Motorcycle engine cooling system Yamaha FZ1 (2006-2015)

Removing the radiator
Order Job/Parts to remove Quantity Remarks Rider and passenger seat Refer to « General chassis ». Fuel tank Refer to « Fuel tank ». Air filter case Refer to « General chassis ». Coolant Drain. Refer to « Changing the coolant » on page 3-19. 1...

Checking the radiator
1. Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. Note: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: Radiator hoses Radiator pipes Cracks/damage →...

Installing the radiator
1. Fill: Cooling system (with the specified amount of the recommended coolant) Refer to « Changing the coolant ». 2. Check: Cooling system. Leaks → Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure. Below the specified...

Removing the oil cooler
Order Job/Parts to remove Quantity Remarks Engine oil Drain. Refer to « Changing the engine oil ». 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 3 Washer 1 4 Oil cooler 1 5 O-ring 1 6 Water pump outlet pipe 1 7 O-ring 1 8 Water jacket joint inlet...

Checking the oil cooler
1. Check: Oil cooler Cracks/damage → Replace. 2. Check: Oil cooler inlet hose Oil cooler outlet hose Cracks/damage/wear → Replace.

Installing the oil cooler
1. Clean: Mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2. Install: O-ring Oil cooler «1» Washer «2» Oil cooler bolt «3» Oil cooler bolt: 63 Nm (6.3 m·kg, 46 ft·lb). Notes: Before installing the oil...

Removing the thermostat assembly
Order Job/Parts to remove Quantity Remarks Rider and passenger seat Refer to « General chassis ». Fuel tank Refer to « Fuel tank ». Air filter case Refer to « General chassis ». Coolant Drain. Refer to « Changing the coolant ». 1 Thermostat assembly...

Disassembling the thermostat assembly
Order Job/Parts to remove Quantity Remarks 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 4 O-ring 1

Checking the thermostat
1. Check: Thermostat Does not open at 71-85°C (160-185°F) → Replace. a. Suspend the thermostat «3» in a container «4» filled with water. b. Slowly heat the water «2». c. Place a thermometer «1» in the water. d. While stirring the water, observe the...

Assembling the thermostat assembly
1. Install: Thermostat housing «1» Thermostat «2» O-ring «3» Thermostat housing cover «4» Thermostat housing cover nut: 10 Nm (1.0 m·kg, 7.2 ft·lb). Note: Install the thermostat with its breather hole «a» facing up.

Installing the thermostat assembly
1. Fill: Cooling system (with the specified amount of the recommended coolant) Refer to « Changing the coolant ». 2. Check: Cooling system Leaks → Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure Below the specified...

Removing the impeller shaft
Order Job/Parts to remove Quantity Remarks Oil/water pump assembly Refer to « Oil pump ». Oil pump rotor Refer to « Oil pump ». 1 Water pump cover 1 2 O-ring 1 3 Pin 2 4 Impeller shaft (along with the impeller) 1 5 Water pump seal 1 6 Oil seal 1 7...

Disassembling the water pump
1. Remove: Water pump seal «1» Water pump housing «2» Note: Tap out the water pump seal from the inside of the water pump housing. 2. Remove: Oil seal «1» Bearing «2» Water pump housing «3» Note: Tap out the bearing and oil seal from the outside of...

Checking the water pump
1. Check: Water pump housing cover «1» Water pump housing «2» Impeller «3» Rubber damper «4» Rubber damper holder «5» Water pump seals Oil seal Cracks/damage/wear → Replace. 2. Check: Bearing Rough movement → Replace. 3. Check: Water pump outlet...

Assembling the water pump
1. Install: Oil seal «1» (into the water pump housing «2») Notes: Before installing the oil seal, apply tap water or coolant onto its out surface. Install the oil seal with a socket that matches its outside diameter. 2. Install: Water pump seal «1»...