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Yamaha Fz1n Service Manual

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    Page
    of 451
    							
    2006
    2D1-28197-E0
    FZ1-N(V)
    FZ1-S(V)
    SERVICE MANUAL 
    						
    							
    EAS20040
    FZ1-N (V)/FZ1-S (V)SERVICE MANUAL
    ©2005 by Yamaha Motor Co., Ltd.
    First edition, December 2005 All rights reserved.
    Any reproduction or unauthorized use without 
    the written permission of Yamaha Motor Co.,  Ltd. is expressly prohibited. 
    						
    							
    EAS20070
    NOTICE
    This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
    ers and their qualified mechanics. It is not possib le to include all the knowledge of a mechanic in one 
    manual. Therefore, anyone who uses this book  to perform maintenance and repairs on Yamaha 
    vehicles should have a basic understanding of me chanics and the techniques to repair these types 
    of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to 
    render the vehicle unsafe and unfit for use.
    This model has been designed and manufactured to per form within certain specifications in regard 
    to performance and emissions. Proper service with th e correct tools is necessary to ensure that the 
    vehicle will operate as designed. If there is any question about a service procedure, it is imperative 
    that you contact a Yamaha dealer for any service in formation changes that apply to this model. This 
    policy is intended to provide the customer with the most satisfaction from his vehicle and to conform 
    to federal environmental quality objectives.
    Yamaha Motor Company, Ltd. is co ntinually striving to improve all of its models. Modifications and 
    significant changes in specifications or proce dures will be forwarded to all authorized Yamaha deal-
    ers and will appear in future editions  of this manual where applicable.
    NOTE:
    • This Service Manual contains information regardi ng periodic maintenance to the emission control 
    system. Please read this material carefully.
     Designs and specifications are  subject to change without notice.
    EAS20080
    IMPORTANT MANUAL INFORMATION
    Particularly important information is distinguished in this manual by the following.
    The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
    SAFETY IS INVOLVED!
    Failure to follow WARNING instructions could result in severe injury or death
     to 
    the vehicle operator, a bystander or a person checking or repairing the vehicle.
    A CAUTION indicates special precautions that must be taken to avoid damage 
    to the vehicle.
    A NOTE provides key information to make procedures easier or clearer.WARNING
    CAUTION:
    NOTE: 
    						
    							
    EAS20090
    HOW TO USE THIS MANUAL
    This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive 
    explanations of all installation, removal, disassembly, assembly, repair and check procedures are 
    laid out with the individual steps in sequential order.
     The manual is divided into chapters and each chapt er is divided into sections. The current section 
    title is shown at the top of each page “1”.
     Sub-section titles appear in smaller print than the section title “2”.
     To help identify parts and clarify procedure steps, t here are exploded diagrams at the start of each 
    removal and disassembly section “3”.
     Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disas- sembly step “4”.
     Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”.
     A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of 
    parts, notes in jobs, etc “6”.
     Jobs requiring more information (such as spec ial tools and technical data) are described sequen-
    tially “7”. 
    						
    							
    EAS20100
    SYMBOLS
    The following symbols are used in this manual 
    for easier understanding.
    NOTE:
    The following symbols are not relevant to every 
    vehicle.
    1. Serviceable with engine mounted
    2. Filling fluid
    3. Lubricant
    4. Special tool
    5. Tightening torque
    6. Wear limit, clearance
    7. Engine speed
    8. Electrical data
    9. Engine oil
    10.Gear oil
    11.Molybdenum-disulfide oil
    12.Wheel-bearing grease
    13.Lithium-soap-based grease
    14.Molybdenum-disulfide grease
    15.Apply locking agent (LOCTITE®)
    GME
    BLSM
    91011
    12 13 14
    15 16
    LTNew
    T R..
    123
    456
    78
    16.Replace the part 
    						
    							
    1
    2
    3
    4
    5
    6
    7
    8
    9
    EAS20110
    TABLE OF CONTENTS
    GENERAL INFORMATION
    SPECIFICATIONS
    PERIODIC CHECKS AND ADJUSTMENTS
    CHASSIS
    ENGINE
    COOLING SYSTEM
    FUEL SYSTEM
    ELECTRICAL SYSTEM
    TROUBLESHOOTING 
    						
    							
    1
    GENERAL INFORMATION
    IDENTIFICATION.......................................................................................... 1-1
    VEHICLE IDENTIFICATION NUMBER................................................... 1-1
    MODEL LABEL .............................. ......................................................... 1-1
    FEATURES ................................................................................................... 1-2
    FI SYSTEM ................................................................................................... 1-3
    INSTRUMENT FUNCTIONS ......................................................................... 1-4
    IMPORTANT INFORMATION ....................................................................... 1-8
    PREPARATION FOR REMOVAL AND DISASSEMBLY.......................... 1-8
    REPLACEMENT PARTS ........................................................................ 1-8
    GASKETS, OIL SEALS AND O- RINGS.................................................. 1-8
    LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-8
    BEARINGS AND OIL SEALS ................................................................. 1-9
    CIRCLIPS ............................................................................................... 1-9
    CHECKING THE CONNECTIONS ............................................................. 1-10
    SPECIAL TOOLS ....................................................................................... 1-11 
    						
    							
    IDENTIFICATION
    1-1
    EAS20130
    IDENTIFICATION
    EAS20140
    VEHICLE IDENTIFICATION NUMBER
    The vehicle identification number “1” is 
    stamped into the right side of the steering 
    head pipe.
    EAS20150
    MODEL LABEL
    The model label “1” is affixed to the frame. This 
    information will be needed to order spare 
    parts. 
    						
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