Periodic service of motorcycle Yamaha FZ1 (2006-2015)
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Periodic maintenance and lubrication chart
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly...
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly...
Adjusting the valve clearance
The following procedure applies to all of the valves. Notes: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the...
The following procedure applies to all of the valves. Notes: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the...
Synchronizing the throttle bodies
Note: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface. Note: Place the vehicle on a suitable...
Note: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface. Note: Place the vehicle on a suitable...
Adjusting the exhaust gas volume
Note: Be sure to set the CO density level to standard, and then adjust the exhaust gas volume. 1. Turn the main switch to "OFF" and set the engine stop switch to "ON". 2. Simultaneously press and hold the "SELECT" and "RESET" buttons, turn the main...
Note: Be sure to set the CO density level to standard, and then adjust the exhaust gas volume. 1. Turn the main switch to "OFF" and set the engine stop switch to "ON". 2. Simultaneously press and hold the "SELECT" and "RESET" buttons, turn the main...
Adjusting the engine idling speed
Note: Prior to adjusting the engine idling speed, the throttle bodies’ synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for...
Note: Prior to adjusting the engine idling speed, the throttle bodies’ synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for...
Adjusting the throttle cable free play
Note: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: Throttle cable free play "a". Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) —...
Note: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Check: Throttle cable free play "a". Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) —...
Checking the spark plugs
The following procedure applies to all of the spark plugs. 1. Remove: Radiator upper bolts Radiator lower bolt. Refer to « Radiator ». 2. Remove: Ignition coils Spark plugs Caution! Before removing the spark plugs, blow away any dirt accumulated in...
The following procedure applies to all of the spark plugs. 1. Remove: Radiator upper bolts Radiator lower bolt. Refer to « Radiator ». 2. Remove: Ignition coils Spark plugs Caution! Before removing the spark plugs, blow away any dirt accumulated in...
Measuring the compression pressure
The following procedure applies to all of the cylinders. Note: Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance. Out of specification → Adjust. Refer to « Adjusting the valve clearance ». 2. Start...
The following procedure applies to all of the cylinders. Note: Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance. Out of specification → Adjust. Refer to « Adjusting the valve clearance ». 2. Start...
Checking the engine oil level
1. Stand the vehicle on a level surface. Note: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: Engine oil level The engine oil level should...
1. Stand the vehicle on a level surface. Note: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: Engine oil level The engine oil level should...
Changing the engine oil
1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: Engine oil filler cap "1" Engine oil drain bolt "2" (along with the gasket) 4. Drain: Engine oil (completely...
1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: Engine oil filler cap "1" Engine oil drain bolt "2" (along with the gasket) 4. Drain: Engine oil (completely...
Measuring the engine oil pressure
1. Check: Engine oil level Below the minimum level mark "a" → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. Caution! When the engine is cold, the engine oil will have a...
1. Check: Engine oil level Below the minimum level mark "a" → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. Caution! When the engine is cold, the engine oil will have a...
Adjusting the clutch cable free play
1. Check Clutch cable free play "a". Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) — 10-15 mm (0.39-0.59 in). 2. Adjust Clutch cable free play Handlebar side a. Turn the adjusting dial "1" in direction "b" or...
1. Check Clutch cable free play "a". Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) — 10-15 mm (0.39-0.59 in). 2. Adjust Clutch cable free play Handlebar side a. Turn the adjusting dial "1" in direction "b" or...
Replacing the air filter element
1. Remove: Rider and passenger seat. Refer to « General chassis ». Fuel tank. Refer to « Fuel tank ». 2. Remove: Air filter case cover "1" 3. Check: Air filter element "1". Damage → Replace. Note: Replace the air filter element every 40000 km (2400...
1. Remove: Rider and passenger seat. Refer to « General chassis ». Fuel tank. Refer to « Fuel tank ». 2. Remove: Air filter case cover "1" 3. Check: Air filter element "1". Damage → Replace. Note: Replace the air filter element every 40000 km (2400...
Cheking the throttle body joints
The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: Throttle bodies. Refer to « Throttle bodies ». 2. Check: Throttle body joints "1". Cracks/damage → Replace. 3. Install: Throttle bodies. Refer to «...
