
ELECTRICAL SYSTEM 7
 GEN
INFO
CHAPTER 1
GENERAL INFORMATION

FEATURES...................................................................................................... 1-1
OUTLINE OF THE ABS............................................................................. 1-1
OUTLINE OF THE ABS............................................................................. 1-2
ABS COMPONENT FUNCTIONS ............................................................. 1-6
ABS OPERATION ...................................................................................1-11
ABS WARNING LIGHT AND OPERATION............................................. 1-14
INDICATOR LIGHTS AND WARNING LIGHT ........................................ 1-16
MULTI-FUNCTION DISPLAY.................................................................. 1-16

SPECIAL TOOLS .......................................................................................... 1-19

GEN
INFO
 GEN
FEATURES INFO
GENERAL INFORMATION

EAS20008
FEATURES

FEATURES (for FZ25-ABS)

EAS30683

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. ABS test coupler 9. Rear wheel sensor rotor

2. ABS solenoid fuse 10. Rear wheel sensor
3. ABS motor fuse
4. ABS control unit fuse
5. ABS warning light
6. Front wheel sensor rotor
7. Front wheel sensor
8. Hydraulic unit assembly

1-1
 GEN
FEATURES INFO
EAS20008

FEATURES (for FAZER25-ABS)

EAS30683

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. ABS test coupler 10. Rear wheel sensor

2. ABS solenoid fuse
3. ABS motor fuse
4. ABS control unit fuse
5. ABS warning light
6. Front wheel sensor rotor
7. Front wheel sensor
8. Hydraulic unit assembly
9. Rear wheel sensor rotor

1-2
 GEN
FEATURES INFO
ABS
The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with
a brake lever for operating the front brake and a brake pedal for operating the rear brake.
When wheel lock is detected during 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.
Slip ratio = (Chassis speed – Wheel speed)/Chassis speed  100 (%)
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).
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 keep-
ing 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 surfac-
es. See figure “B”.
A B
b e

f
a a
c

g
(%) d (%) d
a. Friction force between the tire e. Less slippery road surface
and road surface f. Controlling zone
b. Brake force g. Slippery road surface
c. Side force
d. Slip ratio

1-3
 GEN
FEATURES INFO
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 de-
termines 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 hydraulic pressure in the brake caliper. Once the ABS ECU determines that the tendency
of the wheel to lock has diminished after the hydraulic 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.

b A

A
B
B A
B

A
c A
A

B B B

d e d e d e

a. Chassis speed
b. Wheel speed
c. Brake force
d. Depressurizing phase
e. Pressurizing phase
ABS operation and vehicle control
If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the
limit of control. To make the rider aware of this condition, the ABS has been designed to generate a
reaction-force pulsating action in the brake lever and brake pedal independently.

TIP
When the ABS is activated, a pulsating action may be felt at the brake lever or brake pedal, but this
does not indicate a malfunction.

1-4
 GEN
FEATURES INFO
The higher the side force on a tire, the less traction there is available for braking. This is true whether
the vehicle is equipped with ABS or not. Therefore, sudden braking while cornering is not recommend-
ed. Excessive side force, which ABS cannot prevent, could cause the tire to slip sideways.
EWA16510

WARNING
The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even in vehicles equipped with ABS, overturning of the vehicle cannot be prevented
if it is braked suddenly.

The ABS functions to prevent the tendency of the wheel to lock by controlling the hydraulic pressure.
However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking,
the ABS may not be able to prevent the wheel from locking.
EWA13870

WARNING
The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The
ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine
braking, even if the ABS is operating.

(%)

a. Friction force between the tire and road

surface
b. Brake force
c. Side force
d. Slip ratio
Electronic ABS features
The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic
technology.
The ABS control is processed with good response under various vehicle travel conditions.
The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con-
dition and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and trou-
bleshooting.

1-5
 GEN
FEATURES INFO
ABS block diagram

3
2

4 4

6 5 6

7 7

8
9 9

10 13

11 14
12

1. Rear brake master cylinder 9. Buffer chamber

2. Hydraulic unit assembly 10. Rear brake caliper
3. Front brake master cylinder 11. Rear wheel sensor
4. Inlet solenoid valve 12. ABS warning light
5. ABS motor 13. Front brake caliper
6. Hydraulic pump 14. Front wheel sensor
7. Outlet solenoid valve
8. ABS ECU

EAS30684

ABS COMPONENT FUNCTIONS

Wheel sensors and wheel sensor rotors
Wheel sensors “1” detect the wheel speed and transmit the rotation signal to the ABS ECU.
Each wheel sensor is composed of a permanent magnet and a hall IC. The sensor rotors “2” rotate with
the wheels. The sensor rotors “2” have 40 slots and are installed close to the wheel sensors. As the
sensor rotor rotates, the hall element in the hall IC installed in the wheel sensor generates pulses. The
pulse frequency, which is proportional to the wheel speed, is converted into a wave in the hall IC so that
it can be output.
The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency.

1-6
 GEN
FEATURES INFO

7 3 7 4

8 8
5

3. At low speed 7. Voltage

4. At high speed 8. Time
5. Wheel sensor
6. Wheel sensor rotor

ABS warning light

The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs.
When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit
and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function
check is properly completed at a speed of about 10 km/h (6.3 mi/h)).
TIP
After all checks and servicing are completed, the ABS warning light will go off when the vehicle is ridden
or pushed at a speed of 10 km/h (6.3 mi/h) or faster.
ECA20950

NOTICE
If the rear wheel is raced with the vehicle on a centerstand, the ABS warning light may flash or
come on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation
is normal if the ABS warning light goes off after the vehicle starts off. If the fault codes are not
deleted, the ABS warning light goes off after the vehicle is ridden at a speed of about 30 km/h
(19 mi/h).

1-7
 GEN
FEATURES INFO

ABS

Hydraulic unit assembly

The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid
valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The
hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according
to signals transmitted from the ABS ECU.

Hydraulic control valve

The hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve.
The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle
control voltage that is supplied to it. Since this voltage is continuously variable, the solenoid valve
moves smoothly and the hydraulic pressure is adjusted linearly.
1. When the brakes are operated normally, the inlet solenoid valve “1” is open and the outlet solenoid
valve “2” is closed. The brake line between the brake master cylinder and brake caliper is open.

3. Brake master cylinder

4. Brake caliper
2. When the ABS is activated, the inlet solenoid valve “1” closes and the outlet solenoid valve “2” opens
using the power supplied from the ABS ECU signals. This reduces the hydraulic pressure.

1-8
 GEN
FEATURES INFO

3. Brake caliper
4. ABS motor
3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve
“2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic
pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and
the brake fluid in the lower brake lines (brake caliper side).

Buffer chamber
The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating.

1. Buffer chamber (pressurizing phase)

2. Buffer chamber (depressurizing phase)
3. Raised piston
ABS ECU
The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design.
As shown in the following block diagram, the ABS ECU receives wheel sensor signals from the front
and rear wheels and also receives signals from other monitor circuits.

1-9
 GEN
FEATURES INFO

1. Battery 14. ABS ECU

2. AC magneto 15. ABS motor relay
3. Rectifier/regulator 16. Solenoid relay
4. Main fuse 17. Front brake outlet solenoid
5. ABS motor fuse 18. Front brake inlet solenoid
6. ABS solenoid fuse 19. Rear brake outlet solenoid
7. Main switch 20. Rear brake inlet solenoid
8. ABS control unit fuse 21. ABS motor
9. Rear brake light switch 22. Meter assembly
10. Front brake light switch 23. ABS warning light
11. Tail/brake light 24. ECU (Engine Control Unit)
12. ABS test coupler 25. Front wheel sensor
13. Hydraulic unit assembly 26. Rear wheel sensor

The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the
hydraulic unit assembly.
ABS control operation
The ABS control operation performed in the ABS ECU is divided into the following two parts.
• Hydraulic control
• Self-diagnosis
When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for
easy problem identification and troubleshooting.

1-10
 GEN
FEATURES INFO
TIP
• Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS con-
trol unit fuse).
• The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and
if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal,
but these do not indicate a malfunction.

1
2

1. Software operation flow 6. Receive signals

2. Main switch “ON” 7. Control operation
3. Initialize 8. Depressurize/pressurize
4. Self-diagnosis (when static)
5. Self-diagnosis (when riding)

EAS30710

ABS OPERATION
The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de-
scribes the system for the front wheel only.
Normal braking (ABS not activated)
When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed
because a control signal has not been transmitted from the ABS ECU. Therefore, when the brake lever
is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent
to the brake caliper.
At this time, the inlet and outlet check valves of the hydraulic pump are closed. As a result of eliminating
the orifice, the brake master cylinder directly pressurizes the brake caliper during normal braking. When
the brake lever is released, the brake fluid in the brake caliper returns to the brake master cylinder.

1-11
 GEN
FEATURES INFO

7 6
5
8

9
10

11

12

13
1. Brake master cylinder 8. Brake caliper
2. Brake light switch 9. Wheel sensor
3. ABS motor 10. ABS ECU
4. Hydraulic pump 11. ABS warning light
5. Buffer chamber 12. Brake fluid pressure
6. Outlet solenoid valve 13. Time
7. Inlet solenoid valve

Emergency braking (ABS activated)

1. Depressurizing phase
When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization”
signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the
spring and closes the brake line from the brake master cylinder. Because the outlet solenoid valve
is open, the brake fluid is sent to the buffer chamber. As a result, the hydraulic pressure in the brake
caliper is reduced.
The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy-
draulic pump linked to the ABS motor.

1-12
 GEN
FEATURES INFO

1. Brake master cylinder 8. Brake caliper

2. Brake light switch 9. Wheel sensor
3. ABS motor 10. ABS ECU
4. Hydraulic pump 11. ABS warning light
5. Buffer chamber 12. Brake fluid pressure
6. Outlet solenoid valve 13. Time
7. Inlet solenoid valve

2. Pressurizing phase
The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At
this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve
opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the
brake caliper.

1-13
 GEN
FEATURES INFO

1. Brake master cylinder 8. Brake caliper

2. Brake light switch 9. Wheel sensor
3. ABS motor 10. ABS ECU
4. Hydraulic pump 11. ABS warning light
5. Buffer chamber 12. Brake fluid pressure
6. Outlet solenoid valve 13. Time
7. Inlet solenoid valve

EAS30712

ABS WARNING LIGHT AND OPERATION

ABS warning light
• If the ABS warning light comes on while riding, stop the vehicle, and then turn the main switch to
“OFF”, then back to “ON”. The ABS operation is normal if the ABS warning light goes off after the ve-
hicle starts off.
• If the rear wheel is raced with the vehicle on a centerstand, the ABS warning light may flash or come
on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation is normal if the
ABS warning light goes off after the vehicle starts off.
• The ABS operation is normal if the ABS warning light flashes.
• Even if the ABS warning light remains on and does not go off, or if it comes on after riding, conven-
tional braking performance of the vehicle is maintained.

1-14
 GEN
FEATURES INFO
ABS function
EWA16521

WARNING
• When hydraulic control is performed by the ABS, the brake system alerts the rider that the
wheels have a tendency to lock by generating a reaction-force pulsating action in the brake
lever or brake pedal. When the ABS is activated, the grip between the road surface and tires
is close to the limit. The ABS cannot prevent wheel lock* on slippery surfaces, such as ice,
when it is caused by engine braking, even if the ABS is activated.
Use extreme care when operating the vehicle under these conditions.
• The ABS is not designed to shorten the braking distance or improve the cornering perfor-
mance.
• Depending on the road conditions, the braking distance may be longer compared to that of
vehicles not equipped with ABS. Therefore, ride at a safe speed and keep a safe distance be-
tween yourself and other vehicles.
• The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even vehicles equipped with ABS cannot be prevented from falling over if braked
suddenly.
• The ABS does not work when the main switch is turned to “OFF”. The conventional braking
function can be used.
* Wheel lock: A condition that occurs when the rotation of one or both of the wheels has
stopped, but the vehicle continues to travel.

1-15
 GEN
FEATURES INFO
INDICATOR LIGHTS AND WARNING LIGHT WARNING
If the ABS warning light does not turn off af-
5 ter reaching 10 km/h (6 mi/h), or if the warn-
ing light comes on while riding:
l Use extra caution to avoid possible
ABS
wheel lock during emergency braking.
l Have a Yamaha dealer check the vehicle
as soon as possible.

ZAUE3746 EAU79723

MULTI-FUNCTION DISPLAY
1. Neutral indicator light “ ”
2. Engine trouble warning light “ ”
3. Turn signal indicator light “ ”
4. High beam indicator light “ ”
5. Anti-lock Brake System (ABS) warning light “ ABS ”

ABS

Turn signal indicator light “ ”

This indicator light flashes when a turn signal
ZAUE3747
light is flashing.
1. Multi-function display
2. Selection button “SELECT”

Neutral indicator light “ ” EWA12313

WARNING
This indicator light comes on when the trans-
mission is in the neutral position. Be sure to stop the vehicle before making
any setting changes to the multi-function
display. Changing settings while riding can
High beam indicator light “ ” distract the operator and increase the risk
of an accident.
This indicator light comes on when the high
beam of the headlight is switched on.
The multi-function display is equipped with the
following:
Engine trouble warning light “ ” • Speedometer
• Tachometer
This warning light comes on or flashes if a prob-
• Fuel meter
lem is detected in the engine. If this occurs,
• Odometer
have a Yamaha dealer check the vehicle as
• Two Tripmeters
soon as possible.
• Fuel Reserve Tripmeter
TIP • Instantaneous Fuel Consumption
When the vehicle is turned on, this light should • Average Fuel Consumption
come on for a few seconds and then go off. • Clock
Otherwise, have a Yamaha dealer check the • Self-diagnosis Device
electrical circuit.
Speedometer
The speedometer shows the vehicle’s travel-
ABS warning light “ ABS ” ing speed in kilometers per hour (km/h).
This warning light comes on when the vehicle is
first turned on, and goes off after starting riding.
If the warning light comes on while riding, the
anti-lock brake system may not work correctly.

1-16
 GEN
FEATURES INFO
Tachometer Odometer and tripmeters
A brief push (less than one second) on the
“SELECT” button alternately switches the dis-
play between the odometer “ODO” and tripme-
ters “TRIP 1” and “TRIP 2”, instantaneous fuel
consumption “Km/L”, average fuel consump-
tion “AVE_ _._ Km/L” and clock “CLOCK” in
the following order:
ZAUE3748

ODO  TRIP 1  TRIP 2  Km/L  AVE_ _._ Km/
1. Tachometer L  CLOCK  ODO
The tachometer shows the engine speed in
revolutions per minute (r/min) x 1000. The Odometer
tachometer is used to monitor the engine The odometer shows the total distance trav-
speed and keep it within the ideal power eled by the vehicle.
range.
ECAE0060 Tripmeters
NOTICE The tripmeter shows the total distance traveled
When the engine speed is 9251 r/min and since it was last reset.
above, all tachometer segments will flash. To reset a tripmeter, select it by pushing the
Do not operate the engine in this zone. “SELECT” button for one second.
TIP
Fuel meter • The odometer will lock at 999999 and cannot
be reset.
• The tripmeters will automatically reset and
continue counting after 999.9 is reached.

Fuel reserve tripmeter

The fuel reserve tripmeter shows the total dis-
tance traveled since the fuel level warning light
ZAUE3749 comes on.
1. Fuel meter
If the last segment of the fuel meter starts
flashing, the display automatically changes to
The fuel meter indicates the amount of fuel in the fuel reserve tripmeter mode “TRIP F” and
the fuel tank. The display segments of the fuel starts counting the distance traveled from that
meter disappear from “F” (full) towards “E” point. In this case, push the “SELECT” button
(empty) as the fuel level decreases. When to switch the display between the various trip-
approximately 2.1 L (0.55 US gal, meter, odometer, instantaneous fuel consump-
0.46 Imp.gal) of fuel remains, the last segment tion and average fuel consumption in the
of the fuel meter and the fuel level warning following order:
indicator “ ” will start flashing. When this 
occurs, refuel as soon as possible. TRIP F  TRIP 1  TRIP 2  Km/L  AVE_
TIP
_._ Km/L  CLOCK  ODO  TRIP F
If the last segment continues to flash after fuel- TIP
ing, or if all segments are flashing, have a You can manually reset the fuel reserve trip-
Yamaha dealer check the electrical system. meter, or after refueling and traveling 5 km
(3 mi), it will reset automatically and disappear
from the display.

1-17
 GEN
FEATURES INFO
Instantaneous fuel consumption To set the clock
1. Turn the key to “ ”.
2. Push the “SELECT” switch to change the dis-
play to the clock mode.
3. Push the “SELECT” button for two seconds,
and the hour digits will start flashing.
4. Use the “SELECT” button to set the hours.
5. Push the “SELECT” button for two seconds,
ZAUE3750 and the minute digits will start flashing.
6. Use the “SELECT” button to set the minutes.
1. Instantaneous fuel consumption display 7. Push the “SELECT” button for two seconds to
• “Km/L”: The distance that can be traveled on confirm settings and start the clock.
1.0 L of fuel under the current riding conditions
is shown. Self-diagnosis mode

TIP
If traveling at speeds under 10 km/h (6 mi/h),
“_ _._” is displayed.
ABS

Average fuel consumption

ZAUE3753
1. Engine trouble warning light “ ”
2. Error code display
AVE

This model is equipped with a self-diagnosis

function for various electrical circuits.
ZAUE3751 If a problem is detected in any of those circuits,
the engine trouble warning light will come on
1. Average fuel consumption display and the display will indicate an error code.
This shows the average fuel consumption If the display indicates any error codes, note
since it was last reset. the code number and have a Yamaha dealer
• “AVE_ _._ Km/L”: The average distance that check the vehicle.
ECA11591
can be traveled on 1.0 L of fuel is shown.
NOTICE
To reset the average fuel consumption, push
the “SELECT” button for one second. If the display indicates an error code, the
vehicle should be checked as soon as pos-
TIP sible in order to avoid engine damage.
After resetting the average fuel consumption,
“_ _._” is shown until the vehicle has traveled
0.1 km (0.06 mi).

Clock

ZAUE3752

1. Clock

1-18
 GEN
SPECIAL TOOLS INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques.

Tool name / Tool no. Illustration

Scissor jack
YSST-892A

This tool is used to support the vehicle.

TIP
While removing the front wheel, put the scis-
sor jack under the engine of the vehicle so that
there is no danger of it falling over.

Yamaha diagnostic tool

INS-018

T
(90890-03267)

D
Y
This tool is used to diagnose electrical fault in
advance fuel injection system.
Yamaha diagnostic tool
INS-019
(90890-03262)

This tool is used to diagnose electrical fault in

advance fuel injection system.

