Yamaha fz1 service manual

This is only true when you do not have the resources and tools available for when that time comes! This manual will easily pay for itself on the first oil change, spark plug change, or air filter change that you perform!

The manual includes pictures and easy to follow directions on what tools are needed and how the repair is performed. Just imagine how much you can save by doing simple repairs yourself. Many people buy this manual just to have it around for when the inevitable happens.

Sooner or later, maintenance will need to be performed. Be prepared for it when it happens by simply purchasing this service manual for later use! See below for a list of items that most of our manuals cover. Some manuals actually cover more items that are not even listed!

FZ1-N 1. Tire tread depth Front tire 2. Page A. FZ1-S 1. Remove: 4. Disconnect: 5. FZ1-N B. Headlight sub-wire harness coupler Disconnect. Meter coupler Disconnect. Front cowling assembly Rear view mirror Cowling stay Meter assembly Headlight unit For installation, reverse the removal procedure. Licence plate light lead coupler Disconnect. Turn signal light lead coupler Disconnect. Intake air temperature sensor lead cou- Disconnect. EWA 3. The following procedure applies to both of the NOTE: brake discs.

Start with the lightest weight. NOTE: Make sure that there is enough space between the brake pads before installing the brake cali- pers onto the brake discs. Adjusting bolt left and right Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block left Adjusting block right Rear wheel Brake caliper bracket For installation, reverse the removal NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

Remove the brake caliper piston seals. EAS d. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Water will significantly lower the boiling point of the brake fluid and could EWA cause vapor lock. Install: PADS" on page Check: 2. Recommended fluid 6. Front master cylinder bracket Front brake master cylinder assembly Right handlebar switch Throttle cable housing Apply a thin coat of rubber adhesive onto the left end of the handlebar.

Side the handlebar grip over the left end of the handlebar. Wipe off any excess rubber adhesive with a clean rag. Front fender Cap bolt Loosen. Press down on the spacer with the fork front fork legs. NOTE: b. Compression side B. Damper rod holder Damping rod holder YM 3. Pay attention not to mistake the right and left. NOTE: 3. Install: 4. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. NOTE: Be sure to bleed the front fork leg of any resid- 9.

Remove the rod puller and adapter. Remove the rod puller and the rod puller b. Install the nut. Install the fork spring and spacer. Remove: compressed nitrogen gas. Tighten: shock absorber assembly. Install: 6. Drive chain guard Drive chain For installation, reverse the removal procedure. NOTE: 2. Correct 1. Drive chain roller 2. Oil level switch connector Disconnect. Neutral switch connector Disconnect. Cylinder identification sensor coupler Disconnect.

Speed sensor coupler Disconnect. For assembly, reverse the removal procedure. Tighten: 50 Nm 5. Camshaft sprocket bolt Loosen. Turn the crankshaft clockwise. Correct 5. Measure: 1. Squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring NOTE: and timing chain tensioner rod. Cylinder head Cylinder head gasket Dowel pin Coolant pipe Remove: a. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve stem seal Intake valve lower spring seat Install the valve into the cylinder head.

Measure: i. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.

Engine oil Drain. Install: must be replaced. YUC 2. Clutch cable Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal procedure. After all of the bolts are fully loosened, remove them. Check: 8. The following procedure applies to all of the clutch springs. Check: 1. Tighten Circlip Washer Shift shaft Collar Shift shaft spring Remove: 1. Timing chain Timing chain guide intake side Timing chain guide exhaust side Left side cover O-ring Lower crankcase Page Disassembling The Crankcase Engine oil 2.

Apply: 3. Tap only on reinforced portions of the crankcase, not on the NOTE: crankcase mating surfaces. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Washer Crankshaft drive gear YU 1. Clean the big end bearings, crankshaft 0. Tighten the connecting rod bolts. Connecting rod bolt 20 Nm 2. Select: ing the surface. Offset: 1. Clean the connecting rod bolts. In this case, make sure to replace the con- necting rod bolt. Main axle runout limit 0. NOTE: Oil each gear, shaft, and bearing thoroughly.

Apply compressed air to the rear of the radiator. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure. Page 4. Fuel hose Disconnect. Fuel sender coupler Disconnect. Fuel pump coupler Disconnect.

Fuel tank drain hose Disconnect. Sub-throttle position sensor coupler Disconnect. Sub-throttle motor assembly coupler Disconnect. Intake air pressure sensor coupler Disconnect. Cylinder 1-injector coupler Disconnect. Cylinder 2-injector coupler Disconnect. Cylinder 3-injector coupler Disconnect.

Connect the sub-throttle position sensor coupler to the wire harness. Connect the digital circuit tester to the sub- throttle position sensor. Check whether or not the sub-throttle valve is seized. Air cut-off valve hose 1 Disconnect. Air cut-off valve hose 2 Disconnect.

Air cut-off valve hose 3 Disconnect. When there is neg- ative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.

Install: 0. Main switch 6. Fuse main 7. Battery Relay unit Starting circuit cut-off relay Neutral switch Sidestand switch Crankshaft position sensor Lean angle sensor ECU Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Spark plug Engine stop switch Clutch switch Battery 9. Starter relay Starter motor Start switch Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Main and ignition Replace the fuse s.

High beam indicator light Meter light Pass switch Dimmer switch Auxiliary light Headlight License plate light Fuse tail light Fuse headlight Headlight relay dimmer Page Replace the headlight relay. FZ1-N " on page Fuel pump Speed sensor Fuel level warning light Oil level warning light Neutral indicator light Tacho meter Multi function meter Coolant temperature indicator light Turn signal indicator light left Turn signal indicator light right Front brake light switch Coolant temperature sensor Fuse ignition Radiator fan motor relay Fuse radiator fan motor left Fuse radiator fan motor right Radiator fan motor left Radiator fan motor right Fuse backup 6.

Battery 8. Fuse fuel injection Fuel pump relay Cylinder identification sensor Atmospheric pressure sensor Main, backup, fuel injection and ignition Replace the fuse s. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

Engine trouble warning light off d. Engine trouble warning light on for 1. Able Able open or short circuit Intake air temperature Intake air temperature sensor: sensor open or short circuit detected.

If the bat- tery voltage is lower, recharge the battery. Illuminates the engine trou- ble warning light. Injector 4 Actuates the injector 4 five Check the operating sound times at one-second inter Illuminates the engine trou- ble warning light only while the motor is runnning. Symptom tion sensor. Diagnostic code No. Cranking the tion sensor engine. Symptom Intake air pressure sensor:open or short circuit detected.

Symptom Throttle position sensor:open or short circuit detected. Symptom pressure sensor voltage and intake air pressure sensor voltage differ greatly. Atmospheric pressure sensor Diagnostic code No.

Fault code No. Check for looseness or pinching. Injector 1 Injector 2 Diagnostic code No. Symptom Lean angle sensor:open or short circuit detected.

No normal signals are received from the speed sen- Fault code No. Open circuit is detected in the neutral switch. Speed sensor Diagnostic code No. Symptom mal. Symptom CO adjustment value. Diagnostic monitor- Sub-throttle servo motor ing code No. Main, ignition and fuel injection system Replace the fuse s. Fuse backup 5. Immobilizer unit 6.

Immobilizer indicator This system consists of the following. LED off a. Standby mode on b. Standby mode off c. LED on Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Second standard key a. Registration mode b.

LED on A. Registration of the second standard key is complete. LED off B. Immobilizer system indicator light stops e. Failed to verify continu- more than 50 mm ally for ten times. Light on b. Light off Main switch immobilizer unit 2.

Front brake light switch 3. Starter relay 4.