The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: Throttle bodies. Refer to « Throttle bodies ». 2. Check: Throttle body joints "1". Cracks/damage → Replace. 3. Install: Throttle bodies. Refer to «...
Checking the fuel line
The following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: Rider and passenger seat. Refer to « General chassis ». Fuel tank. Refer to « Fuel tank ». 2. Check: Fuel hose "1" Vacuum hose "2" Breather hose "3"...
The following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: Rider and passenger seat. Refer to « General chassis ». Fuel tank. Refer to « Fuel tank ». 2. Check: Fuel hose "1" Vacuum hose "2" Breather hose "3"...
Cheking the crankcase breather hose
1. Remove: Rider and passenger seat. Refer to « General chassis ». Fuel tank. Refer to « Fuel tank ». 2. Check: Crankcase breather hose "1". Cracks/damage → Replace. Loose connection → Connect properly. Caution! Make sure the crankcase breather hose...
1. Remove: Rider and passenger seat. Refer to « General chassis ». Fuel tank. Refer to « Fuel tank ». 2. Check: Crankcase breather hose "1". Cracks/damage → Replace. Loose connection → Connect properly. Caution! Make sure the crankcase breather hose...
Checking the exhaust system
The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: Exhaust pipe "1" Muffler "2". Cracks/damage → Replace. Gaskets "3". Exhaust gas leaks → Replace. 2. Check: Tightening torque Exhaust pipe nut "4" Exhaust pipe and...
The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: Exhaust pipe "1" Muffler "2". Cracks/damage → Replace. Gaskets "3". Exhaust gas leaks → Replace. 2. Check: Tightening torque Exhaust pipe nut "4" Exhaust pipe and...
Adjusting the EXUP cables
1. Remove: EXUP valve pulley cover "1" 2. Check: EXUP system operation a. Activate the diagnostic mode and select the diagnostic code number "53". Refer to « Fuel injection system ». b. Set the engine stop switch to "q". c. Check that the EXUP valve...
1. Remove: EXUP valve pulley cover "1" 2. Check: EXUP system operation a. Activate the diagnostic mode and select the diagnostic code number "53". Refer to « Fuel injection system ». b. Set the engine stop switch to "q". c. Check that the EXUP valve...
Checking the EXUP servo motor
1. Check: EXUP servo motor operation. Out of specification → Replace. a. Check whether or not the EXUP valve is seized. Disconnect the EXUP cable and check that the EXUP valve is moved smoothly by hand. When the valve is not moved smoothly, repair...
1. Check: EXUP servo motor operation. Out of specification → Replace. a. Check whether or not the EXUP valve is seized. Disconnect the EXUP cable and check that the EXUP valve is moved smoothly by hand. When the valve is not moved smoothly, repair...
Checking the coolant level
1. Stand the vehicle on a level surface. Note: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Coolant level The coolant level should be between the maximum level mark "a" and minimum level mark "b". Below the...
1. Stand the vehicle on a level surface. Note: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Coolant level The coolant level should be between the maximum level mark "a" and minimum level mark "b". Below the...
Checking the cooling system
1. Check: Radiator "1" Radiator inlet hose "2" Radiator outlet hose "3" Oil cooler "4" Oil cooler inlet hose "5" Oil cooler outlet hose "6" Water jacket joint "7" Water jacket joint inlet hose "8" Water pump inlet pipe "9" Water pump outlet pipe...
1. Check: Radiator "1" Radiator inlet hose "2" Radiator outlet hose "3" Oil cooler "4" Oil cooler inlet hose "5" Oil cooler outlet hose "6" Water jacket joint "7" Water jacket joint inlet hose "8" Water pump inlet pipe "9" Water pump outlet pipe...
Changing the coolant
1. Remove: Rider and passenger seat. Refer to « General chassis ». 2. Remove: Coolant reservoir tank Coolant reservoir hose 3. Disconnect: Coolant reservoir cap "1" 4. Drain: Coolant (from the coolant reservoir) 5. Remove: Radiator cap "1" Warning!...