1-19
 SPEC
CHAPTER 2
SPECIFICATIONS

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

MAINTENANCE SPECIFICATION (ENGINE)................................................. 2-2

MAINTENANCE SPECIFICATION (CHASSIS) .............................................. 2-6

MAINTENANCE SPECIFICATION (ELECTRICAL)........................................ 2-8

TIGHTENING TORQUES .............................................................................. 2-10

GENERAL TIGHTENING TORQUE SPECIFICATIONS ......................... 2-10
CHASSIS TIGHTENING TORQUES....................................................... 2-11

CABLE ROUTING ......................................................................................... 2-12

SPEC
 GENERAL SPECIFICATIONS SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS

Model
Model B972 (For FZ25-ABS)
BC42 (For FAZER25-ABS)

Dimensions
Overall length 2015 mm (79.3 in)
Overall width 775 mm (30.5 in)
Overall height 1075 mm (For FZ25-ABS)
1115 mm (For FAZER25-ABS)
Wheelbase 1360 mm (53.5 in)
Ground clearance 160 mm (6.30 in)
Minimum turning radius 2.5 m (8.20 ft)

Weight
Curb weight 152 kg (335 lb) (For FZ25-ABS)
157 kg (346 lb) (For FAZER25-ABS)

Loading
Maximum load 165 kg (364 lb)
Riding capacity 2 persons

2-1
 MAINTENANCE SPECIFICATION (ENGINE) SPEC
MAINTENANCE SPECIFICATION (ENGINE)

Engine
Combustion cycle 4-stroke
Cooling system Air cooled
Valve train SOHC
Displacement 249 cm³
Number of cylinders Single cylinder
Bore  stroke 74.0  58.0 mm (2.91  2.28 in)
Compression ratio 9.8 : 1
Compression pressure 1044-1344 kPa/300 r/min (10.4-13.4
kgf/cm2/300 r/min, 148.5-191.2 psi/300 r/min)
Starting system Electric starter

Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount 2.1 L (0.55 US gal, 0.46 Imp.gal)

Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil API service SL type, JASO standard MA
Lubrication system Wet sump
Engine oil quantity
Oil change 1.35 L (1.43 US qt, 1.19 Imp.qt)
With oil filter removal 1.45 L (1.53 US qt, 1.28 Imp.qt)
Quantity (disassembled) 1.55 L (1.64 US qt, 1.36 Imp.qt)

Oil filter
Oil filter type Paper

Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.000-0.150 mm (0.0059 in)
Limit 0.230 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.100-0.151 mm (0.0039-0.0059 in)
Limit 0.221 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.045-0.095 mm (0.0016-0.0035 in)
Limit 0.165 mm (0.0063 in)
Relief valve operating pressure 850.0 kPa (8.50 kgf/cm2, 123.3 psi)

Spark plug(s)
Manufacturer/model NGK/DR8EA
Spark plug gap 0.6-0.7 mm (0.024-0.028 in)

Cylinder head
Warpage limit 0.05 mm (0.0020 in)

2-2
 MAINTENANCE SPECIFICATION (ENGINE) SPEC

Camshaft
Camshaft lobe dimensions
Lobe height (Intake) 36.890-36.990 mm (1.4524-1.4563 in)
Limit 36.790 mm (1.4484 in)
Lobe height (Exhaust) 36.890-36.990 mm (1.4524-1.4563 in)
Limit 36.790 mm (1.4484 in)
Camshaft runout limit 0.030 mm (0.0012 in)

Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000-12.018 mm (0.4724-0.4731 in)
Limit 12.033 mm (0.4737 in)
Rocker arm shaft outside diameter 11.981-11.991 mm (0.4717-0.4721 in)
Limit 11.950 mm (0.4705 in)

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.05-0.10 mm (0.0020-0.0039 in)
Exhaust 0.08-0.13 mm (0.0032-0.0051 in)
Valve dimensions
Valve seat contact width (intake) 0.90-1.20 mm (0.0354-0.0472 in)
Limit 1.7 mm (0.07 in)
Valve seat contact width (exhaust) 0.90-1.20 mm (0.0354-0.0472 in)
Limit 1.7 mm (0.07 in)
Valve stem diameter (intake) 5.975-5.990 mm (0.2352-0.2358 in)
Limit 5.945 mm (0.2341 in)
Valve stem diameter (exhaust) 5.960-5.975 mm (0.2346-0.2352 in)
Limit 5.930 mm (0.2335 in)
Valve guide inside diameter (intake) 6.000-6.012 mm (0.2362-0.2367 in)
Valve guide inside diameter (exhaust) 6.000-6.012 mm (0.2362-0.2367 in)
Valve-stem-to-valve-guide clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025-0.052 mm (0.0010-0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)

Valve spring
Inner spring
Free length (intake) 36.17 mm (1.42 in)
Limit 34.36 mm (1.35 in)
Free length (exhaust) 36.17 mm (1.42 in)
Limit 34.36 mm (1.35 in)
Spring tilt (intake) 1.7 mm (0.07 in)
Spring tilt (exhaust) 1.7 mm (0.07 in)
Outer spring
Free length (intake) 36.63 mm (1.44 in)
Limit 34.80 mm (1.37 in)
Free length (exhaust) 36.63 mm (1.44 in)
Limit 34.80 mm (1.37 in)
Spring tilt (intake) 1.7 mm (0.07 in)
Spring tilt (exhaust) 1.7 mm (0.07 in)

2-3
 MAINTENANCE SPECIFICATION (ENGINE) SPEC

Cylinder
Bore 74.000-74.016 mm (2.9134-2.9140 in)
Wear limit 74.066 mm (2.9160 in)

Piston
Diameter D 73.983-73.998 mm (2.9127-2.9133 in)
Measuring point (from piston skirt bottom) 5.0 mm (0.20 in)
Piston-to-cylinder clearance 0.010-0.025 mm (0.0004-0.0010 in)
Piston pin bore inside diameter 17.002-17.013 mm (0.6694-0.6698 in)
Limit 17.033 mm (0.6706 in)
Piston pin outside diameter 16.991-17.000 mm (0.6689-0.6693 in)
Limit 16.980 mm (0.6685 in)
Piston-pin-to-piston-pin-bore clearance 0.002-0.022 mm (0.0001-0.0009 in)

Piston ring
Top ring
Ring type Barrel
End gap (installed) 0.19-0.31 mm (0.0075-0.0122 in)
End gap limit 0.56 mm (0.0220 in)
Ring side clearance 0.030-0.065 mm (0.0012-0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap (installed) 0.30-0.45 mm (0.0118-0.0177 in)
End gap limit 0.80 mm (0.0314 in)
Ring side clearance 0.020-0.055 mm (0.0008-0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)

Crankshaft
Crank assembly width 69.25-69.30 mm (2.726-2.728 in)
Runout limit 0.030 mm (0.0012 in)

Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 10.0-15.0 mm (0.39-0.59 in)
Friction plate thickness 2.90-3.10 mm (0.114-0.122 in)
Wear limit 2.60 mm (0.102 in)
Plate quantity 1 pc
Friction plate thickness 2.90-3.10 mm (0.114-0.122 in)
Wear limit 2.60 mm (0.102 in)
Plate quantity 4 pcs
Friction plate thickness 2.90-3.10 mm (0.114-0.122 in)
Wear limit 2.60 mm (0.1024 in)
Plate quantity 1 pc
Clutch plate thickness 1.50-1.70 mm (0.0591-0.0669 in)
Plate quantity 5 pcs
Warpage limit 0.20 mm (0.008 in)
Clutch spring free length 41.60 mm (1.64 in)
Limit 39.60 mm (1.56 in)
Spring quantity 4 pcs
Push rod bending limit 0.30 mm (0.012 in)

2-4
 MAINTENANCE SPECIFICATION (ENGINE) SPEC

Drivetrain
Primary reduction ratio 3.083 (74/24)
Transmission type Constant mesh 5-speed
Gear ratio
1st 2.571 (36/14)
2nd 1.684 (32/19)
3rd 1.273 (28/22)
4th 1.040 (26/25)
5th 0.852 (23/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Main axle assembly width 102.20-102.40 mm (4.02-4.03 in)
Secondary reduction ratio 3.067 (46/15)
Final drive Chain

Air filter
Air filter element Oil-coated paper element

Fuel pump
Pump type Electrical
Maximum consumption amperage 1.7 A

Fuel injector
Resistance 12.2 

Throttle body
ID mark B971 00

Idling condition
Engine idling speed 1300–1500 r/min
O2 feedback control Inactive
Exhaust gas sampling point Sampling port on the exhaust pipe
Engine temperature 115-125 °C (239-257 °F)
CO% 0.0-2.0 %
Fuel line pressure (at idle) 220-300 kPa (2.2-3.0 kgf/cm2, 31.9-43.5 psi)
Throttle grip free play 3.0-5.0 mm (0.12-0.20 in)

2-5
 MAINTENANCE SPECIFICATION (CHASSIS) SPEC
MAINTENANCE SPECIFICATION (CHASSIS)

Chassis
Frame type Diamond
Caster angle 24.5 °
Trail 98 mm (3.9 in)

Front wheel
Wheel type Cast wheel
Rim size 17M/C  MT2.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Rear wheel
Wheel type Cast wheel
Rim size 17M/C  MT4.00
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Front tire
Type Tubeless
Size 100/80-17M/C 52P
Manufacturer/model MRF/NYLOGRIP ZAPPER-FX1

Rear tire
Type Tubeless
Size 140/70-17M/C 66S
Manufacturer/model MRF/NYLOGRIP ZAPPER-S2

Tire air pressure (measured on cold tires)

Front 175 kPa (1.75 kgf/cm2, 25 psi, 1.75 bar)
Rear 200 kPa (2.00 kgf/cm2, 29 psi, 2.00 bar)

Front brake
Type Hydraulic single disc brake
Disc outside diameter  thickness 282.0  4.0 mm (11.10  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 4.3 mm (0.17 in)
Limit 0.6 mm (0.02 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter (Right) 28.00 mm, 28.00 mm (1.10 in, 1.10 in)
Specified brake fluid DOT 4

2-6
 MAINTENANCE SPECIFICATION (CHASSIS) SPEC

Rear brake
Type Hydraulic single disc brake
Disc outside diameter  thickness 220.0  4.5 mm (8.66  0.18 in)
Brake disc thickness limit 4.0 mm (0.1575 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 5.5 mm (0.22 in)
Limit 1.5 mm (0.06 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 30.23 mm (1.19 in)
Specified brake fluid DOT 4

Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Fork spring free length 235.0 mm (9.25 in)
Limit 230.3 mm (9.07 in)
Quantity (left) 469.0 cm3 (15.86 US oz, 16.54 Imp.oz)
Quantity (right) 469.0 cm3 (15.86 US oz, 16.54 Imp.oz)
Level (left) 75 mm (3.0 in)
Level (right) 75 mm (3.0 in)
Recommended oil Yamaha Suspension Oil G10

Rear suspension
Type Swingarm
Spring Coil spring
Shock absorber Hydraulic damper
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Cam position
Adjustment value (Soft) 1
Adjustment value (STD) 3
Adjustment value (Hard) 7

Drive chain
Chain type Sealed type
Number of links 136
Drive chain slack (Maintenance stand) 40.0-45.0 mm (1.57-1.77 in)
Limit 50.0 mm (1.97 in)
15-link length limit 191.5 mm (7.54 in)

2-7
 MAINTENANCE SPECIFICATION (ELECTRICAL) SPEC
MAINTENANCE SPECIFICATION (ELECTRICAL)

Voltage
System voltage 12 V

Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 8.0°-12.0°/1400 r/min

Engine control unit

Model TBDF2W

Ignition coil
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k

Spark plug cap

Resistance 3.75-6.25 k

Lean angle sensor output voltage

Operating angle 50°
Output voltage up to operating angle 0.4-1.4 V
Output voltage over operating angle 3.7-4.4 V

Charging system
Charging system AC magneto
Standard output 14.0 V, 11.5 A at 5000 r/min
Stator coil resistance 0.456-0.684 

Rectifier/regulator
Regulator type Single-phase
Regulated voltage (DC) 14–14.8 V
Rectifier capacity (DC) 16.0 A

Battery
Model ETZ-7
Voltage, capacity 12 V, 6.0 Ah (10 HR)

Bulb, wattage
Headlight LED
Brake/tail light LED
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Auxiliary light 5.0 W (For FZ25-ABS)
LED (For FAZER25-ABS)
License plate light 5.0 W
Meter lighting LED

Indicator light
Neutral indicator light LED
High beam indicator light LED
Turn signal indicator light LED
Engine trouble warning light LED
ABS warning light LED

2-8
 MAINTENANCE SPECIFICATION (ELECTRICAL) SPEC

Starter motor
Power output 0.40 kW
Armature coil resistance 0.0126-0.0154 
Brush overall length 10.0 mm (0.39 in)
Limit 3.50 mm (0.14 in)
Brush spring force 5.52-8.28 N (563-844 gf, 19.87-29.80 oz)
Commutator diameter 22.0 mm (0.87 in)
Limit 21.0 mm (0.83 in)
Mica undercut (depth) 1.50 mm (0.06 in)

Fuel sender unit

Sender unit resistance (full) 10.0-14.0 
Sender unit resistance (empty) 267.0-273.0 

Fuel injection sensor

Crankshaft position sensor resistance 192-288 
Intake air temperature sensor resistance 5700-6300  at 0 °C (5700-6300  at 32 °F)
Engine temperature sensor resistance 28500-31500  at 0 °C (28500-31500  at 32 °F)
Engine temperature sensor resistance 903-1142  at 100 °C (1017  at 212 °F)

Fuse(s)
Main fuse 15.0 A
ABS control unit fuse 2.0 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A

2-9
 TIGHTENING TORQUES SPEC
EAS20320

TIGHTENING TORQUES
EAS20330

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.

A. Distance between flats

B. Outside thread diameter

General tightening
A (nut) B (bolt) torques
N·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13.0 96

2-10
 TIGHTENING TORQUES SPEC
CHASSIS TIGHTENING TORQUES
Thread
Item Q’ty Tightening torque Remarks
size
Hydraulic unit assembly bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Front wheel sensor rotor screw M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft)

Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Rear wheel sensor rotor screw M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft)

Rear wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Front brake hose union bolt
M10 2 29 N.m (2.9 kgf·m, 21 lb·ft)
(Hydraulic unit to master cylinder)
Front brake hose union bolt
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
(Hydraulic unit to brake caliper)
Rear brake hose union bolt
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
(Hydraulic unit to master cylinder)
Rear brake hose union bolt
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
(Hydraulic unit to brake caliper)
Hydraulic unit bracket bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear brake hose holder bracket and
M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
rear arm bolt (RH side)
Rear brake hose holder bolt
M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
(Hydraulic unit to caliper)
Rear brake hose bracket and rear
arm comp. bolt (RH rear arm comp. M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
pivot shaft side)
Rear brake hose bracket and rear
brake hose bolt (RH rear arm comp. M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
pivot shaft side)
Fr. hose holder and fr. brake hoses
bolt (LH head pipe gusset. side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fr. brake hose holder and frame bolt
(LH head pipe gusset. side) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fr. brake hose (master cylinder and
caliper) and holder bolt (upper side of M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
rear engine stay)
Fr. brake hose joint and frame bolt
M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(upper side of rear engine stay)
Fr. brake hose joint and hose holder
M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
bolt (upper side of rear engine stay)
Fr. brake hose connecting bolt
(master cylinder to HCU and HCU to M10 2 37 N·m (3.7 kgf·m, 27 lb·ft) BF
caliper)
Battery box mounting bolt M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft)

2-11
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)

2-12
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)
1 Clutch switch lead È Main switch clamp shall be inserted in the
2 Left handlebar switch lead hole of brake hose holder.
3 Clutch cable É Brown (Right side of vehicle).
4 Horn Ê Pink (Left side of vehicle).
5 Plastic band Ë L-type terminal shall be directed to right side
6 Horn lead
of vehicle.
7 Front brake hose
8 Right handlebar switch lead
Ì Horn lead shall be adjusted without slack
9 Front brake light switch coupler lower side from this plastic band.
0 Front brake light switch lead Í Set tip of the clamp towards backward.
A Front fork assembly Î Set the path of plastic band end into the
tube properly.
Ï Clamp of harness assembly shall be
inserted in the hole of frame.

2-13
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS) È Clamp the clutch switch lead and left handlebar
switch lead to straight portion of handlebar.
1 Clutch switch lead É Clamp the right handlebar switch lead to straight
2 Left handlebar switch lead portion handlebar.
3 Main switch lead
4 Clutch cable
5 Front brake hose
6 Right handlebar switch lead
7 Throttle cable (decelerator)
8 Throttle cable (accelerator)

2-14
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-
ABS)
1 Left handlebar switch lead È Throttle cable (accelerator) and throttle cable
2 Clutch switch lead (Return side) pass to guide of stay.
3 Clutch cable
4 Front brake hose
5 Right handlebar switch lead
6 Right handlebar switch
7 Throttle cable (decelerator)
8 Throttle cable (accelerator)

2-15
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)
1 Headlight lead È Coupler shall be inserted in the hole of support
2 Auxiliary light leads stay.
3 Wire harness assembly (Headlight and auxiliary É Auxiliary light connector shall be fitted to hole of
lights) auxiliary light.
4 Support stay
5 Headlight coupler
6 Auxiliary light
7 Auxiliary light coupler
8 Harness assembly (Auxiliary light lead)

6
7
5
A
4 1

B 8

3
2

2-16
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)

E 13 G

7 8 4
16

F 9

15 10

11
14 12
6 A
13

5
1
4
2

3 17

7 I
C

2-17
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)
1 Clutch switch lead È Front turn signal light leads shall be passed
2 Left handlebar switch lead through headlight stay.
3 Front brake hose É Do not clamp the bare leads.
4 Right handlebar switch lead Ê Insert the harness assembly into the hole of
5 Meter assembly stay.
6 Turn signal light lead (LH & RH) Ë The leads should not cross this area.
7 Stay Ì Set the tip of the clamp upper side and should
8 Clamp not be cut.
9 Headlight stay Í Left handlebar switch lead, right handlebar
0 Left handlebar switch lead coupler switch lead, clutch switch lead and main switch
A Right handlebar switch lead coupler lead can be in random order.
B Main switch lead coupler Î After connecting meter coupler rubber cover
C Coupler cover shall be inserted into the meter assembly.
D Clutch switch lead coupler Ï Except meter assembly lead, left handlebar
E Headlight switch lead, right handlebar switch lead, clutch
F Headlight lead coupler switch lead, headlight switch lead and main
G Meter assembly lead switch lead can be in random order.
Ð Left handlebar switch lead, right handlebar
switch lead, clutch switch lead, headlight switch
lead and main switch lead can be in random
order.

2-18
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)
1 Bracket rib È After headlight coupler is connected, put head-
2 Headlight coupler light coupler between the ribs of bracket.
3 Front turn signal light lead É After installing headlight coupler, cover shall be
4 Auxiliary light lead raised up.
5 Coupler cover Ê Clamped the bare leads downward from termi-
6 Nut nals.
7 Band Ë Both ends of coupler cover shall be inserted.
Ì Nut shall be installed at the end of assembly.
Í Leads shall not be put inside of upper cover.

3 4

2
1

B A
7 C

5 F D E

2-19
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)

2-20
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)
1 Injector È Clamp shall be inserted in the hole of engine
2 Engine temperature sensor lead stay.
3 Fuel pump assembly É After connecting all connectors and couplers
4 Couplers cover shall be properly covered with rubber cover and
5 Lean angle sensor can be in random order.
6 Throttle cable (decelerator) Ê Clamp of harness assembly shall be inserted in
7 Throttle cable (accelerator) the hole of stay support.
8 Meter assembly Ë After connecting meter cover shall be inserted
9 Meter assembly stay into the meter assembly.
0 Harness assembly Ì Clamp shall be inserted in the hole of engine
A Yellow tape stay.
B Clutch cable Í The layout of leads shall be in random order.
C Breather hose (Fuel tank) Î Pass the harness assembly through clamp from
D Fuel hose (Fuel tank to injector) inside the vehicle.
E MAQS (Modularized air quality sensor) Ï Harness assembly with yellow tape shall not be
F FID clamped.
G Main switch lead Ð Clamp shall be inserted in the hole of frame
H Right handlebar switch lead bracket.
I Front brake light switch lead & horn lead Ñ Fit the clamp to the end of harness assembly.
J Engine stay Ò Set the tip of the clamp outside and lower side,
K Clamp cut the tip of the clamp maximum length of the
L Lean angle sensor lead tip should be 5 mm.
M Plastic band Ó These three leads shall be clamped to the
N Frame bracket inside. Layout of leads shall be in random order.

2-21
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)

2-22
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)
1 FID (Fast idling device) È Harness clamp shall be inserted in the hole of
2 Injector frame component.
3 Fuel pump assembly É Pass the main switch lead frontward than throttle
4 Engine temperature sensor lead cable (Both of accelerator and decelerator).
5 Main switch lead Ê Pass throttle cable inside stay of frame compo-
6 Throttle cable (accelerator) nent.
7 Throttle cable (decelerator) Ë Set the tip of the clamp to the lower side, cut the
8 Lean angle sensor tip of the band, maximum length of band tip
9 MAQS (Modularized air quality sensor) 5 mm.
0 Starter motor lead
A Clutch cable
B Engine stay
C Harness assembly
D Clamp
E Frame assembly
F Ignition coil lead
G Right handlebar switch lead
H Front brake hose

2-23
 CABLE ROUTING SPEC
CABLE ROUTING

19
20
N
22
1 O 21
18

17 17
23
16
15 21 17

A B C D 2 3 E 4 F

L
14
13
K
12
11
10

9
Q
4
23
8
Q 26 I
26 H
23 23 P 7
8 6 G

8
24
21 25

2-24
 CABLE ROUTING SPEC
CABLE ROUTING
1 Taillight lead È Harness assembly shall be passed inside of
2 Battery seat rail, also it should not touch the rectifier reg-
3 Relay ulator.
4 Positive battery lead É Fix clamp to the end of bracket tank fitting of
5 MAQS (Modularized air quantity sensor) frame.
6 Starter motor lead Ê The terminal negative battery lead shall be set to
7 Clutch cable the upside.
8 Rear brake light switch lead Ë Harness shall be passed along with the guide of
9 Rear brake light switch battery box.
0 Rear wheel sensor Ì Starter relay shall be properly covered with har-
A Negative battery lead ness assembly cover.
B Fuse box Í Clamp shall be inserted in the hole of frame.
C Rectifier regulator Î Set large diameter open mouth of clamp to
D Air filter assembly inside and assemble bend tube to clutch cable.
E ABS test coupler lead Set small diameter of open mouth of the clamp
F Fender to downward and assemble non protector part of
G Harness assembly starting motor lead.
H Rear turn signal leads (LH & RH) Ï Fit the band to the end of rear arm frame
I coupler cover bracket.
J License plate light lead Ð Rear brake light switch lead shall be clamped at
K Frame assembly the white tape.
L Service tool Ñ Rear brake light switch lead shall be adjusted
M Plastic band without slack lower side of this band.
N Starter relay lead Ò Harness assembly, negative battery lead and
O ABS unit lead batter shall be fixed by battery band.
P Fuse box lead Ó Clamp shall be inserted in the hole rear fender
(right) bracket.
Ô Taillight lead shall be passed inside of fender
pin.
Õ Layout in coupler cover can be in random order.
Ö Set the tip of the clamp to the inner side, tip of
the band should not be cut.
× Set the tip of the clamp to the front side, cut the
tip of the band, maximum length of band tip 5
mm.
Ø Set the tip of the band to the backward.
Ù License plate light lead & both rear turn signal
light leads (LH & RH) shall be passed through
hole of fender, leads shall not be pinched by
other parts.

2-25
 CABLE ROUTING SPEC
CABLE ROUTING

2-26
 CABLE ROUTING SPEC
CABLE ROUTING
1 Engine control unit È ECU lead must be placed on the top.
2 Turn signal relay É After connecting all connectors and couplers
3 Yamaha diagnostic tool coupler shall be properly covered with rubber cover and
4 Taillight lead can be in random order.
5 Rear fender Ê After connected pass front side of rib in fender.
6 Rear turn signal lead (LH/RH), license plate light Ë Fit clamp to the end of bracket set of frame com-
lead ponent.
7 Channel Ì Pass the clamp through the hole on the coupler
8 Frame assembly cover.
9 Coupler cover Í Set the tip of clamp to the lower side. Tip of
0 Clamp clamp shall not be cut.
A ABS coupler lead Î Rear turn signal lead (LH/RH), license plate light
B ABS test coupler lead, brake light lead in guide of fender shall be
C Harness assembly in random order.
Ï Rear turn signal light leads (LH & RH) and
license plate light lead shall be in random order.
Ð Press the coupler until it get fixed properly.

