maintenance YAMAHA FZ8 N 2010 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU18681
TIPAir filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com- pressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
 Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
EAU18743
Removing an d installin g the
cowlin g an d panelThe cowling and panel shown need to
be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
the cowling or panel needs to be re-
moved and installed.
FZ8-NA
EAU46742
Cowlin g A
To remove the cowlingRemove the bolts, and then take the
cowling off. To install the cowling
Place the cowling in the original posi-
tion, and then install the bolts.
EAU19152
Panel A
To remove the panelRemove the bolt, and then pull the
panel off as shown.
1. Cowling A
1
1. Panel A
1. Cowling A
2. Bolt
1
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6
To install the panel
Place the panel in the original position,
and then install the bolt.
EAU19653
Checkin
g the spark plug sThe spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and depos-
its will cause any spark plug to slowly
erode, they should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition of
the engine.
The porcelain insulator around the
center electrode of each spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally), and all spark plugs installed
in the engine should have the same
color. If any spark plug shows a dis-
tinctly different color, the engine could
be operating improperly. Do not at-
tempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced. Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the spark
plug threads.
1. Panel A
2. Bolt
1
2
Specified
spark plu g:
NGK/CR9E
1. Spark plug gap
Spark plu g g ap:
0.7–0.8 mm (0.028–0.031 in)
Ti ghtenin g torque:
Spark plug: 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6
TIPIf a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4–
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.NOTICE
ECA10841
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the i gnition coil coupler may get
d amag ed . The spark plu g cap may
b e difficult to remove b ecause the
ru bber seal on the en d of the cap fits
ti g htly. To remove the spark plu g
cap, simply twist it b ack and forth
while pullin g it out; to install it, twist
it back an d forth while pushin g it in.
EAU19918
En gine oil an d oil filter car-
tri dgeThe engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the en gine oil level
1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for several minutes, and then turn it
off.
3. Wait a few minutes until the oil set- tles, and then check the oil level
through the check window locat-
ed at the bottom-right side of the
crankcase.TIPThe engine oil should be between the
minimum and maximum level marks.
FZ8-N
FZ8-NA1. Engine oil filler cap
2. Engine oil level check window
3. Maximum level mark
4. Minimum level mark
1. Engine oil filler cap
2. Engine oil level check window
3. Maximum level mark
4. Minimum level mark
3
4 1
2
1
2
3
4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
4. If the engine oil is at or below the
minimum level mark, add suffi-
cient oil of the recommended type
to raise it to the correct level.
To chan ge the en gine oil (with or
without oil filter cartri dge replace-
ment) 1. Place the vehicle on a level sur- face.
2. Remove cowling A. (See page 6-8.) (FZ8-NA)
3. Start the engine, warm it up for several minutes, and then turn it
off.
4. Place an oil pan under the engine to collect the used oil.
5. Remove the engine oil filler cap, the engine oil drain bolt and its
gasket to drain the oil from the
crankcase.
TIPSkip steps 6–8 if the oil filter cartridge
is not being replaced.6. Remove the oil filter cartridge withan oil filter wrench.
TIPAn oil filter wrench is available at a
Yamaha dealer.7. Apply a thin coat of clean engineoil to the O-ring of the new oil filter
cartridge.TIPMake sure that the O-ring is properly
seated.8. Install the new oil filter cartridgewith an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
1. Engine oil drain bolt
2. Gasket
1. Oil filter wrench
2. Oil filter cartridge
12
1
2
1. O-ring
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
69. Install the engine oil drain bolt andits new gasket, and then tighten
the bolt to the specified torque.
10. Refill with the specified amount of the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.NOTICE
ECA11621
In or der to prevent clutch slip-
pa ge (since the en gine oil also
lu bricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a hi gh-
er quality than specifie d. In
a ddition, do not use oils la beled
“ENERGY CONSERVING II” or
hi gher.
 Make sure that no forei gn mate-
rial enters the crankcase.
11. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.TIPAfter the engine is started, the engine
oil level warning light should go off if
the oil level is sufficient.NOTICE
ECA10402
If the oil level warnin g lig ht flickers
or remains on even if the oil level is
correct, immed iately turn the en gine
off an d have a Yamaha d ealer check
the vehicle.12. Turn the engine off, wait a few minutes until the oil settles, and
then check the oil level and cor-
rect it if necessary.