1. Remove: Rider and passenger seat. Refer to « General chassis ». 2. Remove: Coolant reservoir tank Coolant reservoir hose 3. Disconnect: Coolant reservoir cap "1" 4. Drain: Coolant (from the coolant reservoir) 5. Remove: Radiator cap "1" Warning!...
Adjusting the front disc brake
1. Adjust: Brake lever position (distance «a» from the throttle grip to the brake lever) Notes: While pushing the brake lever forward, turn the adjusting dial «1» until the brake lever is in the desired position. Be sure to align the setting on the...
1. Adjust: Brake lever position (distance «a» from the throttle grip to the brake lever) Notes: While pushing the brake lever forward, turn the adjusting dial «1» until the brake lever is in the desired position. Be sure to align the setting on the...
Adjusting the rear disc brake
1. Adjust: Brake pedal position a. Loosen the locknut «1». b. Turn the adjusting bolt «2» in direction «a» or «b» until the specified brake pedal position is obtained. Direction «a»: Brake pedal is raised. Direction «b»: Brake pedal is lowered....
1. Adjust: Brake pedal position a. Loosen the locknut «1». b. Turn the adjusting bolt «2» in direction «a» or «b» until the specified brake pedal position is obtained. Direction «a»: Brake pedal is raised. Direction «b»: Brake pedal is lowered....
Checking the brake fluid level
1. Stand the vehicle on a level surface. Notes: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Brake fluid level Below the minimum level mark «a» → Add the recommended brake fluid to the proper level. Recommended...
1. Stand the vehicle on a level surface. Notes: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Check: Brake fluid level Below the minimum level mark «a» → Add the recommended brake fluid to the proper level. Recommended...
Checking the front brake pads
The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Front brake pad Wear indicators «a» almost touch the brake disc → Replace the brake pads as a set. Refer to « Front brake ».
The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Front brake pad Wear indicators «a» almost touch the brake disc → Replace the brake pads as a set. Refer to « Front brake ».
Checking the rear brake pads
The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Rear brake pad Wear indicators «b» almost touch the brake disc → Replace the brake pads as a set. Refer to « Rear brake ».
The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: Rear brake pad Wear indicators «b» almost touch the brake disc → Replace the brake pads as a set. Refer to « Rear brake ».
Cheking the front brake hoses
The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: Brake hose «1» Cracks/damage/wear → Replace. 2. Check: Brake hose clamp «2» Loose → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the front...
The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: Brake hose «1» Cracks/damage/wear → Replace. 2. Check: Brake hose clamp «2» Loose → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the front...
Cheking the rear brake hose
1. Check: Brake hose «1» Cracks/damage/wear → Replace. 2. Check: Brake hose clamp «2» Loose Connection → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: Brake hose Brake fluid leakage → Replace...
1. Check: Brake hose «1» Cracks/damage/wear → Replace. 2. Check: Brake hose clamp «2» Loose Connection → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: Brake hose Brake fluid leakage → Replace...
Adjusting the rear brake light switch
Note: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: Rear brake light operation timing....
Note: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: Rear brake light operation timing....
Bleeding the hydraulic brake system
Warning! Bleed the hydraulic brake system whenever: The system is disassembled. A brake hose is loosened, disconnected or replaced. The brake fluid level is very low. Brake operation is faulty. Notes: Be careful not to spill any brake fluid or allow...
Warning! Bleed the hydraulic brake system whenever: The system is disassembled. A brake hose is loosened, disconnected or replaced. The brake fluid level is very low. Brake operation is faulty. Notes: Be careful not to spill any brake fluid or allow...
Adjusting the shift pedal
1. Adjust: Shift pedal position a. Loosen both locknuts «1». b. Turn the shift rod «2» in direction «a» or «b» to obtain the correct shift pedal position. Direction «a» Shift pedal is raised. Direction «b» Shift pedal is lowered. c. Tighten both...
1. Adjust: Shift pedal position a. Loosen both locknuts «1». b. Turn the shift rod «2» in direction «a» or «b» to obtain the correct shift pedal position. Direction «a» Shift pedal is raised. Direction «b» Shift pedal is lowered. c. Tighten both...
Adjusting the drive chain slack
Note: The drive chain slack must be checked at the tightest point on the chain. Caution! A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident....