2-27
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)

2-28
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)
1 Clutch cable È Clamp of harness assembly shall be inserted in
2 Couplers cover the hole of support stay.
3 Ignition coil É Harness assembly shall pass under the couplers
4 Spark plug lead cover.
5 O2 sensor lead Ê Lead cover shall be insert properly.
6 Horn lead Ë Spark plug lead shall be screwed and tighten
7 Left handlebar switch lead with spark plug cap. (Pull off strength of spark
8 Clamp plug lead shall be minimum 30N).
9 Clutch switch lead Ì Clamp the O2 sensor lead (white mark) at the
0 Stay end of horn bracket (frame) using plastic band,
and lead shall be adjusted from upperside of the
band without slack.
Í Clamp shall be inserted in the hole of frame
assembly.
Î Clutch cable shall be passed from behind the
stay guide.
Ï Set the tip of the clamp to the front side, cut the
tip of the band, maximum length of band
tip10 mm.
Ð The layout of leads shall be in random order.
Ñ Clamp shall be inserted in the hole of stay.

2-29
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)

2-30
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)
1 Front brake hose holder È Horn lead shall be adjusted without slack
2 Clamp between both clamps as shown.
3 Stay (left) É These leads shall be passed behind guide of left
4 Horn lead stay.
5 Horn Ê Clamp the horn lead at white tape.
6 O2 sensor Ë Clamp shall be inserted in the hole of left side
7 Plastic band stay.
8 O2 sensor lead Ì Set the tip of the clamp outside, cut the tip of
9 Horn lead clamp maximum length should be 5 mm.
0 Horn terminal Í L-type terminal should be directed to inside of
vehicle.
Î Brown (Inside of vehicle)
Ï Pink (Left side of vehicle)

2-31
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)

Front left-side of vehicle (Couplers cover)

2-32
 CABLE ROUTING (For FAZER25-ABS) SPEC
CABLE ROUTING (For FAZER25-ABS)
1 Clamp È After connecting all connectors and couplers
2 Clutch cable shall be properly covered with rubber cover, no
3 Harness assembly naked lead should be outside cover and can lay-
4 Front wheel sensor coupler out of leads can be in random order.
5 Brake hose É Clamp of harness assembly shall be inserted in
6 Harness assembly (to left handlebar switch) the hole of frame assembly.
7 Frame assembly Ê Layout of leads shall be in random order.
8 Harness assembly (to headlight) Ë Pass the clamp through hole in cover.
9 Clutch switch lead Ì Set the tip of the clamp to the inside of the vehi-
0 Left handlebar switch lead cle, tip of the clamp shall not be cut.
A Couplers cover
B Harness assembly (to front wheel sensor)

2-33
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)

12 16

N
14

13 15
11 14
M

3 4 17
A 2 B
5 O
1
6
9
T 7
L
C
8
10 K D
E
2 3 J

S
F
5

I
G
10

3 10 3 9
16 L

16
H
P
V R
U

10
Q
18
3 17
O
90
P
18
19

2-34
 CABLE ROUTING (For FZ25-ABS) SPEC
CABLE ROUTING (For FZ25-ABS)
1 Front brake hose (ABS Hydraulic unit to front È Pass the clutch cable from cable guide of brake
brake master cylinder) hose holder.
2 Front brake hose holder É O2 sensor lead and front wheel sensor lead shall
3 O2 sensor lead be passed over the brake hose.
4 Front wheel sensor lead Ê Lead cover shall be inserted properly.
5 Brake hose (ABS Hydraulic unit to front brake Ë Clamp shall be inserted in the hole of frame
caliper) assembly.
6 Spark plug lead Ì Breather hose (fuel tank) shall be passed under
7 Ignition coil the harness assembly.
8 Breather hose (Fuel tank) Í After connecting all connectors and couplers
9 AC magneto lead shall be properly covered with rubber cover and
0 Horn lead can be in random order.
A Harness assembly Î Clamp the AC magneto lead to upper side of
B Clamp cover frame assembly with plastic band and ensure
C Clamp band should not be on bare lead.
D Engine stay (Left) Ï Clamp the O2 sensor lead (while mark) at the
E Engine stay (Right) end of horn bracket (frame) using plastic band,
F Frame and lead shall be adjusted from upper side of the
G Plastic band band without slack.
H Horn Ð Spark plug lead shall be screwed and tighten
I O2 sensor with spark plug cap. (Pull off strength of spark
plug lead shall be minimum 30 N).
Ñ Brake hose, O2 sensor lead, front wheel sensor
lead and horn lead shall be properly arranged
with frame from outside of the vehicle in mention
order.
Ò Coupler cover of O2 sensor lead shall not be
turned up.
Ó Clamp shall be inserted in the hole of frame
assembly.
Ô Pass both the throttle cables (accelerator &
decelerator) between left & right engine stay.
Õ Pass the ignition coil lead between left engine
stay and frame.
Ö Set the tip of the clamp to the innerside, tip of
the band should not be cut.
× Set the tip of the clamp to the innerside cut the
tip of the band, maximum length of band tip 5
mm.
Ø Horn lead shall be adjusted without slack from
upper side of clamp.
Ù L-type terminal shall be directed to inside of
vehicle.
Ú Clamp shall be inserted in the hole of brake
hose holder.
Û Set the tip of the clamp to the front side cut the
tip of the band, maximum length of band tip
5 mm.
Ü Pink (Outside of the vehicle)
Ý Brown (Inside of the vehicle)

2-35
 CABLE ROUTING SPEC
CABLE ROUTING
1 Air filter assembly È Clamp shall be inserted in the hole of frame
2 Battery box assembly.
3 ABS hydraulic unit
4 ABS hydraulic unit lead

2-36
 CABLE ROUTING SPEC
CABLE ROUTING

2-37
 CABLE ROUTING SPEC
CABLE ROUTING
1 Rear wheel speed sensor lead È Fix the clamp on the paint mark of brake hose
2 Plain washer protector and white tape of wheel speed sensor.
3 Brake hose union bolt É Air shall be completely removed.
4 Rear brake hose Ê Clamp shall be inserted in the brake light switch
5 Rear brake hose holder stay.
6 Battery box Ë Wheel sensor shall be clamped at white tape.
7 Frame assembly Ì Clamp shall be inserted in the hole of battery
8 Footrest assembly box.
9 Clamp Í Set the tip of the clamp as shown, cut the tip of
0 Rear brake light switch lead the band, maximum length of band tip 5 mm.
A Rear brake master cylinder Î Adjust the brake light switch until brake light turn
B Split pin “on” before brake starts to be working.
C Rear brake reserve hose guide Ï Install the spring hook into the brake pedal
D Rear brake reserve hose spring stay as shown.
E Rear brake caliper Ð Pin shall be inserted from outside of the vehicle.
F Rear brake hose (ABS hydraulic unit to rear Ñ Reserve hose shall be assembled through the
brake caliper) clamp of plate.
G Rear brake hose (ABS hydraulic unit to rear Ò Rear brake hose shall be assembled to brake
brake master cylinder) caliper by touching right side.
H Bracket Ó Brake hose shall be assembled by touching rear
master cylinder.
Ô Fit the clamp on white tape mark at wheel speed
sensor.
Õ Rear brake hose (ABS hydraulic unit to rear
brake caliper) shall be assembled.
Ö Clamp shall be inserted in the hole of bracket.

2-38
 CABLE ROUTING SPEC
CABLE ROUTING

14
15

9
12 2
B 10
9
10 A 11
13 8
C
12 3
10
D 4
E

7
9 6
5
8

For FAZER25–ABS

2-39
 CABLE ROUTING SPEC
CABLE ROUTING
1 Frame assembly È Clamp shall be attached on paint mark of front
2 Front fender brake hose.
3 Front fork É Pin of front brake hose (ABS hydraulic unit to
4 Lead holder brake caliper) shall touch the brake hose
5 Front wheel speed sensor bracket.
6 Front brake disc Ê End fitting of front brake hose (ABS hydraulic
7 Front brake caliper unit to master cylinder) shall touch brake hose
8 Front brake hose holder bracket.
9 Clamp Ë Band upper edge shall fit to lower edge of paint
0 Front brake hose (ABS hydraulic unit to front mark of front brake hose (ABS hydraulic unit to
brake caliper) master cylinder) both direction of band is
A Front wheel speed sensor lead allowed.
B Front brake hose (ABS hydraulic unit to front Ì Front brake hose shall be set properly to front
brake master cylinder) brake caliper stopper.
C Brake hose bracket Í Brake fluid shall be applied to union bolt thread.
D Plain washer Î Protector edge shall be appealed.
E Union bolt

2-40
 CABLE ROUTING SPEC
CABLE ROUTING

D
7

C
2
4

1 3

8
6
4 1

7 6 5

6
1

A
1 2
7
B

6
9

For FAZER25–ABS

2-41
 CABLE ROUTING SPEC
CABLE ROUTING
1 Front brake hose (ABS hydraulic unit to front È Set the tip of the clamp to the up side, cut the tip
brake master cylinder) of the band, maximum length of band tip 5 mm.
2 Front brake hose bracket É Clamp shall be inserted in the hole of front brake
3 Frame assembly hose bracket.
4 Engine stay Ê Clamp shall be inserted in the hole of engine
5 Brake hose bracket stay.
6 Front brake hose (ABS hydraulic unit to front Ë Both front brake hoses should properly set to
brake caliper) clamp.
7 Clamp
8 Front wheel speed sensor lead

2-42
 CABLE ROUTING SPEC
CABLE ROUTING
1 ABS hydraulic unit È Pin of rear brake hose (to rear brake master cyl-
2 Rear brake hose (to rear brake master cylinder) inder) shall touch to end fitting of rear brake
3 Rear brake hose (to rear brake caliper) hose (to rear brake caliper).
4 ABS hydraulic unit bracket É Pin of rear brake hose (to rear brake caliper)
5 Front brake hose (to front brake caliper) shall touch to end fitting of rear brake hose (to
6 Front brake hose (to front brake master cylinder) rear brake master cylinder).
Ê Pin of front brake hose (to front brake master
cylinder) shall touch to end fitting of front brake
hose (to front brake caliper).
Ë Pin of front brake hose (to front brake caliper
shall touch to end fitting of front brake hose (to
front brake master cylinder).

2-43
 CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENT

PERIODIC MAINTENANCE (For FZ25-ABS)................................................. 3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL 
SYSTEM ................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-1

PERIODIC MAINTENANCE (For FAZER25-ABS) ......................................... 3-4

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL 
SYSTEM ................................................................................................... 3-4
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-4

ENGINE ........................................................................................................... 3-7

ADJUSTING THE VALVE CLEARANCE .................................................. 3-7
CHECKING THE FUEL LINE .................................................................... 3-8
CHECKING AND ADJUSTING THE STEERING HEAD ........................... 3-9

ELECTRICAL SYSTEM................................................................................. 3-11

ADJUSTING THE HEADLIGHT BEAM ................................................... 3-11

CHASSIS ....................................................................................................... 3-12

BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) ......................... 3-12
CHK
ADJ
 CHK
PERIODIC MAINTENANCE (For FZ25-ABS) ADJ
PERIODIC CHECKS AND ADJUSTMENT

PERIODIC MAINTENANCE (For FZ25-ABS)

TIP
l From 25000 km (15000 mi), repeat the maintenance intervals starting from 5000 km (3000 mi).
l Items marked with an asterisk (*) should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
l Maintenance intervals marked with a double asterisk (**) would be paid service.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

• Check fuel hoses for cracks or

1 * Fuel line      
damage.
• Check condition.
2 * Fuel filter  
• Replace if necessary.
• Check condition.
     
3 Spark plug • Clean and regap.
• Replace. Every 15000 km (9000 mi)
• Check valve clearance. Adjust if
4 * Valves      
necessary.
5 * Fuel injection • Adjust engine idling speed.      
• Check for leakage.
6 * Exhaust system • Tighten if necessary. Every 10000 km (6000 mi)
• Replace gasket(s) if necessary.
Evaporative emis- • Check control system for dam-
7 * sion control sys- age.   
tem • Replace if necessary.

GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

• Perform dynamic inspection

Diagnostic sys-
1 * using Yamaha diagnostic tool.      
tem check
• Check the error codes.
2 Air filter element • Replace. Every 15000 km (9000 mi)
Air filter case
3 • Clean.      
check hose
• Check voltage.
4 * Battery      
• Charge if necessary.
• Check operation.
5 Clutch      
• Adjust.
• Check operation, fluid level and
     
6 * Front brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and
     
7 * Rear brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage.
• Check for correct routing and      
8 * Brake hose clamping.
• Replace. Every 4 years
9 * Brake fluid • Change. Every 2 years

3-1
 CHK
PERIODIC MAINTENANCE (For FZ25-ABS) ADJ
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

10 * Wheels • Check runout and for damage.      

• Check tread depth and for
damage.
11 * Tires • Replace if necessary.      
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or
     
damage. Replace if necessary.
12 * Wheel bearings
• Lubricate with lithium-soap-
Every 10000 km (6000 mi)
based grease.
• Check operation and for exces-
     
sive play.
13 * Swingarm
• Lubricate with lithium-soap-
Every 10000 km (6200 mi)
based grease.
• Check chain slack, alignment
and condition.
Every 500 km (300 mi) and after washing the motorcycle, riding in the
14 Drive chain • Adjust and lubricate chain with
rain or riding in wet areas
a special O-ring chain lubricant
thoroughly.
• Check bearing play and steer-
     
ing for roughness.
15 * Steering bearings
• Lubricate with lithium-soap-
Every 10000 km (6200 mi)
based grease.
• Make sure that all nuts, bolts
16 * Chassis fasteners and screws are properly tight-      
ened.
Brake lever pivot
17 • Lubricate with silicone grease.      
shaft
Brake pedal pivot • Lubricate with lithium-soap-
18      
shaft based grease.
Clutch lever pivot • Lubricate with lithium-soap-
19      
shaft based grease.
Shift pedal pivot • Lubricate with lithium-soap-
20      
shaft based grease.
• Check operation.
Sidestand, cen-
21 • Lubricate with lithium-soap-      
terstand
based grease.
• Check operation and for oil
     
22 * Front fork leakage. Repair if necessary.
• Replace oil. Every 10000 km (6000 mi)
Shock absorber • Check operation and shock ab-
23 *      
assembly sorber for oil leakage.
• Change.
24 Engine oil      
• Check vehicle for oil leakage.
Engine oil filter el-
25 • Replace.      
ement
Engine oil strain-
26 • Clean.  Every 15000 km (9000 mi)
er
Front and rear
27 * • Check operation.      
brake switches
Moving parts and
28 • Lubricate.      
cable ends
• Check operation.
• Check throttle grip free play,
29 * Throttle grip and adjust if necessary.      
• Lubricate cable end and grip
housing.

3-2
 CHK
PERIODIC MAINTENANCE (For FZ25-ABS) ADJ
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

Lights, signals • Check operation.

30 *      
and switches • Adjust headlight beam.

TIP
l Air filter
• This model’s air intake system is equipped with a disposable oil-coated paper element. The air filter ele-
ment cannot be cleaned with compressed air, it must be replaced.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
l Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change the fluid. Regularly check the
brake fluid level and fill the reservoir as required.
• Every two years replace the internal components of the brake master cylinder and caliper, and change
the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.

3-3
 CHK
PERIODIC MAINTENANCE (For FAZER25-ABS) ADJ
PERIODIC MAINTENANCE (For FAZER25-ABS)

TIP
l From 25000 km (15000 mi), repeat the maintenance intervals starting from 5000 km (3000 mi).
l Items marked with an asterisk (*) should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
l Maintenance intervals marked with a double asterisk (**) would be paid service.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

• Check fuel hoses for cracks or

1 * Fuel line      
damage.
• Check condition.
2 * Fuel filter  
• Replace if necessary.
• Check condition.
     
3 Spark plug • Clean and regap.
• Replace. Every 15000 km (9000 mi)
• Check valve clearance. Adjust if
4 * Valves      
necessary.
5 * Fuel injection • Adjust engine idling speed.      
• Check for leakage.
6 * Exhaust system • Tighten if necessary. Every 10000 km (6000 mi)
• Replace gasket(s) if necessary.
Evaporative • Check control system for dam-
7 * emission con- age.   
trol system • Replace if necessary.

GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

• Perform dynamic inspection us-

Diagnostic sys-
1 * ing Yamaha diagnostic tool.      
tem check
• Check the error codes.
2 Air filter element • Replace. Every 15000 km (9000 mi)
Air filter case
3 • Clean.      
check hose
• Check voltage.
4 * Battery      
• Charge if necessary.
• Check operation.
5 Clutch      
• Adjust.
• Check operation, fluid level and
     
6 * Front brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and
     
7 * Rear brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage.
• Check for correct routing and      
8 * Brake hose clamping.
• Replace. Every 4 years
9 * Brake fluid • Change. Every 2 years

3-4
 CHK
PERIODIC MAINTENANCE (For FAZER25-ABS) ADJ
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km**
(600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi)

10 * Wheels • Check runout and for damage.      

• Check tread depth and for dam-
age.
11 * Tires • Replace if necessary.      
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or
     
damage. Replace if necessary.
12 * Wheel bearings
• Lubricate with lithium-soap-
Every 10000 km (6000 mi)
based grease.
• Check operation and for exces-
     
sive play.
13 * Swingarm
• Lubricate with lithium-soap-
Every 10000 km (6200 mi)
based grease.
• Check chain slack, alignment and
condition.
Every 500 km (300 mi) and after washing the motorcycle, riding in the
14 Drive chain • Adjust and lubricate chain with a
rain or riding in wet areas
special O-ring chain lubricant
thoroughly.
• Check bearing play and steering
     
Steering bear- for roughness.
15 *
ings • Lubricate with lithium-soap-
Every 10000 km (6200 mi)
based grease.
Chassis fasten- • Make sure that all nuts, bolts and
16 *      
ers screws are properly tightened.
Brake lever piv-
17 • Lubricate with silicone grease.      
ot shaft
Brake pedal piv- • Lubricate with lithium-soap-
18      
ot shaft based grease.
Clutch lever piv- • Lubricate with lithium-soap-
19      
ot shaft based grease.
Shift pedal piv- • Lubricate with lithium-soap-
20      
ot shaft based grease.
• Check operation.
Sidestand, cen-
21 • Lubricate with lithium-soap-      
terstand
based grease.
• Check operation and for oil leak-
     
22 * Front fork age. Repair if necessary.
• Replace oil. Every 10000 km (6000 mi)
Shock absorber • Check operation and shock ab-
23 *      
assembly sorber for oil leakage.
• Change.
24 Engine oil      
• Check vehicle for oil leakage.
Engine oil filter
25 • Replace.      
element
Engine oil
26 • Clean.  Every 15000 km (9000 mi)
strainer
Front and rear
27 * • Check operation.      
brake switches
Moving parts
28 • Lubricate.      
and cable ends
• Check operation.
• Check throttle grip free play, and
29 * Throttle grip adjust if necessary.      
• Lubricate cable end and grip
housing.
Lights, signals • Check operation.
30 *      
and switches • Adjust headlight beam.

3-5
 CHK
PERIODIC MAINTENANCE (For FAZER25-ABS) ADJ
TIP
l Air filter
• This model’s air intake system is equipped with a disposable oil-coated paper element. The air filter ele-
ment cannot be cleaned with compressed air, it must be replaced.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
l Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change the fluid. Regularly check the
brake fluid level and fill the reservoir as required.
• Every two years replace the internal components of the brake master cylinder and caliper, and change
the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.

3-6
 CHK
ENGINE ADJ
ENGINE 5. Measure:
• Valve clearance
ADJUSTING THE VALVE CLEARANCE Out of specification  Adjust.
The following procedure applies to all of the
valves. Valve clearance (cold)
Intake
TIP
o Valve clearance adjustment should be made on a cold engine, at room temperature. 0.05-0.10 mm
l Valve clearance adjustment should be made Exhaust
on a cold engine, at room temperature. 0.08-0.13 mm
l When the valve clearance is to be mea-
sured or adjusted, the piston must be at top tttttttttttttttttttttttttttttttt
dead center (TDC) on the compression a. Turn the crankshaft counterclockwise.
stroke. b. Align the “I” mark “a” on the AC Magneto
rotor with the stationary pointer “b” on the
1. Remove: AC Magneto cover.
• Fuel tank seat knee grip
Refer to “FUEL TANK (For FAZER25-
ABS)” on page 6-1.
2. Disconnect:
• Cylinder head breather hose “1”
• Canister hose from fuel tank “2”.
• Spark plug cap “3”
2
3
c. Check that the cam lobes are positioned as
shown in the illustration.
TIP
At this position, both the valves must have
some valve clearance.
1
3. Remove:
• Cylinder head valve covers along with “O”
rings
Refer to “CYLINDER HEAD” on page 5-6
of base service manual B97-F8197-E0.
4. Remove:
• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
d. Measure the valve clearance with a feeler
gauge “1”.
Out of specification  Adjust.

Feeler gauge
YSST-1215

Center plug spanner

YSST-625

3-7
 CHK
ENGINE ADJ
Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.

Tappet screw holder

YSST-706 (90890-04154)
Tappet adjusting socket
YSST-806A
TIP
Adjust inlet valve clearance from right side of d. Hold the adjusting screw to prevent it from
the vehicle and exhaust valve clearance from moving and tighten the locknut to specifica-
left side of the vehicle. tion.

ssssssssssssssssssssssssssssssss Locknut
14 N·m (1.4 kgf·m, 10 lb·ft)
6. Adjust:
T.
R.

• Valve clearance
e. Measure the valve clearance again.
tttttttttttttttttttttttttttttttt
f. If the valve clearance is still out of specifica-
a. Loosen the locknut “1”. tion, repeat all of the valve clearance
b. Insert a feeler gauge “2” between the end of adjustment steps until the specified clear-
the adjusting screw and the valve tip. ance is obtained.
ssssssssssssssssssssssssssssssss
7. Install:
• Crankshaft end accessing screw
(along with the O-ring New )
• Timing mark accessing screw
(along with the O-ring New )
8. Install:
• Cylinder head valve cover along with 
O-ring
• Fuel tank breather hose
• Canister hose
• Spark plug cap
9. Install:
c. Turn the adjusting screw “3” in direction “a” • Fuel tank seat knee grip
or “b” until the specified valve clearance is Refer to “FUEL TANK (For FAZER25-
obtained. ABS)” on page 6-1.

