Front suspension of motorcycle Yamaha FZ1 (2006-2015)

Removing the handlebar
Order Job/Parts to remove Quantity Remarks Front cowling (FZ1-S(X)/FZ1-SA) Refer to « General chassis ». 1 Rear view mirror (FZ1-N(X)), (FZ1-NA) 2 2 Front brake light switch connector 2 Disconnect. 3 Front master cylinder bracket 1 4 Front brake...

Checking the handlebar
1. Check: Handlebar Bends/cracks/damage → Replace. Warning! Do not attempt to straighten a bent handlebar as this may dangerously weaken it.

Installing the handlebar
1. Stand the vehicle on a level surface. Warning! Securely support the vehicle so that there is no danger of it falling over. 2. Install: Lower handlebar holders «1» Note: Temporarily tighten the nuts «2». 3. Install: Handlebar «1» Upper handlebar...

Removing the front fork legs
Order Job/Parts to remove Quantity Remarks Front wheel Front brake calipers Refer to « Checking the tires » and « Checking the wheels ». 1 Front fender 1 2 Cap bolt 1 Loosen. 3 Upper bracket pinch bolt 1 Loosen. 4 Lower bracket pinch bolt 2 Loosen....

Disassembling the front fork legs
Order Job/Parts to remove Quantity Remarks 1 Cap bolt 1 2 O-ring 1 3 Damper adjusting rod 1 4 Nut 1 5 Washer 1 6 Spacer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper washer 1 14...

Checking the front fork legs
The following procedure applies to both of the front fork legs. 1. Check: Inner tube «1» Outer tube «2» Bends/damage/scratches → Replace. Warning! Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: Spring...

Assembling the front fork legs
The following procedure applies to both of the front fork legs. Warnings! Make sure the oil levels in both front fork legs are equal. Uneven oil levels can result in poor handling and a loss of stability. Notes: When assembling the front fork leg,...

Installing the front fork legs
The following procedure applies to both of the front fork legs. Note: Each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screw and left front fork is equipped...

Removing the lower bracket
Order Job/Parts to remove Quantity Remarks Front wheel Refer to « Front wheel ». Front brake calipers Refer to « Front brake ». Front cowling (FZ1-S(X)/FZ1-SA) Refer to « General chassis ». Headlight and meter assembly (FZ1-N(X)), (FZ1-NA) Refer to...

Checking the steering head
1. Wash: Bearings Bearing races Recommended cleaning solvent: Kerosene. 2. Check: Bearings «1» Bearing races «2» Damage/pitting → Replace. 3. Replace: Bearings Bearing races a. Remove the bearing races from the steering head pipe with a long rod «1»...

Installing the steering head
1. Lubricate: Upper bearing Lower bearing Bearing races Recommended lubricant: Lithium-soap-based grease. 2. Install: Lower ring nut «1» Rubber washer «2» Upper ring nut «3» Lock washer «4» Refer to « Installing the steering head ». 3. Install:...