Note: The drive chain slack must be checked at the tightest point on the chain. Caution! A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident....
Lubricating the drive chain
The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive...
The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive...
Checking and adjusting the steering head
1. Stand the vehicle on a level surface. Warning! Securely support the vehicle so that there is no danger of it falling over. Note: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: Steering head Grasp the bottom...
1. Stand the vehicle on a level surface. Warning! Securely support the vehicle so that there is no danger of it falling over. Note: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: Steering head Grasp the bottom...
Checking the front fork
1. Stand the vehicle on a level surface. Warning! Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube «1». Damage/scratches → Replace. Oil seal «2». Oil leakage → Replace. 3. Hold the vehicle upright and...
1. Stand the vehicle on a level surface. Warning! Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube «1». Damage/scratches → Replace. Oil seal «2». Oil leakage → Replace. 3. Hold the vehicle upright and...
Adjusting 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 front fork leg is equipped with a rebound damping force adjusting screw and left front fork leg...
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 front fork leg is equipped with a rebound damping force adjusting screw and left front fork leg...
Adjusting the rear shock absorber assembly
Warning! Securely support the vehicle so that there is no danger of it falling over. Spring preload Caution! Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Spring preload a. Adjust the spring preload with the special wrench...
Warning! Securely support the vehicle so that there is no danger of it falling over. Spring preload Caution! Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Spring preload a. Adjust the spring preload with the special wrench...
Checking the tires
The following procedure applies to both of the tires. 1. Check: Tire pressure. Out of specification → Regulate. Warnings! The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire...
The following procedure applies to both of the tires. 1. Check: Tire pressure. Out of specification → Regulate. Warnings! The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire...
Checking the wheels
he following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round → Replace. Warning! Never attempt to make any repairs to the wheel. Note: After a tire or wheel has been changed or replaced, always balance the wheel.
he following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round → Replace. Warning! Never attempt to make any repairs to the wheel. Note: After a tire or wheel has been changed or replaced, always balance the wheel.
Checking and lubricating the cables
The following procedure applies to all of the inner and outer cables. Warning! Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: Outer...
The following procedure applies to all of the inner and outer cables. Warning! Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: Outer...
Lubricating the levers
Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant: Lithium - soap - based grease.
Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant: Lithium - soap - based grease.
Lubricating the pedal
Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium - soap - based grease.
Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium - soap - based grease.
Lubricating the sidestand
Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium - soap - based grease.
Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium - soap - based grease.
Lubricating the centerstand (FZ1-S(X)/FZ1-SA)
Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium - soap - based grease.
Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium - soap - based grease.
Lubricating the rear suspension
Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease.
Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease.
Replacing the headlight bulbs
1. Remove: Headlight side cover bolts «1» (FZ1-N(X)), (FZ1-NA) 2. Disconnect: Headlight sub-wire harness coupler «2» (FZ1-N(X)), (FZ1-NA) 3. Disconnect: Headlight coupler «1» A. FZ1-N(X)/FZ1-NA; B. FZ1-S(X)/FZ1-SA 4. Remove: Headlight bulb cover «1»...
1. Remove: Headlight side cover bolts «1» (FZ1-N(X)), (FZ1-NA) 2. Disconnect: Headlight sub-wire harness coupler «2» (FZ1-N(X)), (FZ1-NA) 3. Disconnect: Headlight coupler «1» A. FZ1-N(X)/FZ1-NA; B. FZ1-S(X)/FZ1-SA 4. Remove: Headlight bulb cover «1»...
Adjusting the headlight beam
1. Adjust: Headlight beam (vertically) a. Turn the adjusting screw «1» in direction «a» or «b». Direction «a» Headlight beam is raised. Direction «b» Headlight beam is lowered. A. FZ1-N(X)/FZ1-NA; B. FZ1-S(X)/FZ1-SA 2. Adjust: Headlight beam...
1. Adjust: Headlight beam (vertically) a. Turn the adjusting screw «1» in direction «a» or «b». Direction «a» Headlight beam is raised. Direction «b» Headlight beam is lowered. A. FZ1-N(X)/FZ1-NA; B. FZ1-S(X)/FZ1-SA 2. Adjust: Headlight beam...
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