CHECKING THE FUEL LINE

(a)
1. Remove:
• Fuel tank seat knee grip
3 Refer to “FUEL TANK (For FAZER25-
3 ABS)” on page 6-1.
(b)

3-8
 CHK
ENGINE ADJ
2. Check: 3. Remove:
• Fuel hose “1” • Upper bracket
Cracks/damage  Replace. Refer to “STEERING HEAD (For
Loose connection  Connect properly. FAZER25-ABS)” on page 4-39.

TIP
While removing the front wheel, put the scissor
jack under the engine of the vehicle.

4. Adjust:
• Steering head
tttttttttttttttttttttttttttttttt
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.
3. Install:
• Fuel tank seat knee grip 
Refer to “FUEL TANK (For FAZER25-
ABS)” on page 6-1.

CHECKING AND ADJUSTING THE

STEERING HEAD
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there b. Tighten the lower ring nut “4” with a steering
is no danger of it falling over. nut socket “5”.
TIP
TIP Set the torque wrench at a right angle to the
Place the vehicle on a centerstand so that the steering nut socket.
front wheel is elevated.

2. Check:
• Steering head
Grasp the bottom of the front fork legs
and gently rock the front fork.
Binding/looseness  Adjust the steering
head.

Steering nut socket

YSST-721

Lower ring nut (initial tightening

torque)
T.

33 N·m (3.3 kgf·m, 24 lb·ft)

R.

3-9
 CHK
ENGINE ADJ
c. Loosen the lower ring nut “4” 1/4 turn out,
and then tighten it to specification with a
steering nut socket.
WARNING
Do not overtighten the lower ring nut.

Lower ring nut (final tightening

torque)
T.

22 N·m (2.2 kgf·m, 16 lb·ft)

R.

d. Check the steering head for looseness or

binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD (For FAZER25-
ABS)” on page 4-39.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, and
then align the slots of both ring nuts. If nec-
essary, hold the lower ring nut and tighten
the upper ring nut until their slots are
aligned.
TIP
Make sure the lock washer tabs “a” sit cor-
rectly in the ring nut slots “b”.

ssssssssssssssssssssssssssssssss
5. Install:
• Upper bracket
Refer to “STEERING HEAD (For
FAZER25-ABS)” on page 4-39.

3-10
 CHK
ELECTRICAL SYSTEM ADJ
ELECTRICAL SYSTEM
ADJUSTING THE HEADLIGHT BEAM (For
FAZER25-ABS)
The following procedure applies to the adjust-
ment of the headlight beam.
Adjust the headlight beam by rotating the
headlight beam adjusting screw “1” with the
help of Phillip screwdriver “2” in direction “a” or
“b” from bottom side of headlight.
Direction “a”
Headlight beam is lowered.
Direction “b”
Headlight beam is raised.

BOTTOM SIDE

3-11
 CHK
CHASSIS ADJ
EAS20024

CHASSIS A

EAS30893

BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
EWA13100

WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA18050

NOTICE B
• Bleed the brake system in the following or-
der.
• 1st step: Front brake calipers
• 2nd step: Rear brake caliper
EWA15740

WARNING
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced. A. Front
• the brake fluid level is very low. B. Rear
• brake operation is faulty.
d. Place the other end of the hose into a con-
TIP tainer.
• Be careful not to spill any brake fluid or allow e. Slowly apply the brake several times.
the brake master cylinder reservoir or brake f. Fully pull the brake lever or fully press
fluid reservoir to overflow. down the brake pedal and hold it in posi-
• When bleeding the hydraulic brake system, tion.
make sure there is always enough brake fluid g. Loosen the bleed screw.
before applying the brake. Ignoring this pre- TIP
caution could allow air to enter the hydraulic Loosening the bleed screw will release the pres-
brake system, considerably lengthening the sure and cause the brake lever to contact the
bleeding procedure. throttle grip or the brake pedal to fully extend.
• If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat h. Tighten the bleed screw, and then release
the bleeding procedure when the tiny bubbles the brake lever or brake pedal.
in the hose have disappeared. i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
1. Bleed:
fluid in the plastic hose.
• ABS
j. Check the operation of the hydraulic unit.
a. Fill the brake fluid reservoir to the proper
Refer to “HYDRAULIC UNIT OPERA-
level with the specified brake fluid.
TION TESTS” on page 4-32.
b. Install the diaphragm (brake master cylin-
der reservoir or brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to
the bleed screw “2”.

3-12
 CHK
CHASSIS ADJ
ECA18060

NOTICE
Make sure that the main switch is turned to
“OFF” before checking the operation of the
hydraulic unit.
k. After operating the ABS, repeat steps (e)
to (i), and then fill the brake master cylin-
der reservoir or brake fluid reservoir to the
proper level with the specified brake fluid.
l. Tighten the bleed screw to specification.
Front brake caliper bleed screw
14 N·m (1.4 kgf·m, 10 lb·ft)
T.

Rear brake caliper bleed screw

R.

6 N·m (0.6 kgf·m, 4.4 lb·ft)

m. Fill the brake master cylinder or brake fluid

reservoir to the proper level with the spec-
ified brake fluid.
Specified brake fluid
DOT 4
EWA13110

WARNING
After bleeding the hydraulic brake system,
check the brake operation.

3-13
 CHAS
CHAPTER 4
GENERAL CHASSIS

GENERAL CHASSIS....................................................................................... 4-1

REMOVING THE REAR VIEW MIRROR ASSEMBLY.............................. 4-4
INSTALLING THE REAR VIEW MIRROR ASSEMBLY ............................ 4-4
REMOVING THE PANEL CONSOLE ....................................................... 4-5
INSTALLING THE PANEL CONSOLE ...................................................... 4-5
REMOVING THE PANEL ASSEMBLY...................................................... 4-6
INSTALLING THE PANEL ASSEMBLY .................................................... 4-7
REMOVING THE UNDER COVER ........................................................... 4-8
INSTALLING THE UNDER COVER .......................................................... 4-8
REMOVING THE HEADLIGHT COWLING ASSEMBLY........................... 4-9
INSTALLING THE HEADLIGHT COWLING ASSEMBLY ......................... 4-9
REMOVING THE AUXILIARY LIGHT ASSEMBLY ................................. 4-10
INSTALLING THE AUXILIARY LIGHT ASSEMBLY................................ 4-10
REMOVING THE BODY FRONT UPPER ............................................... 4-11
INSTALLING THE BODY FRONT UPPER ............................................. 4-11

FRONT WHEEL............................................................................................. 4-12

REMOVING THE FRONT WHEEL (For FAZER25-ABS)........................ 4-13
MAINTENANCE OF THE WHEEL SENSOR AND SENSOR ROTOR ... 4-13
INSTALLING THE FRONT WHEEL ........................................................ 4-15

REAR WHEEL ............................................................................................... 4-17

REMOVING THE REAR WHEEL ............................................................ 4-19
MAINTENANCE OF THE REAR WHEEL SENSOR 
AND SENSOR ROTOR .......................................................................... 4-19
INSTALLING THE REAR WHEEL...........................................................4-19

FRONT BRAKE ............................................................................................. 4-22

REMOVING THE FRONT BRAKE CALIPER .......................................... 4-23
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-23

REAR BRAKE ............................................................................................... 4-25

REMOVING THE REAR BRAKE CALIPER ............................................ 4-26
INSTALLING THE REAR BRAKE CALIPER ........................................... 4-26

ABS (ANTI-LOCK BRAKE SYSTEM)...........................................................4-28

REMOVING THE HYDRAULIC UNIT ASSEMBLY ................................. 4-30
CHECKING THE HYDRAULIC UNIT ASSEMBLY .................................. 4-30
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-31
HYDRAULIC UNIT OPERATION TESTS................................................4-32
CHECKING THE ABS WARNING LIGHT ............................................... 4-36
 CHAS
FRONT FORK (For FAZER25-ABS).............................................................4-37
CHECKING THE FRONT FORK OUTER TUBE .....................................4-38

STEERING HEAD (For FAZER25-ABS)....................................................... 4-39

 GENERAL CHASSIS CHAS
GENERAL CHASSIS
GENERAL CHASSIS

Removing the under cover (For FAZER25-ABS)

Order Job/Parts to remove Q’ty Remarks

1 Rear view mirror (left side) 1 For removing and installing process
refer page 4-4.
2 Rear view mirror (right side) 1
3 License plate bracket 1
4 Panel console (left side) 1 For removing and installing process
5 Panel console (right side) 1 refer page 4-4 & 4-5.

6 Turn signal light connector (left side) 1 Disconnect.

Panel assembly (left side) 1 For removing and installing process
7
refer page 4-5.
8 Turn signal light connector (right side) 1 Disconnect
Panel assembly (right side) 1 For removing and installing process
9
refer page 4-5, same as left side.
Under cover assembly 1 For removing and installing process
10
refer page 4-7 & 4-8.
For installation, reverse the removal proce-
dure.

4-1
 GENERAL CHASSIS CHAS
Removing the headlight cowling assembly / meter assembly / auxiliary light assembly (For FAZER25-ABS)

Order Job/Parts to remove Q’ty Remarks

Rear view mirror (left/right), License plate Refer to “GENERAL CHASSIS” on
bracket, Panel console (left/right), Panel page 4-1.
assembly (left/right)
1 Left cover 1
2 Right cover 1
3 Auxiliary light coupler 2 Disconnect.
4 Headlight coupler 1 Disconnect.
5 Headlight cowling assembly 1
6 Meter coupler 1 Disconnect.
7 Meter assembly 1
8 Meter pad 1
9 Support stay (left side) 1
10 Support stay (right side) 1
11 Stay 1
12 Windshield 1

4-2
 GENERAL CHASSIS CHAS
Removing the headlight cowling assembly / meter assembly / auxiliary light assembly (For FAZER25-ABS)

Order Job/Parts to remove Q’ty Remarks

13 Headlight 1
14 Auxiliary light (left side) 1
15 Auxiliary light (right side) 1
16 Body front upper 1
17 Body front lower 1
18 Headlight bracket stay upper 1
19 Headlight bracket stay lower 1
For installation, reverse the removal proce-
dure.

4-3
 GENERAL CHASSIS CHAS
REMOVING THE REAR VIEW MIRROR
ASSEMBLY
1. Remove the rear view mirror bolt caps “1”
from the rear view mirror bolts.

TIP
Before opening the right side rear view mirror
bolts, hold the license plate bracket to avoid
the scratches at body front upper.
2. Remove the left side rear view mirror “2” by
removing the bolts “3”.
3. Remove the right side rear view mirror “4” INSTALLING THE REAR VIEW MIRROR
by removing the bolts “5” along with license ASSEMBLY
plate bracket “6”. 1. Install the collars “1” and rubber plates “2”.

5
6
3

2
4. Remove the rubber plates “7” and collars
“8”.

4-4
 GENERAL CHASSIS CHAS
TIP 4. Pull the panel console from rear in direction
When installing the rear view mirror assembly. “b” to release tabs from slots.
Make sure rubber plate indication mark “a” 5. Lift the body front upper cover in direction
should be same as shown. “c” and then pull the panel console back-
ward.
2. Install the rear view mirror assembly along
c
with license plate bracket and tighten the
bolts as per specified torque. a

Rear view mirror assembly bolt

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.

b
3. Install the rear view mirror bolt caps.
4. Adjust the rear view mirror “1” according to
need as shown.

6. Similarly remove the right side panel con-

1 1 sole.

INSTALLING THE PANEL CONSOLE

1. First install the right side panel console.
Refer to “REMOVING THE UNDER
COVER” on page 4-8.
2. Install the left side panel console “1”.
TIP
Before installing the left side panel console,
REMOVING THE PANEL CONSOLE ensure grommet is fitted properly at right side
panel console.
1. Remove the rear view mirror assembly.
Refer to “REMOVING THE REAR VIEW 3. Align the projection “2” in to the hole “3” at
MIRROR ASSEMBLY” on page 4-4. right side panel console.
TIP 4. Insert the tabs into the slots, and then push
First remove left side panel console and then the panel console in to its original position.
right side panel console. 5. Install the quick fastener and screws.
2. Remove the left side panel console “1” by
removing the screws “2” and quick fastener “3”.
2

1 1

2 3

Panel console screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

6. Install the rear view mirror assembly.

3. To remove the left side panel console, pull Refer to “INSTALLING THE REAR VIEW
the panel console upward to release the MIRROR ASSEMBLY” on page 4-4.
projection “a” from the hole as shown.

4-5
 GENERAL CHASSIS CHAS
REMOVING THE PANEL ASSEMBLY 5. Remove the hook “6” by pushing the posi-
1. Remove the panel console. tion of the left panel assembly “7” under the
Refer to “REMOVING THE PANEL CON- third hole downward left cover “8”.
SOLE” on page 4-5.
2. Remove the quick fastener “1” under the
auxiliary light.
8

6
6. Insert your fingers into the space, removing
the hook “9” by lifting the left side panel
1 assembly “10”.

3. Remove the screw “2” and bolt “3”.

2
Insert your finger and
10 slide your finger to front
side pulling the left side
panel assembly upward
9

3 7. Remove the projection “11” from the grom-

met of seat knee grip and projection “12”
4. Remove the hook by pushing edge of left from the grommet of left cover by pulling it
cover “4” from body front upper “5”. outward direction.

Remove hook
by pushing edge
of cover “7” 4

12
11
5
8. Remove the hook “13” by pushing the end
The hook
of the left panel assembly “14” downward
in back and sliding the left cover downward.

13

14

4-6
 GENERAL CHASSIS CHAS
9. Remove the projection “15” by inserting 12.Pulling the left side panel assembly “18” as
your fingers into the space. shown in upward direction “a” from bottom
side to remove the hole from projection “b”.

18
15

a
10.Remove the hook “16” by pushing the left
panel assembly as shown in downward
direction. 13.Similarly remove the right side panel
assembly.

INSTALLING THE PANEL ASSEMBLY

TIP
l Before installing panel assembly ensure all
the tabs “1”, Projections “2” grommet “3”
and collar “4” are properly installed and free
16 from damages and cracks.
l Ensure all screws “5” are tighten as per
specification.
11.Disconnect the connector’s “17” of the turn l Ensure damper “6” available at shown loca-
signal light. tion.
l Ensure grommet available at under cover.

2
3
1
4

6
5
1. Connect the turn signal light connector’s
17 and ensure for proper connection.
2. Align the hole “1” into the projection “2” and
then secure the panel at body front upper
and slide backward.
3. Align the projections “3” into the holes “4”
and ensure all tabs installed in slots prop-
erly.

4-7
 GENERAL CHASSIS CHAS
INSTALLING THE UNDER COVER
4 3
1. Align the tab “1” into the slot “2” and slide
the under cover as shown.
2. Align the pin “3” into the hole “4” and then
install the screw of under cover.

1 1
2
4. Install the quick fastener and tighten the
screw and bolt to the specified torque. 2

Panel assembly bolt

5 N·m (0.5 kgf·m, 3.7 lb·ft) 4
T.

Panel assembly screw

R.

3
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Under cover screw
5. Install the panel console. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.

Refer to “INSTALLING THE PANEL CON-

R.

SOLE” on page 4-5. 3. Install the under cover by installing the

screws.
REMOVING THE UNDER COVER
TIP
1. Remove the panel assembly. Before installing the under cover, ensure avail-
Refer to “REMOVING THE PANEL ability of grommets “5” and collars “6”.
ASSEMBLY” on page 4-6.
2. Remove the under cover assembly “1” by
removing the screws “2”. 6

5
1 2
4. Tighten the screws of under cover to speci-
3. To separate the under cover remove the
fied torque.
screws “3”.
4. Remove the pin from hole and gently slide Under cover screw
the under cover “4” to release the tab “5” 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.

from slot “6” as shown.

R.

5. Install the panel assembly.

4 Refer to “INSTALLING THE PANEL
ASSEMBLY” on page 4-7.

6
3

4-8
 GENERAL CHASSIS CHAS
REMOVING THE HEADLIGHT COWLING 6. Remove headlight lead coupler “2” by
ASSEMBLY pressing the lock “3” from stay support.
1. Remove the panel assembly.
Refer to “REMOVING THE PANEL
ASSEMBLY” on page 4-6.
2. Remove the left cover.
2
• Unlock the hook by pushing the edge of
3
left cover as shown “a”.
• Pull outward to remove the projection
from hole “b” and then slide backward to
release the hole from lug as shown “c”.
7. Remove the headlight “4” from the body
a front upper “5” by removing the screws “6”.
c

b 4
6
1 5

3. Similarly remove the right cover.

4. Disconnect the headlight coupler and auxil-
iary light couplers. INSTALLING THE HEADLIGHT COWLING
5. Remove the headlight cowling assembly by ASSEMBLY
removing the bolts “1”. TIP
Before installing headlight cowling assembly,
check lugs for damage.

1. For installing the headlight, align the lug “1”

into the hole “2” as shown.

1 2 1

2
1
1 2. Install the screws “3” and tighten as speci-
fied torque.
4

3
5

4-9
 GENERAL CHASSIS CHAS
TIP REMOVING THE AUXILIARY LIGHT
Before installing the headlight assembly ASSEMBLY
ensure the damper “4” is fixed properly at body 1. Remove the headlight assembly.
front upper “5”.
Refer to “REMOVING THE HEADLIGHT
COWLING ASSEMBLY” on page 4-9.
Headlight screw 2. Remove the headlight bracket stay lower by
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) removing bolts “1” and screws “2”.
T.
R.

3. Install headlight assembly by installing bolts 1

at stay.
TIP
Before installing headlight assembly at stay 1
ensure rubber plate “1” is properly fixed at its
location.

2
3. Remove the auxiliary light assembly by
removing the screws “3”.

Headlight cowling assembly and

stay bolt
T.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

R.

3
4. Install the left cover.
• Align the hole “1” into the projection “2” INSTALLING THE AUXILIARY LIGHT
and then slide forward as shown. ASSEMBLY
• Insert the lug “3” into hole “4” as shown. 1. Install the auxiliary light assembly.
• Lock the hook by pressing the edge of left • Align the hole “a” into the lug “b” as
cover. shown.
2 1
a
3

4 b
b
a

5. Similarly install the right cover. 2. Install the auxiliary light assembly by install-
6. Install the panel assembly. ing the screws and tighten as per specified
Refer to “INSTALLING THE PANEL torque.
ASSEMBLY” on page 4-7.

4-10
 GENERAL CHASSIS CHAS
3. Install the headlight bracket stay lower by 2. Install the headlight.
installing bolts and screws and tighten as Refer to “INSTALLING THE HEADLIGHT
per specified torque. COWLING ASSEMBLY” on page 4-9.
Headlight bracket stay lower and
auxiliary light assembly screw
T.
R.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

Headlight bracket stay and head-
light assembly bolt
4 N·m (0.40 kgf·m, 3.0 lb·ft)

4. Install the headlight assembly.

Refer to “INSTALLING THE HEADLIGHT
COWLING ASSEMBLY” on page 4-9.

REMOVING THE BODY FRONT UPPER

1. Remove the headlight assembly.
Refer to “REMOVING THE HEADLIGHT
COWLING ASSEMBLY” on page 4-9.
2. Remove the lugs “1” from slots “2” as
shown.

1
2

INSTALLING THE BODY FRONT UPPER

TIP
Before assembling body front upper and lower,
check lugs and slots for crack and damage.

1. Align the lugs “1” into the slots “2” as

shown.

2
1

2
1

4-11
 FRONT WHEEL CHAS
EAS20028

FRONT WHEEL
Removing the front wheel and brake disc

38 N·m (3.8 kgf·m, 28 lb·ft)

For Fazer25(ABS)

Order Job/Parts to remove Q’ty Remarks

1 Front brake hose holder 1
2 Sensor lead holder 1
3 Front brake caliper 1
4 Front wheel sensor 1
5 Front wheel axle nut 1
6 Washer 1
7 Front wheel axle 1
8 Front wheel 1
9 Collar 2
10 Front brake disc 1
Use “Torx bit T-25” for wheel sensor rotor
11 Front wheel sensor rotor 1 bolt.
For installation, reverse the removal proce-
dure.

4-12
 FRONT WHEEL CHAS
REMOVING THE FRONT WHEEL
(For FAZER25-ABS) • Do not drop the front wheel sensor rotor or
1. Stand the vehicle on a level surface. subject it to shocks.
• If any solvent gets on the front wheel sen-
WARNING sor rotor, wipe it off immediately.
Securely support the vehicle so that there
is no danger of it falling over. ECA21700

NOTICE
2. Elevate: Do not apply the brake lever when removing
• Front wheel the brake calipers.
TIP
l Place the vehicle on a center stand so that 4. Remove:
the front wheel is elevated. • Front wheel axle nut
l While removing the front wheel, put the scis- • Washer
sor jack “a” under the engine of the vehicle. • Front wheel axle
• Front wheel
• Collars
EAS31151

MAINTENANCE OF THE WHEEL SENSOR

AND SENSOR ROTOR
ECA21070

NOTICE
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The wheel sensor cannot be disassembled.
(a) Do not attempt to disassemble it. If faulty,
replace with a new one.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the wheel sensor or wheel
sensor rotor.
Scissor Jack • Do not drop or shock the wheel sensor or
YSST-892 A the wheel sensor rotor.

1. Check:
3. Remove: • Wheel sensor “1”
• Front brake hose holder Cracks/bends/distortion  Replace.
• Front wheel sensor Iron powder/dust  Clean.
• Front brake caliper
ECA20981

NOTICE
• Keep any type of magnets (including mag- 1
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys-
tem.