13. Install the cowling. (FZ8-NA)
1. Torque wrenchTi ghtenin g torque:
Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf)
Ti ghtenin g torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
1
Recommen ded en gine oil:
See page 8-1.
Oil quantity: Without oil filter cartridge replace-
ment:2.90 L (3.07 US qt, 2.55 Imp.qt)
With oil filter cartridge replacement:
3.10 L (3.28 US qt, 2.73 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
EAU20071
CoolantThe coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU3908A
To check the coolant level1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.TIPThe coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
 Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.2. Check the coolant level in the
coolant reservoir.TIPThe coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below theminimum level mark, remove pan-
el A to access the coolant reser-
voir. (See page 6-8.)
4. Remove the coolant reservoir cap, add coolant to the maximum level
mark, and then install the reservoir
cap. WARNING! Remove only
the coolant reservoir cap. Never
attempt to remove the ra diator
cap when the en gine is hot.
[EWA15162]
NOTICE: If coolant is not
availa ble, use distille d water or
soft tap water instead . Do not
use har d water or salt water
since it is harmful to the en gine. If water has
been used instead
of coolant, replace it with cool-
ant as soon as possi ble, other-
wise the coolin g system will not
b e protecte d a gainst frost an d
corrosion. If water has been
a dd ed to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possi ble, otherwise the
effectiveness of the coolant will
b e re duce d.
[ECA10473]
5. Install the panel.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1
2
3
1. Coolant reservoir cap
Coolant reservoir capacity (up to
the maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
EAU33032
Changin g the coolant
The coolant must be changed at the in-
tervals specified in the periodic main-
tenance and lubrication chart. Have a
Yamaha dealer change the coolant.
WARNING! Never attempt to remove the ra diator cap when the en gine is
hot.
[EWA10382] EAU49664
Replacin
g the air filter ele-
mentThe air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the rider seat. (See page 3-18.)
2. Remove the fuel tank cowling bolts on both sides.
3. Pull the bottom of the cowling out- ward on both sides, then remove
the cowling by moving it forward,
and then lifting it up. 4. Remove the fuel tank bolt on both
sides.
5. Lift the front of the fuel tank, and carefully tilt it back and away from
the air filter case, but do not dis-
connect the fuel hoses.
WARNING! Make sure that the
fuel tank is well supporte d. Do1. Fuel tank cowling
2. Fuel tank cowling bolt
1
2
1. Fuel tank bolt
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
not tilt or pull the fuel tank too
much, otherwise the fuel hoses
may come loose, which could
cause fuel leaka
ge an d a fire
hazar d.
[EWA10412]
6. Remove the air filter case cover by
removing the screws. NOTICE:
When removing the air filter
case cover, be careful not to al-
low forei gn o bjects to drop into
the air intake manifold .
[ECA12882]
7. Pull the air filter element out. 8. Insert a new air filter element into
the air filter case. NOTICE: Make
sure that the air filter element is
properly seated in the air filter
case. The en gine shoul d never
b e operated without the air filter
element installed , otherwise the
piston(s) an d/or cylin der(s) may
b ecome excessively worn.
[ECA10482]
9. Install the air filter case cover by
installing the screws.
10. Place the fuel tank in the original position. Make sure that the fuel
hoses are properly connected and
routed, and not pinched. Be sure
to place the fuel tank breather
hose and the fuel tank overflow
hose in the original position.
WARNING! Before placin g the
fuel tank in the ori ginal position,
make sure that the fuel hoses
are not damag ed . If any fuel
hose is damag ed , do not start
the en gine but have a Yamaha
d ealer replace the hose, other-
wise fuel may leak, creatin g a
fire hazar d.
[EWA11362]
1. Air filter case
2. Fuel tank
1. Fuel tank hose
1
2
1
1. Screw
1. Air filter element
2. Air intake manifold
1
1
1
2
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
611. Install the fuel tank bolt on bothsides.
12. Place the fuel tank cowling in the original position. 13. Install the cowling bolts on both
sides.
14. Install the rider seat.
EAU34302
A djustin g the en gine i dlin g
spee dThe engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.
Check the engine idling speed and, if
necessary, adjust it to specification by
turning the idle adjusting screw. To in-
crease the engine idling speed, turn
the screw in direction (a). To decrease
the engine idling speed, turn the screw
in direction (b).
1. Fuel tank overflow hose
2. Original position (paint mark)
3. Clamp
4. Fuel tank breather hose
12
43
1. Idle adjusting screw
(b)
(a)
1
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