Engine fuel supply system of motorcycle Yamaha FZ1 (2006-2015)

Removing the fuel tank
Order Job/Parts to remove Quantity Remarks Rider and passenger seat Refer to « General chassis ». 1 Fuel hose 1 Disconnect. 2 Fuel sender coupler 1 Disconnect. 3 Fuel pump coupler 1 Disconnect. 4 Fuel tank drain hose 1 Disconnect. 5 Fuel tank...

Removing the fuel pump
1. Remove: Fuel pump Cautions! Do not drop the fuel pump or give it a strong shock. Do not touch the base section of the fuel sender.

Checking the fuel pump body
1. Check: Fuel pump body, Obstruction → Clean. Cracks/damage → Replace fuel pump assembly. 2. Check: Diaphragms and gaskets Turn/fatigue/cracks → Replace fuel pump assembly. 3. Check: Valves Cracks/damage → Replace fuel pump assembly.

Installing the fuel pump
1. Install: Fuel pump Fuel pump bolt: 4 Nm (0.4 m·kg, 2.9 ft·lb). Notes: Do not damage the installation surface of the fuel tank when installing the fuel pump. Always use a new fuel pump gasket. Install the fuel pump as shown in the illustration....

Installing the fuel tank
1. Install: Fuel hose Fuel hose connector cover Caution! When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, otherwise the fuel hose will not be properly installed....

Removing the throttle bodies
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 ». 1 Sub-wire harness coupler 2 Disconnect. 2 Coolant temperature sensor...

Removing the injectors
Order Job/Parts to remove Quantity Remarks 1 Throttle position sensor coupler 1 Disconnect. 2 Sub-throttle position sensor coupler 1 Disconnect. 3 Sub-throttle motor assembly coupler 1 Disconnect. 4 Intake air pressure sensor coupler 1 Disconnect. 5...

Checking the injectors
1. Check: Injectors Damage → Replace.

Checking the throttle bodies
1. Check: Throttle bodies Cracks/damage → Replace the throttle bodies as a set. 2. Check: Fuel passages Obstructions → Clean. a. Wash the throttle bodies in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution. b. Blow out...

Checking the fuel pressure
1. Check: Fuel pressure a. Remove the rider and passenger seat. Refer to « General chassis ». b. Disconnect the fuel hose (fuel tank to primary injector fuel rail) «1» from the primary injector fuel rail. Warning! Cover fuel hose connections with a...

Adjusting the throttle position sensor
Note: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: Throttle position sensor Refer to « Checking the throttle position sensor ». 2. Adjust: Throttle position sensor angle a. Connect the...

Adjusting the sub-throttle position sensor
1. Check: Sub-throttle position sensor Refer to « Checking the sub-throttle position sensor ». 2. Adjust: Sub-throttle position sensor full open angle a. Turn the nut «1» of the worm shaft of the sub-throttle counterclockwise until it contacts with...

Checking the sub-throttle servo motor
1. Check: Sub-throttle servo motor operation Out of specification → Replace. a. Check whether or not the sub-throttle valve is seized. 1. Turn the nut of worm shaft of the subthrottle servo motor by hand to check that the sub-throttle valve is moved...

Checking the thermo wax
1. Check: Thermo wax «1» Damage → Replace the thermo wax assembly.

Adjusting the thermo wax
1. Adjust: Thermo wax the end face distance «a» a. Before adjusting the distance, push the rod «b» in order to be fitted in several times by hand. b. Measure the outside air temperature, and adjust the distance «a» by turning the adjusting screw...

Removing the air cut-off valve assembly and hoses
Order Job/Parts to remove Quantity Remarks 1 Air cut-off valve coupler 1 Disconnect. 2 Air cut-off valve hose 1 1 Disconnect. 3 Air cut-off valve hose 2 1 Disconnect. 4 Air cut-off valve hose 3 1 Disconnect. 5 Air cut-off valve 1 6 Reed valve cap 2...

Checking the air induction system
Air injection The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens,...

Installing the air induction system
1. Install: Plate Reed valve assembly Reed valve cap 2. Install: Air cut-off valve Air cut-off valve hose 1 Air cut-off valve hose 2 Air cut-off valve hose 3 Air cut-off valve coupler