4-13
 FRONT WHEEL CHAS
2. Check:
• Wheel sensor rotor “1”
Cracks/damage/scratches  Replace the
wheel sensor rotor.
Iron powder/dust/solvent  Clean.
TIP
• The wheel sensor rotor is installed on the inner
side of the wheel hub.
• When cleaning the wheel sensor rotor, be
careful not to damage the surface of the sensor
rotor.

c. If the deflection is above specification, re-

3. Measure: move the sensor rotor from the wheel, ro-
• Wheel sensor rotor runout limit tate it by one or two bolt holes, and then
Out of specification  Clean the installation install it.
surface of the wheel sensor rotor and correct
the wheel sensor rotor runout limit, or replace Front wheel sensor rotor bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
the wheel sensor rotor.
T.
R.

ECA18100
Wheel sensor rotor runout limit
NOTICE
limit
0.25 mm (0.0098 in) Replace the wheel sensor rotor bolts with
new ones.
a. Hold the dial gauge at a right angle against
the wheel sensor rotor surface. d. If the deflection is still above specification,
b. Measure the wheel sensor rotor runout replace the wheel sensor rotor.
limit. TIP
TIP • Install the wheel sensor rotor with the stamped
Do not touch the surface of the wheel sensor ro- mark “a” facing outward.
tor with a sharp object. • Use “Torx bit T-25” for opening/tightening
wheel sensor rotor bolt.

4-14
 FRONT WHEEL CHAS
EAS30932 ECA21020

INSTALLING THE FRONT WHEEL NOTICE

1. Lubricate: Make sure there are no foreign materials in
• Oil seal lips the front wheel sensor rotor and front wheel
sensor. Foreign materials cause damage to
Recommended lubricant the front wheel sensor rotor and front wheel
Lithium-soap-based grease
sensor.
2. Install: TIP
• Collars • When installing the front wheel sensor, check
• Front wheel the wheel sensor lead for twists.
• Front wheel axle • To route the front wheel sensor lead, refer to
• Front wheel axle nut “CABLE ROUTING (For FAZER25-ABS)” on
TIP page 2-12.
• Install the tire and wheel with the mark “1”
pointing in the direction of wheel rotation. 5. Measure:
• Align the DOT mark “2” with the tire air valve in- • Distance “a”
stallation point. (between the front wheel sensor rotor “1” and
• Apply lithium-soap-based grease to the con- front wheel sensor “2”)
tact surface and threads of the front wheel axle Out of specification  Check the wheel bear-
nut. ing for looseness, and the front wheel sensor
and sensor rotor installation conditions (war-
page caused by overtorque, wrong installa-
tion direction, rotor decentering, LOCTITE®
1
on the mounting surface of the rotor, defor-
mation caused by an impact during service
2 and caught foreign materials). If there is any
defective part, repair or replace the defective
part.
Distance “a” (between the front
G088891 wheel sensor rotor and front
wheel sensor)
3. Tighten: 1.29 mm (0.050 in)
• Front wheel axle nut
Front wheel axle nut TIP
38 N·m (3.8 kgf·m, 28 lb·ft) Measure the distance between the front wheel
T.

sensor rotor and front wheel sensor in several

R.

ECA14140 places in one rotation of the front wheel. Do not

NOTICE turn the front wheel while the feeler gauge is in-
Before tightening the wheel axle nut, push stalled. This may damage the front wheel sensor
down hard on the handlebar(s) several times rotor and the front wheel sensor.
and check if the front fork rebounds smooth-
ly.
Feeler gauge
4. Install:
• Front wheel sensor
Front wheel sensor bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

4-15
 FRONT WHEEL CHAS

a
1

2
2
1

G088903

6. Install:
• Front brake caliper
• Front brake hose holder
Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
T.

Front brake hose holder bolt

R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

4-16
 REAR WHEEL CHAS
EAS20029

REAR WHEEL
Removing the rear wheel

Order Job/Parts to remove Q’ty Remarks

Mud protector Refer to “GENERAL CHASSIS” in base ser-

vice manual B97-F8197-E0 on page 4-1.
Rear wheel speed sensor
1 Axle nut 1
2 Washer 1
3 Drive chain adjusting locknut 2 Loosen.
4 Drive chain adjusting nut 2 Loosen.
5 Rear wheel axle 1
6 Washer 1
7 Rear wheel 1
8 Collar sprocket axle 1
9 Collar wheel 1
10 Drive chain puller 2
For installation, reverse the removal proce-
dure.

4-17
 REAR WHEEL CHAS
Removing the rear brake disc and rear wheel sprocket

43 N·m (4.3 kgf·m, 32 lb·ft)

8.0 N·m (0.8 kgf·m, 5.9 lb·ft)

23 N·m (2.3 kgf·m, 17 lb·ft)

Order Job/Parts to remove Q’ty Remarks

1 Rear wheel sprocket 1
2 Rear wheel drive hub 1
3 Rear wheel drive hub damper 6
4 Rear brake disc 1
5 Rear wheel sensor rotor 1
6 Oil seal 1
7 Bearing 1
8 Spacer 1
9 Oil seal 1
10 Bearing 1
11 Collar 1
For installation, reverse the removal proce-
dure.

4-18
 REAR WHEEL CHAS
EAS30156
TIP
REMOVING THE REAR WHEEL
Push the rear wheel forward and remove the
ECA21030
drive chain from the rear wheel sprocket.
NOTICE
• Keep any type of magnets (including mag-
MAINTENANCE OF THE REAR WHEEL
netic pick-up tools, magnetic screwdrivers,
SENSOR AND SENSOR ROTOR
etc.) away from the rear wheel sensor or
rear wheel sensor rotor; otherwise, the sen- NOTICE
sor or rotor may be damaged, resulting in
improper performance of the ABS system. • Handle the ABS components with care
• Do not drop the rear wheel sensor rotor or since they have been accurately adjusted.
subject it to shocks. Keep them away from dirt and do not sub-
• If any solvent gets on the rear wheel sensor ject them to shocks.
rotor, wipe it off immediately. • The wheel sensor cannot be disassembled.
Do not attempt to disassemble it. If faulty,
1. Stand the vehicle on a level surface. replace with a new one.
EWA13120 • Keep any type of magnets (including mag-
WARNING netic pick-up tools, magnetic screwdrivers,
Securely support the vehicle so that there is etc.) away from the wheel sensor or wheel
no danger of it falling over. sensor rotor.
• Do not drop or shock the wheel sensor or
TIP the wheel sensor rotor.
Place the vehicle on a centerstand so that the Refer to “MAINTENANCE OF THE WHEEL
rear wheel is elevated. SENSOR AND SENSOR ROTOR” on page
4-13.
2. Remove:
• Rear wheel sensor EAS30165
ECA21470
INSTALLING THE REAR WHEEL
NOTICE
1. Install:
Do not depress the brake pedal when remov- • Rear wheel sensor rotor
ing the brake caliper. • Rear brake disc
3. Loosen: Rear wheel sensor rotor bolt
• Wheel axle nut “1” 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.

• Drive chain puller locknuts “2” LOCTITE®

• Drive chain adjusting nuts “3” Rear brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
ECA21011

NOTICE
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones.
4. Remove:
• Rear wheel axle nut TIP
• Washer • Install the wheel sensor rotor with the stamped
• Rear wheel axle along with washer mark “1” facing outward.
• Drive chain puller • Tighten the brake disc bolts in stages and in a
• Collars crisscross pattern.
• Rear wheel along with rear brake caliper

4-19
 REAR WHEEL CHAS
• Apply lithium-soap-based grease to the con-
tact surface and threads of the rear wheel axle
1 nut.

2
G088900

G088891

LT

1. Install:
• Rear wheel sprocket
Refer to “CHECKING AND REPLACING
THE REAR WHEEL SPROCKET” in base
service manual B97-F8197-E0 on page 4-14. 5. Lubricate:
2. Check: • Rear brake caliper bolt
• Rear brake disc Recommended lubricant
Refer to “CHECKING THE FRONT BRAKE Silicone grease
DISC” in base service manual B97-F8197-E0
on page 4-23. 6. Install:
3. Lubricate: • Rear brake caliper
• Oil seal lips 7. Adjust:
Recommended lubricant • Drive chain slack
Lithium-soap-based grease Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in base service manual B97-F8197-
4. Install: E0 on page 3-17.
• Collar (right) Drive chain slack
• Collar (left) 40.0–45.0 mm (1.57–1.77 in)
• Brake caliper
• Rear wheel 8. Tighten:
• Rear wheel axle • Rear wheel axle nut
• Washers • Rear brake caliper bolt
• Rear wheel axle nut
Rear wheel axle nut
TIP
59 N·m (5.9 kgf·m, 44 lb·ft)
For tires with a direction of rotation mark “1”:
T.
R.

• Install the tire with the mark pointing in the di- EWA13500

rection of wheel rotation. WARNING

• Align the mark “2” with the valve installation Make sure the brake hose is routed properly.
point.
• Align the projection “a” in the swingarm with the
slot “b” of the brake caliper bracket.

4-20
 REAR WHEEL CHAS
9. Install:
• Rear wheel sensor 1
Rear wheel sensor bolt 2
7 N·m (0.7 kgf·m, 5.2 lb·ft) 2
T.
R.

ECA21080

NOTICE a
Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel 1
G088906
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.

TIP
To route the rear wheel sensor lead, refer to
“CABLE ROUTING (For FAZER25-ABS)” on
page 2-12.

10.Measure:
• Distance “a”
(between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
Out of specification  Check the wheel bear-
ing for looseness, and the rear wheel sensor
and sensor rotor installation conditions (war-
page caused by overtorque, wrong installa-
tion direction, rotor decentering, LOCTITE®
on the mounting surface of the rotor, defor-
mation caused by an impact during service
and caught foreign materials). If there is any
defective part, repair or replace the defective
part.
Distance “a” (between the rear
wheel sensor rotor and rear
wheel sensor)
1.29 mm (0.050 in)

TIP
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the feeler gauge is in-
stalled. This may damage the rear wheel sensor
rotor and the rear wheel sensor.

Feeler gauge

4-21
 FRONT BRAKE CHAS
EAS20030

FRONT BRAKE
Removing the front brake caliper

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.
1 Front brake hose union bolt (brake caliper side) 1
2 Brake hose gasket 2
Front brake hose (brake hose joint to brake cali-
3 per) 1

4 Front brake caliper bolt 2

5 Sensor lead holder 1
6 Front brake caliper 1

4-22
 FRONT BRAKE CHAS
EAS30724

REMOVING THE FRONT BRAKE CALIPER Front brake caliper bolt

TIP
35 N·m (3.5 kgf·m, 26 lb·ft)

T.
R.
Before removing the brake caliper, drain the
brake fluid from the entire brake system. Front brake hose union bolt
(brake caliper side)

T.
ECA20981
29 N·m (2.9 kgf·m, 21 lb·ft)

R.
NOTICE
• Keep any type of magnets (including mag- EWA13531

netic pick-up tools, magnetic screwdrivers, WARNING

etc.) away from the rear wheel sensor or Proper brake hose routing is essential to in-
rear wheel sensor rotor; otherwise, the sen- sure safe vehicle operation.
sor or rotor may be damaged, resulting in
ECA18220
improper performance of the ABS system.
• Do not drop the rear wheel sensor rotor or NOTICE
subject it to shocks. When installing the brake hose “3” onto the
• If any solvent gets on the rear wheel sensor brake caliper “1”, make sure the brake hose
rotor, wipe it off immediately. “a” passes between the projection “b” on
the brake caliper.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gaskets “2”
• Front brake hose (brake hose joint to brake 3
caliper) “3” 4 a b
• Wheel sensor holder
• Brake caliper
TIP 1
Put the end of the brake hose into a container
and pump out the brake fluid carefully. New 2

Refer to “REPLACING THE FRONT BRAKE

PADS” in base service manual B97-F8197-
3 E0 on page 4-24.
2. Fill:
• Brake master cylinder reservoir
1 (with the specified amount of the specified
brake fluid)
Specified brake fluid
2 DOT 4

EAS30934 EWA13090

INSTALLING THE FRONT BRAKE CALIPER WARNING

1. Install: • Use only the designated brake fluid. Other
• Front brake caliper “1” brake fluids may cause the rubber seals to
(temporarily) along with wheel sensor holder deteriorate, causing leakage and poor
• Brake hose gaskets “2” New brake performance.
• Front brake hose (brake hose joint to brake • Refill with the same type of brake fluid that
caliper) “3” is already in the system. Mixing brake fluids
• Brake hose union bolt “4” may result in a harmful chemical reaction,
leading to poor brake performance.

4-23
 FRONT BRAKE CHAS
• When refilling, 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.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.

3. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.
4. Check:
• Brake fluid level
Below the minimum level mark “a”  Add the
specified brake fluid to the proper level.

5. Check:
• Brake lever operation
Soft or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.

4-24
 REAR BRAKE CHAS
EAS20031

REAR BRAKE
Removing the rear brake caliper

Order Job/Parts to remove Q’ty Remarks

Rear wheel sensor Refer to “REAR WHEEL” on page 4-17.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.
Rear wheel Refer to “REAR WHEEL” on page 4-17.
1 Rear brake hose union bolt 1
2 Brake hose gasket 2
3 Rear brake hose 1
4 Rear brake caliper 1
For installation, reverse the removal proce-
dure.

4-25
 REAR BRAKE CHAS
EAS30186
• Rear brake caliper “1” along with rear wheel
REMOVING THE REAR BRAKE CALIPER
• Rear wheel sensor
TIP Refer to “REPLACING THE REAR BRAKE
Before disassembling the brake caliper, drain PADS” in base service manual B97-F8197-
the brake fluid from the entire brake system. E0 on page 4-35.
ECA20981 • Brake hose gaskets “2” New
NOTICE • Rear brake hose (hydraulic unit to brake cali-
per) “3”
• Keep any type of magnets (including mag-
• Rear brake hose union bolt “4”
netic pick-up tools, magnetic screwdrivers,
etc.) away from the rear wheel sensor or Rear brake hose union bolt (brake
rear wheel sensor rotor; otherwise, the sen- caliper side)

T.
29 N·m (2.9 kgf·m, 21 lb·ft)

R.
sor or rotor may be damaged, resulting in
improper performance of the ABS system.
• Do not drop the rear wheel sensor rotor or
subject it to shocks. 3
• If any solvent gets on the rear wheel sensor 4
New 2
rotor, wipe it off immediately.

1. Remove:
• Rear wheel sensor
• Rear brake hose union bolt “1” 1
• Brake hose gaskets “2”
• Rear brake hose (hydraulic unit to brake cali-
per) “3” EWA13531

• Rear wheel along with caliper WARNING

TIP Proper brake hose routing is essential to in-
Put the end of the brake hose into a container sure safe vehicle operation.
and pump out the brake fluid carefully.
ECA19080

NOTICE

3 When installing the brake hose onto the

1 brake caliper, be sure to position the brake
2 pipe “a” touches the projection “b” in the
brake caliper.

EAS30190

INSTALLING THE REAR BRAKE CALIPER

1. Lubricate:
• Rear brake caliper bolt
Recommended lubricant
Silicone grease

2. Install:
• Brake pad shims
(onto the brake pads)
• Brake pads

4-26
 REAR BRAKE CHAS
3. Fill: 6. Check:
• Brake fluid reservoir • Brake pedal operation
(with the specified amount of the specified Soft or spongy feeling  Bleed the brake
brake fluid) system.
Refer to “BLEEDING THE HYDRAULIC
Specified brake fluid BRAKE SYSTEM (ABS)” on page 3-12.
DOT 4
EWA13090

WARNING
• 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 refilling, 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.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.

4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.
5. Check:
• Brake fluid level
Below the minimum level mark “a”  Add the
specified brake fluid to the proper level.

a
UPPER

LOWER

4-27
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
EAS20033

ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to“BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.
Refer to “GENERAL CHASSIS (1)” in base
Rider and passenger seat service manual B97-F8197-E0 on page 4-1.
Refer to “GENERAL CHASSIS (2)” in base
Side cover assembly LH & RH service manual B97-F8197-E0 on page 4-1.
Refer to “GENERAL CHASSIS” in base ser-
Rear left side cover vice manual B97-F8197-E0 on page 4-1.
Refer to “GENERAL CHASSIS” in base ser-
Side panel assembly LH & RH (Fuel tank) vice manual B97-F8197-E0 on page 4-1.
Refer to “GENERAL CHASSIS” in base ser-
Air filter assembly vice manual B97-F8197-E0 on page 4-3.
Refer to “CHECKING AND CHARGING
Battery and Battery box THE BATTERY” in base service manual
B97-F8197-E0 on page 7-62.
Refer to “FUEL TANK” in base service man-
Fuel tank cover assembly ual B97-F8197-E0 on page 6-1.

4-28
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
Removing the hydraulic unit assembly

Order Job/Parts to remove Q’ty Remarks

1 ABS ECU coupler 1

2 Rear brake hose (hydraulic unit to rear brake 1

caliper)
3 Rear brake hose joint 1
4 Rear brake hose bracket 1

5 Rear brake hose (hydraulic unit to rear brake 1

master cylinder)

6 Front brake hose (hydraulic unit to front brake 1

master cylinder)

7 Front brake hose (hydraulic unit to front brake 1

caliper)
8 Rubber band 1
9 Front brake hose (to brake caliper) 1
10 Front brake hose (to brake master cylinder) 1
11 Brake hose holder 1
12 Hydraulic unit assembly 1
13 Hydraulic unit bracket 1
14 Hydraulic unit 1

4-29
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
EAS30197
2. Remove:
REMOVING THE HYDRAULIC UNIT
• Brake hoses
ASSEMBLY
ECA21091
TIP
NOTICE Do not operate the brake lever and brake pedal
while removing the brake hoses.
Unless necessary, avoid removing and in-
stalling the brake hoses of the hydraulic unit ECA14530

assembly. NOTICE

EWA13930
When removing the brake hoses, cover the
WARNING
area around the hydraulic unit to catch any
spilt brake fluid. Do not allow the brake fluid
Refill with the same type of brake fluid that is
to contact other parts.
already in the system. Mixing fluids may re-
sult in a harmful chemical reaction, leading 3. Remove:
to poor braking performance. • Hydraulic unit assembly “1”
ECA18241 TIP
NOTICE • To avoid brake fluid leakage and to prevent for-
• Handle the ABS components with care eign materials from entering the hydraulic unit
since they have been accurately adjusted. assembly, insert a rubber plug “a” or a bolt
Keep them away from dirt and do not sub- (M10  1.25) into each brake hose union bolt
ject them to shocks. hole.
• Do not turn the main switch to “ON” when • When using a bolt, do not tighten the bolt until
removing the hydraulic unit assembly. the bolt head touches the hydraulic unit. Other-
• Do not clean with compressed air. wise, the brake hose union bolt seating surface
• Do not reuse the brake fluid. could be deformed.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 1
up any spilt brake fluid immediately.
• Do not allow any brake fluid to contact the
a
couplers. Brake fluid may damage the cou-
plers and cause bad contacts.
• If the union bolts for the hydraulic unit as-
sembly have been removed, be sure to
tighten them to the specified torque and
bleed the brake system.

1. Disconnect: EAS30198

• ABS ECU coupler “1” CHECKING THE HYDRAULIC UNIT

TIP ASSEMBLY
Push the lock “a” and pull the lever “b” of the 1. Check:
ABS ECU coupler in the direction of the arrow • Hydraulic unit assembly
shown, and then dis-connect the coupler. Cracks/damage  Replace the hydraulic unit
assembly and the brake hoses that are con-
nected to the assembly as a set.

4-30
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
EAS30200
c. Position the front brake hose (hydraulic
INSTALLING THE HYDRAULIC UNIT
unit to front brake master cylinder) “1” so
ASSEMBLY that pin shall contact “b” of front brake
1. Install: hose (hydraulic unit to front brake caliper)
• Hydraulic unit assembly “2” and then temporarily tighten the union
bolt for the brake hose “1”.
Hydraulic unit assembly bolt
d. Position the rear brake hose (hydraulic
7 N·m (0.7 kgf·m, 5.2 lb·ft)
unit to rear brake master cylinder) “3” so
T.
R.

that pin shall contact “d” of front brake

TIP
hose (hydraulic unit to front brake master
Do not allow any foreign materials to enter the
cylinder) “1” and then temporarily tighten
hydraulic unit assembly or the brake hoses
the union bolt for the brake hose “3”.
when installing the hydraulic unit assembly.
e. Position the rear brake hose (hydraulic
ECA21110 unit to rear brake caliper) “4” so that pin
NOTICE shall contact “c” of rear brake hose (hy-
Do not remove the rubber plugs or bolts draulic unit to rear brake master cylinder)
(M10  1.25) installed in the brake hose union “3” and then temporarily tighten the union
bolt holes before installing the hydraulic unit bolt for the brake hose “4”.
assembly. f. Tighten the brake hose union bolts to
specification.
2. Remove:
• Rubber plugs or bolts (M10  1.25)
3. Install:
• Rear brake hose (brake master cylinder to
hydraulic unit) “1”
• Front brake hose (brake hose joint to hydrau-
lic unit) “2”
• Front brake hose (hydraulic unit to brake
hose joint) “3”
• Rear brake hose (hydraulic unit to brake cali-
per) “4”
Front brake hose union bolt 4. Connect:
29 N·m (2.9 kgf·m, 21 lb·ft) • ABS ECU coupler “1”
T.

Rear brake hose union bolt

R.

TIP
29 N·m (2.9 kgf·m, 21 lb·ft) • Connect the ABS ECU coupler, and then push
ECA21121
the lock lever “a” of the coupler in the direction
of the arrow shown.
NOTICE
• Make sure that the ABS ECU coupler is con-
If the brake hose union bolt does not turn nected in the correct position as shown in illus-
easily, replace the hydraulic unit assembly, tration “A”.
brake hoses, and related parts as a set.

a. Temporarily install the brake hoses as

shown in the illustration.
b. Position the front brake hose (hydraulic
unit to front brake caliper) “2” so that pin
shall touch to end fitting of bracket “a” and
then temporarily tighten the union bolt for
the brake hose “2”.
a 1

4-31
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
7. Check the operation of the hydraulic unit ac-
A B cording to the brake lever and the brake ped-
al response. (Refer to “HYDRAULIC UNIT
OPERATION TESTS” on page 4-32.)
ECA14770

NOTICE
Always check the operation of the hydraulic
unit according to the brake lever and the
brake pedal response.

8. Delete the fault codes. (Refer to “[B-3] DE-

A. The ABS ECU coupler is connected correctly. LETING THE FAULT CODES” on page
B. The ABS ECU coupler is not connected. 7-75.)
9. Perform a trial run. (Refer to “CHECKING
5. Fill:
THE ABS WARNING LIGHT” on page 4-36.)
• Brake master cylinder reservoir
• Brake fluid reservoir EAS30930

(with the specified amount of the specified HYDRAULIC UNIT OPERATION TESTS
brake fluid) The reaction-force pulsating action generated in
the brake lever and brake pedal when the ABS
Specified brake fluid
DOT 4 is activated can be tested when the vehicle is
stopped.
EWA13090 The hydraulic unit operation can be tested using
WARNING the following two methods.
• Use only the designated brake fluid. Other • Brake line routing confirmation: this test
brake fluids may cause the rubber seals to checks the function of the ABS after the sys-
deteriorate, causing leakage and poor tem was disassembled, adjusted, or serviced.
brake performance. • ABS reaction-force confirmation: this test gen-
• Refill with the same type of brake fluid that erates the same reaction-force pulsating action
is already in the system. Mixing brake fluids that is generated in the brake lever and brake
may result in a harmful chemical reaction, pedal when the ABS is activated.
leading to poor brake performance.
• When refilling, be careful that water does Brake line routing confirmation
EWA13120
not enter the brake fluid reservoir. Water WARNING
will significantly lower the boiling point of
Securely support the vehicle so that there is
the brake fluid and could cause vapor lock.
no danger of it falling over.
ECA13540

NOTICE TIP
• For the brake line routing confirmation, use the
Brake fluid may damage painted surfaces
diagnosis mode of the Yamaha diagnostic tool.
and plastic parts. Therefore, always clean up
• Before performing the brake line routing confir-
any spilt brake fluid immediately.
mation, make sure that no malfunctions have
6. Bleed: been detected in the ABS ECU and that the
• Brake system wheels are not rotating.
Refer to “BLEEDING THE HYDRAULIC
1. Place the vehicle on a centerstand.
BRAKE SYSTEM (ABS)” on page 3-12.
2. Turn the main switch to “OFF”.
3. Remove:
• Rider seat and passenger seat
Refer to “GENERAL CHASSIS (1)” in base
service manual B97-F8197-E0 on page 4-1.

4-32
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
4. Check: 6. Start the Yamaha diagnostic tool and display
• Battery voltage the diagnosis mode screen.
Lower than 12.8 V  Charge or replace the 7. Select code No. 2, “Brake line routing confir-
battery. mation”.
8. Click “Actuator check” “1”, and then operate
Battery voltage the brake lever “2” and brake pedal “3” simul-
Higher than 12.8 V
taneously.
TIP TIP
If the battery voltage is lower than 12.8 V, charge • The hydraulic unit operates 1 second after the
the battery, and then perform brake line routing brake lever and brake pedal are operated si-
confirmation. multaneously and continues for approximately
5 seconds.
• The operation of the hydraulic unit can be con-
firmed using the indicator.
On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
draulic unit have not been met.
Off: The brake lever and brake pedal are not
being operated.

5. Removing the protective cap “1”, and then

connect the Yamaha diagnostic tool to the
ABS test coupler (4 Pin).
Yamaha diagnostic tool USB
INS-018
90890-03267
INS-019
90890-03262

2 3
9. Check:
• Hydraulic unit operation
Click “Actuator check”, a single pulse will be
generated in the brake lever “1”, brake pedal
“2”, and again in the brake lever “1”, in this or-
der.

4-33
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
1. Place the vehicle on a centerstand.
2. Turn the main switch to “OFF”.
3. Remove:
• Passenger seat
• Rider seat
Refer to “GENERAL CHASSIS (1)” in base
service manual B97-F8197-E0 on page 4-1.
4. Check:
• Battery voltage
1 2 Lower than 12.8 V  Charge or replace the
battery.
TIP
“ON” and “OFF” on the tool screen indicate Battery voltage
when the brakes are being applied and released Higher than 12.8 V
respectively.
ECA18280
TIP
NOTICE
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
• Check that the pulse is felt in the brake le- force confirmation.
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.

10.If the operation of the hydraulic unit is normal,

delete all of the fault codes. 5. Removing the protective cap “1”, and then
connect the Yamaha diagnostic tool to the
ABS reaction-force confirmation ABS test coupler (4 Pin).
EWA13120

WARNING Yamaha diagnostic tool USB

INS-018
Securely support the vehicle so that there is 90890-03267
no danger of it falling over. INS-019
90890-03262
TIP
• For the ABS reaction-force confirmation, use
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.

4-34
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
6. Start the Yamaha diagnostic tool and display • “ON” and “OFF” on the tool screen indicate
the diagnosis mode screen. when the brakes are being applied and re-
7. Select code No. 1, “ABS reaction-force con- leased respectively.
firmation”.
8. Click “Actuator check” “1”, and then operate
the brake lever “2” and brake pedal “3” simul-
taneously.
TIP
• The hydraulic unit operates 1 second after the
brake lever and brake pedal are operated si-
multaneously and continues for approximately
5 seconds. 1
• The operation of the hydraulic unit can be con-
firmed using the indicator.
On: The hydraulic unit is operating. 10.After the pulsating action has stopped in the
Flashing: The conditions for operating the hy- brake lever, it is generated in the brake pedal
draulic unit have not been met. “1” and continues for a few seconds.
Off: The brake lever and brake pedal are not TIP
being operated. • The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the brake lever
and brake pedal even after the pulsating action
has stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.

1
11.After the pulsating action has stopped in the
brake pedal, it is generated in the brake lever
and continues for a few seconds.
2 3 TIP
9. A reaction-force pulsating action is generated • The reaction-force pulsating action consists of
in the brake lever “1” and continues for a few quick pulses.
seconds. • “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
TIP
leased respectively.
• The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the brake lever
and brake pedal even after the pulsating action
has stopped.

4-35
 ABS (ANTI-LOCK BRAKE SYSTEM) CHAS
ECA18280

NOTICE
• Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.

12.Turn the main switch to “OFF”.

13.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
14.Turn the main switch to “ON”.
15.Set the start/engine stop switch to “ ”.
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage  Replace the hydraulic
unit, brake hoses, and related parts as a set.
17.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
EAS30202

CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 10 km/h
(6.3 mi/h) or performing a trial run.

4-36
 FRONT FORK (For FAZER25-ABS) CHAS
FRONT FORK (For FAZER25-ABS)
Removing the front fork legs

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both

of the front fork legs.

Front wheel Refer to “FRONT WHEEL” on page

4-12.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Lower bracket pinch bolt 1 Loosen.
4 Front fork leg 1
For installation, reverse the removal
procedure.

4-37
 FRONT FORK (For FAZER25-ABS) CHAS
CHECKING THE FRONT FORK OUTER
TUBE
1. Check:
• Outer tube protector seal “1”
Damage/scratches  Replace.

4-38
 STEERING HEAD (For FAZER25-ABS) CHAS
STEERING HEAD (For FAZER25-ABS)
Removing the upper and lower bracket

Order Job/Parts to remove Q’ty Remarks

Front fork legs Refer to “FRONT FORK (For FAZER25-
ABS)” on page 4-37.
1 Steering stem nut/washer 1/1
2 Upper bracket 1
3 Horn 1
4 Front brake holder 1
5 Upper bracket stay 1
6 Lock washer 1
7 Upper ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Lower bracket 1
11 Bearing cover 1
12 Upper bearing inner race 1
13 Upper bearing 1
14 Lower bearing 1

4-39
 STEERING HEAD (For FAZER25-ABS) CHAS
Removing the upper and lower bracket

Order Job/Parts to remove Q’ty Remarks

15 Upper bearing outer race 1
16 Lower bearing outer race 1
17 Lower bearing inner race 1
18 Dust seal 1
For installation, reverse the removal
procedure.

4-40
 CHAS

4-41
 ENG
CHAPTER 5
ENGINE

ENGINE REMOVAL ........................................................................................ 5-1

CRANKCASE .................................................................................................. 5-4

ENG
 ENGINE REMOVAL ENG
ENGINE

ENGINE REMOVAL
Removing the muffler (For FAZER25-ABS)

Order Job/Parts to remove Q’ty Remarks

TIP
Remove the under cover.
1 O2 sensor coupler 1 Refer to “GENERAL CHASSIS” on page
4-1.

Disconnect.
2 Muffler 1
3 Exhaust pipe gasket 1
For installation, reverse the removal proce-
dure

TIP
While installing muffler, first tighten all bolts temporary then tighten cylinder head side bolts as per
specified torque valve. Now, tighten remaining bolts as per specified torque value.

5-1
 ENGINE REMOVAL ENG
Disconnecting the leads and couplers

4 N.M (0.4 kgf.m, 3.0 lb.ft

Order Job/Parts to remove Q’ty Remarks

NOTICE
First, disconnect the negative battery
lead, and then the positive battery lead.

Rider seat and passenger seat, Side covers Refer to “GENERAL CHASSIS” in base
LH & HR, Fuel tank panels LH & RH manual B97-F8197-E0 on page 4-1.
Refer to “CHECKING AND CHARGING
Negative battery lead/Positive battery lead THE BATTERY” in base manual B97-F8197-
E0 on page 7-62.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” in
base manual B97-F8197-E0 on page 3-9.
Throttle body/clamp 1 Loosen.
1 Cylinder head breather hose 1 Disconnect.
2 Engine ground cable/clutch cable holder 1
3 Clutch cable 1 Disconnect.
4 Oil cooler pipe/collar with O-ring 2/2 Disconnect.
5 Engine oil temperature sensor coupler 1 Disconnect.
6 Spark plug cap 1 Disconnect.
7 Throttle cables 2

5-2
 ENGINE REMOVAL ENG
Disconnecting the leads and couplers

4 N.M (0.4 kgf.m, 3.0 lb.ft

Order Job/Parts to remove Q’ty Remarks

8 Stator coil coupler/crankshaft sensor coupler 1/1 Disconnect.
9 Shift arm 1
10 Drive chain sprocket cover 1
11 Drive chain 1
12 Horn leads 2 Disconnect.
13 Starting motor lead 1 Disconnect.
For installation, reverse the removal proce-
dure

5-3
 CRANKCASE ENG
CRANKCASE
Separating the crankcase

Order Job/Parts to remove Q’ty Remarks

Engine
Refer to “CYLINDER HEAD” in base manual
Cylinder head
B97-F8197-E0 on page 5-6.
Refer to “CYLINDER AND PISTON” in base
Cylinder/Piston
manual B97-F8197-E0 on page 5-23.
Refer to “CLUTCH” in base manual B97-
Clutch housing
F8197-E0 on page 5-38.
Refer to “OIL PUMP” in base manual B97-
Oil pump assembly
F8197-E0 on page 5-46.
Refer to “SHIFT SHAFT” in base manual
Shift shaft
B97-F8197-E0 on page 5-50.
Refer to “ELECTRIC STARTER” in base
Starter motor
manual B97-F8197-E0 on page 5-34.
Refer to “BALANCER GEAR” in base manu-
Balancer gears
al B97-F8197-E0 on page 5-52.
Refer to “MAGNETO AND STARTER
Magneto rotor CLUTCH” in base manual B97-F8197-E0 on
page 5-29.

5-4
 CRANKCASE ENG
Separating the crankcase

Order Job/Parts to remove Q’ty Remarks

1 Timing chain 1
2 Timing chain guide (intake side) 1
3 Circlip 1
4 Rotor 1
5 Circlip 1
6 Drive sprocket nut 1
7 Lock washer 1
8 Drive sprocket 1
9 Neutral switch 1
10 Right crankcase 1
11 Dowel pin 2
12 Left crankcase 1
For installation, reverse the removal proce-
dure

5-5
 FI
CHAPTER 6
FUEL SYSTEM

FUEL TANK..................................................................................................... 6-1

REMOVING THE FUEL TANK COVER .................................................... 6-2
INSTALL THE FUEL TANK COVER ......................................................... 6-3
 FUEL TANK (For FAZER25-ABS) FI
FUEL SYSTEM

FUEL TANK (For FAZER25-ABS)

Removing the fuel tank cover

Order Job/Parts to remove Q’ty Remarks

Rear view mirror (left/right), License plate brack-
Refer to “GENERAL CHASSIS” on page
et, Panel console (left/right), Panel assembly 1
4-1.
(left/right)
Rider seat and passenger seat/left side and Refer to “GENERAL CHASSIS” on page 4-1
1
right side cover of base service manual B97-F8197-E0.
1 Panel inner (left side) 1
2 Seat knee grip (left side) 1
3 Panel inner (right side)
4 Seat knee grip (right side) 1
5 Fuel tank cover assembly 1
For installation, reverse the removal proce-
dure.

6-1
 FUEL TANK (For FAZER25-ABS) FI
EAS26630

REMOVING THE FUEL TANK COVER

1. Remove:
• Rider seat and passenger seat / left side
and right side cover.
Refer to “GENERAL CHASSIS” on page
4-1 of base service manual B97-F8197-
E0.
• Left and right panel console / left and
right panel assembly / left and right
cover.
Refer to “GENERAL CHASSIS” on page
4-1 and 4-2. 5. Remove:
• Fuel tank cover bolts “8” from both side
2. Remove: • Fuel tank cover assembly “9”
• Screw “1”.
• Quick fasteners “2”
• Panel inner “3”

9
8

TIP
To remove the fuel tank cover assembly, gen-
3. Remove: tly pull the fuel tank cover assembly upward as
• Quick fastener “4” shown to release the projection from the hole.
• Seat knee grip “5”

TIP
Hold the seat knee grip from lower backside
and gently pull it out side and then slide for-
ward to remove hole “a” from projection “b” as
shown.

4. Remove:
• Stay guide “6” by removing the bolts “7”
from both side

6-2
 FUEL TANK (For FAZER25-ABS) FI
ECA3C11005
TIP
INSTALL THE FUEL TANK COVER
Before installing the fuel tank cover, ensure
1. Install: the availability of all grommets “a” and collars
• Align the lugs “1” of fuel tank cover “b” are fitted properly.
assembly “3” into the hole “2” and press
fuel tank cover with both hands as
shown.
• Install the fuel tank cover bolt “4” of both
side.

2. Install:
• Seat knee grip cover “5”
• Align the hole “6” into the projection “7”
and then slide backward then gently
push the upper and rear of the seat knee
grip to install all tabs into the slots.
• Quick fastener.

7
5

Fuel tank cover bolt 3. Install:

4 N·m (0.4 kgf·m, 3.0 lb·ft) • Panel inner “8”
T.
R.

• Align the pin “9” into the hole “10”.

• install the screw and quick fasteners.

6-3
 FUEL TANK (For FAZER25-ABS) FI

4. Install:
• Stay guide by installing the bolts of both
side.

11

TIP
Before installing the stay guide “11”, align the
mark “c” and pin “d”.

Stay guide bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

6-4
 – +
ELEC
CHAPTER 7
ELECTRICAL SYSTEM

IGNITION SYSTEM ......................................................................................... 7-1

CIRCUIT DIAGRAM (For FZ25-ABS)........................................................ 7-1
CIRCUIT DIAGRAM (For FAZER25-ABS) ................................................ 7-3
TROUBLESHOOTING .............................................................................. 7-5

ELECTRIC STARTING SYSTEM .................................................................... 7-7

CIRCUIT DIAGRAM (For FZ25-ABS)........................................................ 7-7
CIRCUIT DIAGRAM (For FAZER250-ABS) .............................................. 7-9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 7-11
TROUBLESHOOTING ............................................................................ 7-13

CHARGING SYSTEM.................................................................................... 7-15

CIRCUIT DIAGRAM (For FZ25-ABS)...................................................... 7-15
CIRCUIT DIAGRAM (For FAZER25-ABS) ..............................................7-17
TROUBLESHOOTING ............................................................................ 7-19

LIGHTING SYSTEM ...................................................................................... 7-20

CIRCUIT DIAGRAM (For FZ25-ABS)...................................................... 7-20
CIRCUIT DIAGRAM (For FAZER25-ABS) ..............................................7-22
TROUBLESHOOTING ............................................................................ 7-24

SIGNALING SYSTEM ................................................................................... 7-25

CIRCUIT DIAGRAM (For FZ25-ABS)...................................................... 7-25
CIRCUIT DIAGRAM (For FAZER25-ABS) ..............................................7-27
TROUBLESHOOTING ............................................................................ 7-29

FUEL INJECTION SYSTEM.......................................................................... 7-33

CIRCUIT DIAGRAM (For FZ25-ABS)...................................................... 7-33
CIRCUIT DIAGRAM (For FAZER25-ABS) ..............................................7-35
TROUBLESHOOTING ............................................................................ 7-37

FUEL PUMP SYSTEM................................................................................... 7-38

CIRCUIT DIAGRAM (For FZ25-ABS)...................................................... 7-38
CIRCUIT DIAGRAM (For FAZER25-ABS) ..............................................7-40

ABS (ANTI-LOCK BRAKE SYSTEM)...........................................................7-42

CIRCUIT DIAGRAM (For FZ25-ABS)...................................................... 7-42
ABS COUPLER LOCATION CHART ...................................................... 7-44
MAINTENANCE OF THE ABS ECU ....................................................... 7-45
ABS TROUBLESHOOTING OUTLINE....................................................7-45
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................7-46
BASIC PROCESS FOR TROUBLESHOOTING .....................................7-47
[A] CHECKING THE ABS WARNING LIGHT.......................................... 7-48
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 7-48
 – +
ELEC
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................7-48
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 7-48
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE 
(The select unit screen does not appear.) ..............................................7-49
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE 
(Cannot connect due to a tool error.)...................................................... 7-49
[B-1] MALFUNCTION ARE CURRENTLY DETECTED ..........................7-49
[B-2] DIAGNOSIS USING THE FAULT CODES .....................................7-49
[B-3] DELETING THE FAULT CODES....................................................7-73
[C-1] FINAL CHECK ................................................................................ 7-73

ELECTRICAL COMPONENTS......................................................................7-74
CHECKING THE SWITCHES ................................................................. 7-76
CHECKING THE FUSES ........................................................................7-77
 – +
IGNITION SYSTEM ELEC
ELECTRICAL SYSTEM

IGNITION SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-1
 – +
IGNITION SYSTEM ELEC
1. Crankshaft position sensor
13. Battery positive lead
14. Battery
15. Battery negative lead
16. Engine ground
17. Fuse
20. Main switch
21. Right handlebar switch
23. Engine stop switch
34. ECU (Engine control unit)
35. Ignition coil
36. Spark plug
41. J/C 2 (Joint connector)

7-2
 – +
IGNITION SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-3
 – +
IGNITION SYSTEM ELEC
1. Crankshaft position sensor
13. Battery positive lead
14. Battery
15. Battery negative lead
16. Engine ground
17. Main switch
18. Fuse
23. Right handlebar switch
25. Engine stop switch
31. Lean angle sensor
33. ECU (Engine Control Unit)
34. Ignition coil
35. Spark plug
39. J/C 2 (Joint connector)
40. J/C 3 (Joint connector)

7-4
 – +
IGNITION SYSTEM ELEC
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Left side cover and right side cover
3. Fuel tank panels

1. Check the fuse. NG

Refer to “CHECKING THE FUSES” Replace the fuse.
on page 7-81.

OK
2. Check the battery. NG
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” in base • Recharge or replace the battery.
service manual B97-F8197-E0 on
page 7-62.
OK
3. Check the spark plug. NG
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” in base service manual B97-
F8197-E0 on page 3-8.
OK
4. Check the spark gap. OK
Refer to “CHECKING THE
IGNITION SPARK GAP” in base Ignition system is OK.
service manual B97-F8197-E0 on
page 7-67.
NG
5. Check the ignition coil. NG
Refer to“CHECKING THE
IGNITION COIL” in base service Replace the ignition coil.
manual B97-F8197-E0 on page 7-
66.
OK
6. Check the crankshaft position NG
sensor.
Refer to “CHECKING THE Replace the crankshaft position
CRANKSHAFT POSITION sensor/stator assembly.
SENSOR” in base service manual
B97-F8197-E0 on page 7-67.
OK
7. Check the main switch. NG
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-80.

OK

7-5
 – +
IGNITION SYSTEM ELEC
8. Check the lean angle sensor. NG
Refer to “CHECKING THE LEAN
ANGLE SENSOR” in base Replace the lean angle sensor.
service manual B97-F8197-E0 on
page 7-68.
OK

9. Check the engine stop switch. NG The engine stop switch is faulty. Replace
Refer to“CHECKING THE
the right handlebar switch.
SWITCHES” on page 7-80.

OK

10.Check the entire ignition system NG Properly connect or repair the ignition
wiring. system wiring.

OK

Replace the ECU.

7-6
 – +
ELECTRIC STARTING SYSTEM ELEC
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-7
 – +
ELECTRIC STARTING SYSTEM ELEC
2. Neutral switch
13. Battery positive lead
14. Battery
15. Battery negative lead
16. Engine ground
17. Fuse
18. Starter relay
19. Starter motor
20. Main switch
21. Right handlebar switch
22. Start switch
23. Engine stop switch
24. Starting circuit cut off relay
25. Clutch switch
41. J/C 2 (Joint connector)
43. Meter assembly
47. Neutral switch

7-8
 – +
ELECTRIC STARTING SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-9
 – +
ELECTRIC STARTING SYSTEM ELEC
3. Neutral switch
13. Battery positive lead
14. Battery
15. Battery negative lead
16. Engine ground
17. Main switch
18. Fuse
19. Starter relay
20. Starter motor
21. Starting circuit cut off relay
22. Clutch switch
23. Right handlebar switch
24. Start switch
25. Engine stop switch
39. J/C 2 (Joint connector)

7-10
 – +
ELECTRIC STARTING SYSTEM ELEC
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the
starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the start switch “ ”.

2
3

9
5
8

10
7 6

a b

7-11
 – +
ELECTRIC STARTING SYSTEM ELEC
a. WHEN THE TRANSMISSION IS IN
NEUTRAL
b. WHEN CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Fuse
3. Main switch
4. Engine stop switch
5. Starting circuit cut-off relay
6. Clutch switch
7. Neutral switch
8. Start switch
9. Starter relay
10. Starter motor

7-12
 – +
ELECTRIC STARTING SYSTEM ELEC
TROUBLESHOOTING
The starter motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Left side cover and right side cover

1. Check the fuse. NG

Refer to “CHECKING THE FUSES” Replace the fuse.
on page 7-81.

OK
2. Check the battery. NG
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” in base • Recharge or replace the battery.
service manual B97-F8197-E0 on
page 7-62.
OK
3. Check the starter motor operation. OK
Refer to “CHECKING THE Starter motor is OK. Perform the electric
STARTER MOTOR OPERATION” in starting system troubleshooting, starting
base service manual B97-F8197-E0 with step 5.
on page 7-68.
NG
4. Check the starter motor. NG
Refer to “CHECKING THE STARTER
Repair or replace the starter motor.
MOTOR” in base service manual
B97-F8197-E0 on page 5-36.
OK
5. Check the starting circuit cut-off NG
relay.
Refer to “CHECKING THE RELAYS” Replace the starting circuit cut-off relay.
in base service manual B97-F8197-
E0 on page 5-65.
OK
6. Check the starter relay. NG
Refer to “CHECKING THE RELAYS”
Replace the starter relay.
in base service manual B97-F8197-
E0 on page 5-36.
OK
7. Check the main switch. NG
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-80.

OK

7-13
 – +
ELECTRIC STARTING SYSTEM ELEC

8. Check the engine stop switch. NG

The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the right handlebar switch.
SWITCHES” on page 7-80.

OK
9. Check the neutral switch. NG
Refer to “CHECKING THE Replace the neutral switch.
SWITCHES” on page 7-80.

OK
10.Check the clutch switch. NG
Refer to “CHECKING THE Replace the clutch switch.
SWITCHES” on page 7-80.

OK
NG
11.Check the start switch.
The start switch is faulty. Replace the right
Refer to “CHECKING THE
handlebar switch.
SWITCHES” on page 7-80.

OK

12.Check the entire starting system NG

Properly connect or repair the starting
wiring.
system wiring.
Refer to “CIRCUIT DIAGRAM”.

OK
The starting system circuit is OK.

7-14
 – +
CHARGING SYSTEM ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-15
 – +
CHARGING SYSTEM ELEC
3. Stator coil
4. Rectifier/Regulator
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Fuse

7-16
 – +
CHARGING SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-17
 – +
CHARGING SYSTEM ELEC
2. Stator coil
4. Rectifier/Regulator
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
18.Fuse

7-18
 – +
CHARGING SYSTEM ELEC
TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Right side cover

1. Check the fuse. NG

Refer to “CHECKING THE FUSES” Replace the fuse.
on page 7-81.

OK
2. Check the battery. NG
Refer to “CHECKING AND
CHARGING THE BATTERY” in base • Clean the battery terminals.
service manual B97-F8197-E0 on • Recharge or replace the battery.
page 7-62.
OK
3. Check the stator coil. NG
Refer to “CHECKING THE STATOR Replace the crankshaft position
COIL” in base service manual B97- sensor/stator assembly.
F8197-E0 on page 7-68.
OK
4. Check the rectifier/regulator. NG
Refer to “CHECKING THE
RECTIFIER/REGULATOR” in base Replace the rectifier/regulator.
service manual B97-F8197-E0 on
page 7-69.
OK
5. Check the entire charging system NG
wiring.
Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” in
system wiring.
base service manual B97-F8197-E0
on page 7-11.
OK
The charging system circuit is OK.

7-19
 – +
LIGHTING SYSTEM ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-20
 – +
LIGHTING SYSTEM ELEC
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Fuse
20.Main switch
34.ECU (Engine control unit)
41.J/C 2 (Joint connector)
43.Meter assembly
51.High beam indicator
52.Brake/taillight
57.Left handlebar switch
58.Dimmer and pass switch
65.Headlight assembly
66.Auxiliary light

7-21
 – +
LIGHTING SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-22
 – +
LIGHTING SYSTEM ELEC
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Main switch
18.Fuse
33.ECU (Engine Control Unit)
39.J/C 2 (Joint connector)
40.J/C 3 (Joint connector)
46.Meter assembly
54.High beam indicator light
57.Brake/taillight
63.Left handlebar switch
64.Dimmer and pass switch
72.Headlight assembly
73.Auxiliary light (right)
74.Auxiliary light (left)

7-23
 – +
LIGHTING SYSTEM ELEC
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Left side cover and right side cover
3. Headlight

1. Check the each bulbs and bulb NG

sockets condition.
Refer to “CHECKING THE BULBS
Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” in base
service manual B97-F8197-E0 on
page 7-60.
OK
2. Check the fuse. NG
Refer to “CHECKING THE FUSES” Replace the fuse.
on page 7-81.
OK
3. Check the battery. NG
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in base
• Recharge or replace the battery.
service manual B97-F8197-E0 on
page 7-62.
OK
4. Check the main switch. NG
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-80.
OK
5. Check the dimmer and pass. NG The dimmer switch is faulty. Replace the
Refer to “CHECKING THE
left handlebar switch.
SWITCHES” on page 7-80.
OK

6. Check the entire lighting system NG Properly connect or repair the lighting
wiring. system wiring.

OK
This circuit is OK.

7-24
 – +
SIGNALING SYSTEM ELEC
SIGNALING SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-25
 – +
SIGNALING SYSTEM ELEC
2. Neutral switch
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Fuse
20.Main switch
21.Right handlebar switch
26.Front brake light switch
34.EGU (Engine control unit)
39.Yamaha diagnostic tool coupler
40.Rear brake light switch
41.J/C 2 (Joint connector)
42.J/C 3 (Joint connector)
43.Meter assembly
46.Multi-function display
47.Neutral indicator light
50.Turn signal light indicator
53.Fuel sender
55.Turn signal relay
56.Horn
57.Left handlebar switch
59.Horn switch
60.Turn signal switch
62.Rear turn signal light (right)
63.Rear turn signal light (left)
64.Front turn signal light (right/left)

7-26
 – +
SIGNALING SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-27
 – +
SIGNALING SYSTEM ELEC
3. Neutral switch
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Main switch
18.Fuse
33.ECU (Engine Control Unit)
38.Yamaha diagnostic tool coupler
39.J/C 2 (Joint connector)
40.J/C 3 (Joint connector)
46.Meter assembly
49.Multi-function display
50.Neutral Indicator light
53.Turn signal indicator light
57.Brake light
58.Front brake light switch
59.Rear brake light switch
60.Turn signal relay
61.Horn 1
62.Horn 2
63.Left handlebar switch
65.Horn switch
66.Turn signal switch
68.Rear turn signal light (right)
69.Rear turn signal light (left)
70.Front turn signal light (right)
71.Front turn signal light (left)

7-28
 – +
SIGNALING SYSTEM ELEC
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light or indicator lights.
• The horn fails to sound.
• The fuel gauge fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Left side cover and right side cover
3. Headlight
4. LCD Meter

1. Check the fuse. NG

Refer to “CHECKING THE FUSES” Replace the fuse.
on page 7-81

OK
2. Check the battery. NG
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” in base • Recharge or replace the battery.
service manual B97-F8197-E0 on
page 7-62.
OK
3. Check the main switch. NG
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-80.

OK
4. Check the entire signaling system NG
wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” in system wiring.
base service manual B97-F8197-E0
on page 7-17.
OK
Check the condition of each of the
signaling system circuits. Refer to
“Checking the signaling system”.

Check the signaling system

The horn fails to sound.
1. Check the horn switch. NG
The horn switch is faulty. Replace the left
Refer to “CHECKING THE
handlebar switch.
SWITCHES” on page 7-80.

OK
2. Check the horn. NG
Refer to “CHECKING THE HORN” in
Replace the horn.
base service manual B97-F8197-E0
on page 7-69.
OK

7-29
 – +
SIGNALING SYSTEM ELEC

3. Check the entire signaling system NG Properly connect or repair the signaling
wiring. system wiring.

OK
This circuit is OK.

The brake/tail light fails to come on.

1. Check the brake/tail light bulb and NG
socket.
Refer to “CHECKING THE BULBS Replace the brake/tail light assembly,
AND BULB SOCKETS” in base socket or both.
service manual B97-F8197-E0 on
page 7-60.
OK

2. Check the front brake light switch. NG

Refer to “CHECKING THE FUSES” Replace the front brake light switch.
on page 7-81.

OK
NG
3. Check the rear brake light switch.
Refer to “CHECKING THE Replace the rear brake light switch.
SWITCHES” on page 7-80.

OK

4. Check the entire signaling system NG

wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” in
system wiring.
base service manual B97-F8197-E0
on page 7-17.

OK
This circuit is OK.

The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulb and NG
socket.
Refer to “CHECKING THE BULBS Replace the turn signal light bulb, socket or
AND BULB SOCKETS” in base both.
service manual B97-F8197-E0 on
page 7-60.
OK

2. Check the turn signal switch. NG

The turn signal switch is faulty. Replace
Refer to “CHECKING THE
the left handlebar switch.
SWITCHES” on page 7-80.

OK

7-30
 – +
SIGNALING SYSTEM ELEC
3. Check the turn signal relay. NG
Refer to “CHECKING THE TURN
SIGNAL RELAY” in base service Replace the turn signal relay.
manual B97-F8197-E0 on page 7-
65.
OK

4. Check the entire signaling system NG Properly connect or repair the signaling
wiring. system wiring.

OK
Replace the meter assembly.

The neutral indicator light fails to come on.

1. Check the neutral switch. NG
Refer to “CHECKING THE Replace the neutral switch.
SWITCHES” on page 7-80.
OK
NG
2. Check the entire signaling system Properly connect or repair the signaling
wiring. system wiring.

OK
Replace the meter assembly.

The fuel gauge fails to operate.

NG
1. Check the fuel sender.
Refer to “CHECKING THE FUEL
Replace the fuel pump.
SENDER” in base service manual
B97-F8197-E0 on page 7-65.

OK

2. Check the entire signaling system NG Properly connect or repair the signaling
wiring. system wiring.

OK
Replace the meter assembly.

7-31
 – +
SIGNALING SYSTEM ELEC
The speedometer fails to operate.

1. Check the speed sensor. NG

Refer to “CHECKING THE FUEL
Replace the speed sensor.
SENDER” in base service manual
B97-F8197-E0 on page 7-70.

OK
NG
2. Check the entire signaling system Properly connect or repair the signaling
wiring. system wiring.

OK
Replace the meter assembly.

7-32
 – +
FUEL INJECTION SYSTEM ELEC
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-33
 – +
FUEL INJECTION SYSTEM ELEC
1. Crankshaft position sensor
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Fuse
20.Main switch
21.Right handlebar switch
23.Engine stop switch
27.Throttle body sensor assembly
28.Intake air pressure sensor
29.Intake air temperature sensor
30.Throttle position sensor
31.Engine temperature sensor
32.Lean angle sensor
33.FID (Fast idle device)
34.ECU (Engine control unit)
35.Ignition coil
36.Spark plug
37.Fuel injection
38.O2 sensor
39.Yamaha diagnostic tool coupler
41.J/C 2 (Joint connector)
42.J/C 3 (Joint connector)
43.Meter assembly
45.Engine trouble warning light
46.Multi-function display
54.Fuel pump

7-34
 – +
FUEL INJECTION SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-35
 – +
FUEL INJECTION SYSTEM ELEC
1. Crankshaft position sensor
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Main switch
18.Fuse
23.Right handlebar switch
25.Engine stop switch
26.Throttle body sensor assembly
27.Intake air pressure sensor
28.Intake air temperature sensor
29.Throttle position sensor
30.Engine temperature sensor
31.Lean angle sensor
32.FID (Fast Idle Device)
33.ECU (Engine Control Unit)
34.Ignition coil
35.Spark plug
36.Fuel injector
37.O2 sensor
38.Yamaha diagnostic tool coupler
39.J/C 2 (Joint connector)
40.J/C 3 (Joint connector)
46.Meter assembly
48.Engine trouble warning light
49.Multi-function display
55.Fuel pump

7-36
 – +
FUEL PUMP SYSTEM ELEC
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM (For FZ25-ABS)

7-37
 – +
FUEL PUMP SYSTEM ELEC
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Fuse
20.Main switch
21.Right handlebar switch
23.Engine stop switch
34.ECU (Engine control unit)
54.Fuel pump

7-38
 – +
FUEL PUMP SYSTEM ELEC
CIRCUIT DIAGRAM (For FAZER25-ABS)

7-39
 – +
FUEL PUMP SYSTEM ELEC
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Main switch
18.Fuse
23.Right handlebar switch
25.Engine stop switch
33.ECU (Engine Control Unit)
39.J/C 2 (Joint connector)
55.Fuel pump

7-40
 – +
FUEL PUMP SYSTEM ELEC
TROUBLESHOOTING
The fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger and rider seat
2. Left side cover and right side cover
3. Headlight assembly

1. Check the fuse. NG

Refer to “CHECKING THE FUSES” Replace the fuse.
on page 7-81.

OK
2. Check the battery. NG
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” in base • Recharge or replace the battery.
service manual B97-F8197-E0 on
page 7-62.
OK
3. Check the main switch. NG
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-80.

OK
4. Check the engine stop switch. NG
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the right handlebar switch.
SWITCHES” on page 7-80.

OK
5. Check the fuel pump. NG
Refer to “CHECKING THE FUEL
Replace the fuel pump assembly.
PUMP BODY” in base service
manual B97-F8197-E0 on page 6-3.

OK

6. Check the entire fuel pump system NG Properly connect or repair the fuel pump
wiring. system wiring.

OK
Replace the ECU.

7-41
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
EAS20085

ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30843

CIRCUIT DIAGRAM (For FZ25-ABS)

7-42
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
5. Fuse box 1
8. ABS control unit fuse
9. Fuse box 2
11.ABS motor fuse
12.ABS solenoid fuse
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Fuse
20.Main switch
21.Right handlebar switch
26.Front brake light switch
34.ECU (Engine Control Unit)
40.Rear brake light switch
41.J/C 2 (Joint connector)
42.J/C 3 (Joint connector)
43.Meter assembly
48.Meter light
49.ABS warning light
68.ABS ECU
69.Front speed sensor
70.Rear speed sensor
71.Joint
72.ABS test coupler

7-43
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
EAS20085

ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30843

CIRCUIT DIAGRAM (For FAZER25-ABS)

7-44
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
5. Fuse box 1
8. ABS control unit fuse
9. Fuse box 2
11.ABS motor fuse
12.ABS solenoid fuse
13.Battery positive lead
14.Battery
15.Battery negative lead
16.Engine ground
17.Main switch
18.Fuse
33.ECU (Engine Control Unit)
39.J/C 2 (Joint connector)
40.J/C 3 (Joint connector)
41.Front speed sensor
42.Rear speed sensor
43.Joint
44.ABS test coupler
45.ABS ECU (electric control unit)
46.Meter assembly
49.Multi-function display
51.Meter light
52.ABS warning light
58.Front brake light swicth
59.Rear brake light swicth

7-45
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
EAS30844

ABS COUPLER LOCATION CHART

W/L

R G R Br Y W/L W B
R/L G/L Br W/B L/B B/W B

1. Meter assembly coupler

2. Rear wheel sensor coupler
3. ABS test coupler
4. ABS ECU coupler
5. Front wheel sensor coupler

7-46
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
EAS30845

MAINTENANCE OF THE ABS ECU

Checking the ABS ECU

1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages  Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off  Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.

1
2

EAS30528

ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG-
NOSIS USING THE FAULT CODES” on page 7-51. For troubleshooting items other than the following
items, follow the normal service method.
EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.

TIP
To final check, refer to “[C-1] FINAL CHECK” on page 7-75.

ABS operation when the ABS warning light comes on

1. The ABS warning light remains on  ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6.3 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6.3 mi/h)).  ABS operation is normal.
3. The ABS warning light flashes  ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 7-48.

7-47
 – +
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Self-diagnosis and servicing
The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page 7-75.
By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly
if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from inside of the right
air scoop, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the
lever and pedal, but these do not indicate a malfunction.

Self-diagnosis using the ABS ECU

The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.

Special precautions for handling and servicing a vehicle equipped with ABS
ECA18490

WARNING
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.

• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420

WARNING
• Perform the troubleshooting [A][B][C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.

[A] Malfunction check using the ABS warning light

[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
EAS30530

BASIC PROCESS FOR TROUBLESHOOTING

Fails to
[A] Turn the main switch to “ON”, come on [A-1] Does only the ABS Yes • The ABS warning light (LED) is
and check the ABS warning warning light fail to defective.
light. come on? • The wire harness is grounded Return to [A].
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.

No
Yes • The main switch is defective.
[A-2] Do all indicator lights • The battery voltage is low.
fail to come on? Return to [A].
• The main fuse is blown.
• The meter assembly circuit is
defective.

Cannot
[A-3] The ABS warning light communicate Yes • The ABS control unit fuse is
[A-4] Only the ABS ECU
comes on. blown. Return to [A].
fails to communicate.
Connect the Yamaha • The ABS ECU coupler is
diagnostic tool, and then disconnected.
execute functional diagnosis. • The wire harness is defective.
Can the tool communicate • The hydraulic unit assembly is
with the ABS ECU? defective.

Can communicate
[A-5] ABS ECU and FI ECU Yes
• The connection with the Yamaha
fail to communicate. diagnostic tool is defective. Return to [A].
• The wire harness is defective.

Yes
[B-1] Check for ABS fault codes in [B-2] Diagnose by the fault [B-3] Delete the fault codes. Return to [A].
the screen for the Yamaha code.
diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?

No The reaction force generated

during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. No pipes are not connected
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes checked.
(Check that the ABS warning • The malfunction is not
light goes off during the ABS corrected.
warning light check.) • There is a break in the wire
harness between the ABS
ECU and the meter
assembly.
• The meter assembly circuit is
defective.
• The ABS warning light circuit
in the hydraulic unit
assembly is defective.

Finished.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.

TIP
To final check, refer to “[C-1] FINAL CHECK” on page 7-75.

EAS30531

[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the white/blue terminal of the ABS ECU coupler and
white/blue terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30964

[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 7-80.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” in base service manual B97-F8197-E0 on
page 7-62.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 7-81.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “Signaling system” CIRCUIT DIAGRAM (For FAZER25-ABS) on page 7-27.
• If the meter assembly circuit is open, replace the wire harness.
EAS31162

[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in-
formation about how to execute functional diagnosis, refer to the operation manual that is included with
the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
EAS31163

[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE (The select unit screen does not appear.)
1. ABS control unit fuse
• Check the ABS control unit fuse for continuity.
Refer to “CHECKING THE FUSES” on page 7-81.
• If the ABS control unit fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-31.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between brown terminal of the main switch coupler and brown terminal of the
ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground, and between
the black terminal of the ABS ECU coupler and ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
ABS test coupler.
Check for continuity between white/black terminal of the ABS ECU coupler and white/black terminal
of the ABS test coupler.
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164

[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE (Cannot connect due to a tool error.)
1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler.
Check for continuity between white/black terminal of the ABS ECU coupler and white/black terminal
of the ABS test coupler.
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the ABS test coupler.
EAS31165

[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed
on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166

[B-2] DIAGNOSIS USING THE FAULT CODES

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Yamaha diagnostic tool USB
INS-018
90890-03267
INS-019
90890-03262

Connecting the Yamaha diagnostic tool

Removing the passenger seat. Refer to “GENERAL CHASSIS (1)” in base service manual B97-F8197-
E0 on page 4-1.
Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.

Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.

Operation of the Yamaha diagnostic tool (Fault diagnosis mode)

Malfunction results are displayed in the top part of the window area.
7 3 8 5 5 2

4
1
6

13 12 11 10 9

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
1. Detected
The malfunction currently occurred are displayed.
2. Recovered
The malfunction detected in the past (already recovered) are displayed.
3. Diagnosis code the diagnosis codes related to the detected malfunction are displayed.

A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed. (e.g., FI, ABS)
5. Status of malfunction
The current conditions are displayed. (Malfunction/Recover)
6. Item
If a fault code is detected, the symptoms are displayed along with the item name.
7. Trouble list
The item list of the “detected malfunction” or “recover malfunction” are displayed.
8. Trouble Information
This appears to click on “detected malfunction (1)” for the details of the diagnosis are displayed.
Click [Service Manual/F10] to open the service manual and check the details of the fault.
9. Save
To save the result of diagnosis of malfunction, click [Save/F12].
Note:- Must save the result for future reference.
10.Update
To run the diagnosis of malfunction again, click [Update/F11].
11.Service Manual
To view the service manual, click [Service Manual/F10].
Note:- Service Manual of related model can be downloaded when system is connected with YMC
server.
12.Erase all (Only recovered item can be Erased)
To delete all of the fault codes, click [Erase All/F2].
13.Delete selected items (Only recovered item can be Deleted)
To delete the selected fault codes, click [Delete selected items/F1].

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code table
TIP
Record all of the fault codes displayed and inspect the check points.

Fault code No. Item Symptom Check point

11* Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
25* tent pulses or no pulses) not received properly. (Puls- around the front wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the rear wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. Item Symptom Check point
15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
• Defective front wheel sen-
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
rear wheel sensor and the
hydraulic unit assembly
• Defective rear wheel sen-
sor or hydraulic unit as-
sembly
17* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
18* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. Item Symptom Check point
24 Brake light switch or Brake light signal is not re- • Defective signaling system
tail/brake light ceived properly while the ve- (tail/brake light or brake
hicle is traveling. (Brake light light switch)
circuit, or front or rear brake • Defective coupler between
light switch circuit) the signaling system
(tail/brake light or brake
light switch) and the hy-
draulic unit assembly
• Open or short circuit in the
wire harness between the
signaling system (tail/brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Defective hydraulic unit as-
sembly
31 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS solenoid fuse
normal ABS solenoid power solenoid circuit in the hy- • Defective coupler between
supply) draulic unit assembly. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS solenoid the solenoid power supply sembly
power supply circuit) circuit in the hydraulic unit
assembly.
33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. Item Symptom Check point
42 Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the
47 tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault
incorrect depressurization) mittently while the vehicle code No. 42)
is traveling. (for fault code • Incorrect rotation of the
No. 42) rear wheel
• Rear wheel will not recover • Rear brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43 Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
44 Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
51 • Vehicle system power sup- • Power voltage supplied to • Defective battery
52 ply (voltage of ABS ECU the ABS ECU in the hy- • Disconnected battery ter-
power supply is high) (for draulic unit assembly is too minal
fault code No. 51) high. (for fault code No. 51) • Defective charging system
• Vehicle system power sup- • Power voltage supplied to
ply (voltage of wheel sen- the wheel sensor is too
sor power supply is high) high. (for fault code No. 52)
(for fault code No. 52)
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. Item Symptom Check point
54 Hydraulic unit assembly (de- Abnormality is detected in • Defective battery
fective ABS solenoid and the solenoid or motor power • Defective coupler between
ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau-
cuits) unit assembly. lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
• Defective hydraulic unit as-
sembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality is detected in • Defective hydraulic unit as-
normal internal power sup- the power supply circuit in sembly
ply) the hydraulic unit assembly.
63 Front wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the front ness between the front
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective front wheel sen-
sor
• Defective hydraulic unit as-
sembly
64 Rear wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the rear ness between the rear
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective rear wheel sen-
sor
• Defective hydraulic unit as-
sembly
* The fault code number varies according to the vehicle conditions.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 11, 25
TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code
No. 11) or for longer than about 2 seconds (fault code No. 25).

11
Fault code No.
25

Item Front wheel sensor (intermittent pulses or no pulses)

Front wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-7.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

Fault code No. 12

Fault code No. 12

Item Rear wheel sensor (intermittent pulses or no pulses)

Rear wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-14.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 13, 26
TIP
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.
• Vehicle possibly ridden on uneven roads.

13
Fault code No.
26

Item Front wheel sensor (abnormal pulse period)

Front wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-7.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

Fault code No. 14, 27

TIP
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.

14
Fault code No.
27

Item Rear wheel sensor (abnormal pulse period)

Rear wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
14
Fault code No.
27

Item Rear wheel sensor (abnormal pulse period)

Rear wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-14.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

Fault code No. 15

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 15

Item Front wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the front wheel sensor.

Order Item/components and probable cause Check or maintenance job

1 Defective coupler between the front wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 15
Item Front wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the front wheel sensor.

Order Item/components and probable cause Check or maintenance job

2 Open or short circuit in the wire harness • Check for continuity between the green terminal “1”
between the front wheel sensor and the and the green terminal “4” and between the red termi-
hydraulic unit assembly nal “2” and the red terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the green
terminal “1” and the red terminal “2” and between the
green terminal “4” and the red terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the
black/white terminal “3” and the green terminal “4” and
between the black/white terminal “3” and the red termi-
nal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
1 2 3 4 5

R G R Br Y W/L W B
G R W B
R/L G/Y Br W/B L/B B/W B

6 7
6. ABS ECU
7. Front wheel sensor
3 Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “FRONT WHEEL” on page 4-12 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 7-42.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 16
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 16

Item Rear wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the rear wheel sensor.

Order Item/components and probable cause Check or maintenance job

1 Defective coupler between the rear wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
2 Open or short circuit in the wire harness • Check for continuity between the yellow terminal “1”
between the rear wheel sensor and the and the yellow terminal “4” and between the brown ter-
hydraulic unit assembly minal “2” and the brown terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the yellow
terminal “1” and the brown terminal “2” and between
the yellow terminal “4” and the brown terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the black
terminal “3” and the yellow terminal “4” and between
the black terminal “3” and the brown terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
2 1 3 5 4

R G R Br Y W/L W B
Br Y W B
R/L G/Y Br W/B L/B B/W B

6 7
6. ABS ECU
7. Rear wheel sensor
3 Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “REAR WHEEL” on page 4-17 and “ABS (ANTI-
LOCK BRAKE SYSTEM)” on page 7-42.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 17, 45
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 45 will be recorded first and fault code No. 17 will be recorded if the condition continues.

17
Fault code No.
45
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing pulses
Symptom
are detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-7.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

Fault code No. 18, 46

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 46 will be recorded first and fault code No. 18 will be recorded if the condition continues.

18
Fault code No.
46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing pulses are
Symptom
detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-14.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
18
Fault code No.
46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing pulses are
Symptom
detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

Fault code No. 21

Fault code No. 21

Item Hydraulic unit assembly (defective solenoid drive circuit)

Solenoid drive circuit in the hydraulic unit assembly is open or short-

Symptom
circuited.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 24

Fault code No. 24

Item Brake light switch or tail/brake light

Brake light signal is not received properly while the vehicle is travel-
Symptom
ing (Brake light circuit, or front or rear brake light switch circuit).

Order Item/components and probable cause Check or maintenance job

1 Defective signaling system (tail/brake light Check the brake light switches.
or brake light switch) Refer to “CHECKING THE SWITCHES” on page 7-80.
2 Defective coupler between the signaling • Check the coupler for any pins that may be pulled out.
system (tail/brake light or brake light • Check the locking condition of the coupler.
switch) and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
3 Open or short circuit in the wire harness • Between ABS ECU coupler and front brake light switch
between the signaling system (tail/brake coupler.
light or brake light switch) and the hydrau- (green/yellow–yellow)
lic unit assembly • Between ABS ECU coupler and rear brake light switch
coupler.
(green/yellow–yellow)

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 24
Item Brake light switch or tail/brake light

Brake light signal is not received properly while the vehicle is travel-
Symptom
ing (Brake light circuit, or front or rear brake light switch circuit).
Order Item/components and probable cause Check or maintenance job
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 31

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 31

Item Hydraulic unit assembly (abnormal ABS solenoid power supply)

Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.

Order Item/components and probable cause Check or maintenance job

1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
Refer to “CHECKING THE SWITCHES” on page 7-80.
2 Defective coupler between the battery • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS solenoid fuse.
assembly (red–red)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 32

Fault code No. 32

Hydraulic unit assembly (short circuit in ABS solenoid power supply

Item
circuit)

Short circuit is detected in the solenoid power supply circuit in the hy-
Symptom
draulic unit assembly.
Order Item/components and probable cause Check or maintenance job
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 33
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 33

Item Hydraulic unit assembly (abnormal ABS motor power supply)

Power is not supplied to the motor circuit in the hydraulic unit assem-
Symptom
bly.

Order Item/components and probable cause Check or maintenance job

1 Blown ABS motor fuse Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
Refer to “CHECKING THE FUSES” on page 7-81.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (red/blue–red/blue)
• Between ABS ECU coupler and ground.
(black–black)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 34

Fault code No. 34

Hydraulic unit assembly (short circuit in ABS motor power supply cir-
Item
cuit)
Short circuit is detected in the motor power supply circuit in the hy-
Symptom
draulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 41
Fault code No. 41

Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)

• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.
Order Item/components and probable cause Check or maintenance job
1 Incorrect installation of the front wheel Check the components for looseness, distortion, and
sensor bends.
Refer to “CHECKING THE FRONT WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-7.
2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-7. and “CHECK-
ING THE FRONT BRAKE DISC” in base service
manual B97-F8197-E0 on page 4-23.
3 Front brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE FRONT BRAKE DISC” in
base service manual B97-F8197-E0 on page 4-23.
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 42, 47

42
Fault code No.
47
Rear wheel ABS (intermittent wheel speed pulses or incorrect depres-
Item
surization)

• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

1 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
sensor (for fault code No. 42) bends.
Refer to “CHECKING THE REAR WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-14.
2 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel and
make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-14.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
42
Fault code No.
47

Rear wheel ABS (intermittent wheel speed pulses or incorrect depres-

Item
surization)
• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

3 Rear brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake pedal is operat-
ed and that the pressure decreases when the pedal is
released.
Refer to “CHECKING THE REAR BRAKE DISC” in base
service manual B97-F8197-E0 on page 4-35.
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 43

Fault code No. 43
Item Front wheel sensor (missing pulses)

Front wheel sensor signal is not received properly. (Missing pulses

Symptom
are detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-7.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 44
Fault code No. 44

Item Rear wheel sensor (missing pulses)

Rear wheel sensor signal is not received properly. (Missing pulses are
Symptom
detected in the signal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” in base ser-
vice manual B97-F8197-E0 on page 4-14.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE WHEEL SENSOR
AND SENSOR ROTOR” on page 4-13.

Fault code No. 51, 52

51
Fault code No.
52

• Vehicle system power supply (voltage of ABS ECU power supply is

high) (for fault code No. 51)
Item
• Vehicle system power supply (voltage of wheel sensor power supply
is high) (for fault code No. 52)

• Power voltage supplied to the ABS ECU in the hydraulic unit assem-
bly is too high. (for fault code No. 51)
Symptom
• Power voltage supplied to the wheel sensor is too high. (for fault
code No. 52)

Order Item/components and probable cause Check or maintenance job

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
in base service manual B97-F8197-E0 on page 7-62.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 7-15.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 53
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 53

Vehicle system power supply (voltage of ABS ECU power supply is

Item
low)

Power voltage supplied to the ABS ECU in the hydraulic unit assem-
Symptom
bly is too low.

Order Item/components and probable cause Check or maintenance job

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
in base service manual B97-F8197-E0 on page 7-62.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS control unit fuse.
assembly (brown–brown)
4 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 7-15.

Fault code No. 54

Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 54

Hydraulic unit assembly (defective ABS solenoid and ABS motor

Item
power supply circuits)
Abnormality is detected in the solenoid or motor power supply circuit
Symptom
in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
in base service manual B97-F8197-E0 on page 7-62.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (red/blue–red/blue)
• Between ABS ECU coupler and ABS solenoid fuse.
(red–red)

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 54
Hydraulic unit assembly (defective ABS solenoid and ABS motor
Item
power supply circuits)

Abnormality is detected in the solenoid or motor power supply circuit

Symptom
in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

4 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 7-15.
5 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 55

Fault code No. 55

Item Hydraulic unit assembly (defective ABS ECU)

Symptom Abnormal data is detected in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

Fault code No. 56

Fault code No. 56

Item Hydraulic unit assembly (abnormal internal power supply)

Abnormality is detected in the power supply circuit in the hydraulic

Symptom
unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

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ABS (ANTI-LOCK BRAKE SYSTEM) ELEC
Fault code No. 63
Fault code No. 63

Item Front wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the front wheel sensor is
Symptom
too low.

Order Item/components and probable cause Check or maintenance job

1 Short circuit in the wire harness between • Check that there is no short circuit between the green
the front wheel sensor and the hydraulic terminal “1” and the red terminal “2”.
unit assembly • Check that there is no short circuit between the black
terminal “3” and the green terminal “1”.
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.

3 1 2

R G R Br Y W/L W B
G R W B
R/L G/Y Br W/B L/B B/W B

4 5

4. ABS ECU
5. Front wheel sensor
2 Defective front wheel sensor • Check that there is no short circuit between the black
terminal “1” and the white terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.

2 1

R G R Br Y W/L W B
G R W B
R/L G/Y Br W/B L/B B/W B

3 4
3. ABS ECU
4. Front wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

7-73
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ELECTRICAL COMPONENTS ELEC
Fault code No. 64
Fault code No. 64

Item Rear wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the rear wheel sensor is
Symptom
too low.

Order Item/components and probable cause Check or maintenance job

1 Short circuit in the wire harness between • Check that there is no short circuit between the yellow
the rear wheel sensor and the hydraulic terminal “1” and the brown terminal “2”.
unit assembly • Check that there is no short circuit between the black
terminal “3” and the yellow terminal “1”.
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.

3 2 1
R G R Br Y W/L W B
Br Y W B
R/L G/Y Br W/B L/B B/W B

4 5
4. ABS ECU
5. Rear wheel sensor
2 Defective rear wheel sensor • Check that there is no short circuit between the black
terminal “1” and the white terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.

2 1

R G R Br Y W/L W B
Br Y W B
R/L G/Y Br W/B L/B B/W B

3 4
3. ABS ECU
4. Rear wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
7-42.

7-74
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ELECTRICAL COMPONENTS ELEC
EAS31167

[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault
codes, refer to the operation manual of the Yamaha diagnostic tool.
Check that all the displayed fault codes are deleted.

Yamaha diagnostic tool USB

NS-018
90890-03267
INS-019
90890-03262

Connecting the Yamaha diagnostic tool

Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.

EAS31168

[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.

Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL” on page 4-15 and “REMOVING THE REAR WHEEL”
on page 4-19.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-32.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 7-75.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If ABS warning light does not come on or if it does not goes off, refer to “[A] CHECKING THE ABS
WARNING LIGHT” on page 7-50.
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between white/blue terminal of the ABS ECU coupler and white/blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.

7-75
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ELECTRICAL COMPONENTS ELEC
EAS20089

ELECTRICAL COMPONENTS

1. Main switch
2. Front brake light switch
3. Ignition coil
4. Fuel sender
5. Fuel pump
6. Fuel injector
7. Battery

7-76
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ELECTRICAL COMPONENTS ELEC
8. Fuse box
9. Rear brake light switch
10.AC magneto
11.Crankshaft position sensor
12.Throttle body sensor assembly
13.Starter motor
14.Clutch switch

7-77
 – +
ELEC

16 17

18

19
26

20

25

24
21

22

23

15. Rectifier/regulator
16. Starter relay
17.Hydraulic unit assembly
18.ECU (Engine Control Unit)
19. Turn signal relay
20.Rear wheel sensor

7-78
 – +
ELEC
21. Neutral switch
22.Engine temperature sensor
23.O2 sensor
24.Front wheel sensor
25.Horn
26.Lean angle sensor

7-79
 – +
ELEC
EAS30549

CHECKING THE SWITCHES

Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check the wir-
ing connections and if necessary, replace the switch.

1. Main switch
2. Front brake light switch
3. Starter switch
4. Engine stop switch
5. Rear brake light switch
6. Clutch switch
7. Horn switch
8. Dimmer/Pass switch
9. Turn signal light switch
10.Neutral switch

7-80
 – +
ELEC
EAS30551

CHECKING THE FUSES

The following procedure applies to all of the fuses.
ECA20520

NOTICE
To avoid a short circuit, always turn the main switch to “OFF” when checking or replacing a
fuse.

1. Remove:
• Rider seat and passenger seat
Refer to “GENERAL CHASSIS” in base service manual B97-F8197-E0 on page 4-1.
2. Check:
• Fuse
a. Connect the multimeter to the fuse and check the continuity.
TIP
Set the multimeter selector to “  1”.

Multimeter
INS-003
(90890-03189)

b. If the multimeter indicates “”, replace the fuse.

3. Replace:
• Blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage rating.
c. Set on the switches to verify if the electrical circuit is operational.
d. If the fuse immediately blows again, check the electrical circuit.
Amperage
Fuses Q’ty
rating
Main 15 A 1
ABS solenoid 15 A 1
ABS motor 30 A 1
ABS control unit 2A 1
Spare 30 A 1
Spare 15 A 1
Spare 2A 1

7-81
 – +
ELEC
EWA13310

WARNING
Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse
with the wrong amperage rating may cause extensive damage to the electrical system, cause
the lighting and ignition systems to malfunction and could possibly cause a fire.

4. Install:
• Rider seat and passenger seat
Refer to “GENERAL CHASSIS” in base service manual B97-F8197-E0 on page 4-1.

7-82
WIRING DIAGRAM (FZ25-ABS)
WIRING DIAGRAM (For FZ25-ABS) COLOR CODE

1. Crankshaft position sensor 47.Neutral indicator light B Black

2. Neutral switch 48.Meter light Br Brown
3. Stator coil 49.ABS warning light Ch Chocolate
4. Rectifier/Regulator 50.Turn signal light indicator Dg Dark green
G Green
5. Fuse box 1 51.High beam indicator
Gy Gray
6. ABS solenoid spare fuse 52.Brake/taillight L Blue
7. ABS control unit spare fuse 53.Fuel sender Lg Light green
8. ABS control unit fuse 54.Fuel pump Or Orange
9. Fuse box2 55.Turn signal relay P Pink
10.ABS motor spare fuse 56.Horn R Red
Sb Sky blue
11.ABS motor fuse 57.Left handlebar switch
W White
12.ABS solenoid fuse 58.Dimmer and pass switch Y Yellow
13.Battery positive lead 59.Horn switch B/L Black/Blue
14.Battery 60.Turn signal switch B/R Black/Red
15.Battery negative lead 61.Licence plate light B/W Black/White
16.Engine ground 62.Rear turn signal light (right) Br/W Brown/White
B/Y Black/Yellow
17.Fuse 63.Rear turn signal light (left) G/B Green/Black
18.Starter relay 64.Front turn signal light G/L Green/Blue
19.Starter motor (right/left) G/R Green/Red
20.Main switch 65.Head light assembly G/Y Green/Yellow
21.Right handlebar switch 66.Auxiliary light Gy/R Gray/Red
22.Start switch 67.Head light L/B Blue/Black
68.ABS ECU clutch control unit L/W Blue/White
23.Engine stop switch L/Y Blue/Yellow
24.Starting circuit cut off relay 69.Front wheel sensor Or/B Orange/Black
25.Clutch switch 70.Rear wheel sensor unit Or/W Orange/White
26.Front brake light switch 71.Joint 1 P/W Pink/White
27.Throttle body sensor 72.ABS test coupler R/B Red/Black
assembly R/L Red/Blue
28.Intake air pressure sensor R/W Red/White
Y/B Yellow/Black
29.Intake air temperature sen- Y/G Yellow/Green
sor Y/L Yellow/Blue
30.Throttle position sensor Y/R Yellow/Red
31.Engine temperature sensor Y/W Yellow/White
32.Lean angle sensor W/B White/Black
33.FlD (Fast idle device) W/L White/Blue
W/R White/Red
34.ECU (Engine control unit)
WIY White/Yellow
35.Ignition coil
36.Spark plug
37.Fuel injection
38.O2 sensor
39.Yamaha diagnostic tool
coupler
40.Rear brake light switch
41.J/C 2 (Joint connector)
42.J/C 3 (Joint connector)
43.Meter assembly
44.FFV
45.Engine trouble warning light
46.Multifunction display
WIRING DIAGRAM (FAZER25-ABS)
WIRING DIAGRAM (For FAZER25-ABS) COLOR CODE

1. Crankshaft position sensor 46.Meter assembly B Black

2. Stator coil 47.FFV Br Brown
3. Neutral switch 48.Engine trouble warning light Ch Chocolate
4. Rectifier/Regulator 49.Multi-function display Dg Dark green
5. Fuse box 1 50.Neutral Indicator light G Green
Gy Gray
6. ABS solenoid spare fuse 51.Meter light L Blue
7. ABS control unit spare fuse 52.ABS warning light Lg Light green
8. ABS control unit fuse 53.Turn signal indicator light Or Orange
9. Fuse box 2 54.High beam indicator light P Pink
10.ABS motor spare fuse 55.Fuel pump R Red
Sb Sky blue
11.ABS motor fuse 56.Fuel sender
W White
12.ABS solenoid fuse 57.Brake/taillight Y Yellow
13.Battery positive lead 58.Front brake light switch B/L Black/Blue
14.Battery 59.Rear brake light switch B/R Black/Red
15.Battery negative lead 60.Turn signal relay B/W Black/White
16.Engine ground 61.Horn 1 Br/W Brown/White
B/Y Black/Yellow
17.Main switch 62.Horn 2 G/B Green/Black
18.Fuse 63.Left handlebar switch G/L Green/Blue
19.Starter relay 64.Dimmer and pass switch G/R Green/Red
20.Starter motor 65.Horn switch G/Y Green/Yellow
21.Starting circuit cut off relay 66.Turn signal switch Gy/R Gray/Red
22.Clutch switch 67.License plate light L/W Blue/White
L/Y Blue/Yellow
23.Right handlebar switch 68.Rear turn signal light (right) Or/B Orange/Black
24.Start switch 69.Rear turn signal light (left) Or/W Orange/White
25.Engine stop switch 70.Front turn signal light (right) P/W Pink/White
26.Throttle body sensor 71.Front turn signal light (left) R/B Red/Black
assembly 72.Headlight assembly R/L Red/Blue
27.Intake air pressure sensor R/W Red/White
73.Auxiliary light (right)
28.Intake air temperature sen- Y/B Yellow/Black
74.Auxiliary light (left) Y/G Yellow/Green
sor
Y/L Yellow/Blue
29.Throttle position sensor Y/R Yellow/Red
30.Engine temperature sensor Y/W Yellow/White
31.Lean angle sensor W/B White/Black
32.FID (Fast Idle Device) W/L White/Blue
33.ECU (Engine Control Unit) W/R White/Red
W/Y White/Yellow
34.Ignition coil
35.Spark plug
36.Fuel injector
37.O2 sensor
38.Yamaha diagnostic tool
coupler
39.J/C 2 (Joint connector)
40.J/C 3 (Joint connector)
41.Front speed sensor
42.Rear speed sensor
43.Joint
44.ABS test coupler
45.ABS ECU (electric control
unit)
BC4-F8197-E1

1Y199(SSM-01)1352-03-19-E