Yamaha FZ1-SV Manuals

Manuals and User Guides for Yamaha FZ1-SV. We have 1 Yamaha FZ1-SV manual available for free PDF download: Service Manual

Yamaha FZ1-SV Service Manual

Yamaha FZ1-SV Service Manual (451 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18.29 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
  - Fi System
    12
  - Instrument Functions
    13
  - Important Information
    17
    
    Preparation for Removal and Disassembly
    17
    
    Replacement Parts
    17
    
    Gaskets, Oil Seals and O-Rings
    17
    
    Lock Washers/Plates and Cotter Pins
    17
    
    Bearings and Oil Seals
    18
    
    Circlips
    18
  - Checking the Connections
    19
  - Special Tools
    24
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  35
- Electrical Specifications
  37
- Tightening Torques
  39
- Lubrication Points and Lubricant Types
  47
  - Engine
    47
  - Chassis
    49
- Lubrication System Chart and Diagrams
  50
  - Engine Oil Lubrication Chart
    50
  - Lubrication Diagrams
    52
- Cooling System Diagrams
  62
- Cable Routing
  66
Periodic Checks and Adjustments

83
- Periodic Maintenance
  
  86
  - Introduction
    86
- Engine
  
  89
  - Adjusting the Valve Clearance
    89
  - Synchronizing the Throttle Bodies
    91
  - Adjusting the Exhaust Gas Volume
    93
  - Adjusting the Engine Idling Speed
    94
  - Adjusting the Throttle Cable Free Play
    94
  - Checking the Spark Plugs
    95
  - Measuring the Compression Pressure
    95
  - Checking the Engine Oil Level
    96
  - Changing the Engine Oil
    97
  - Measuring the Engine Oil Pressure
    98
  - Adjusting the Clutch Cable Free Play
    99
  - Replacing the Air Filter Element
    100
  - Checking the Throttle Body Joints
    101
  - Checking the Fuel Line
    101
  - Checking the Crankcase Breather Hose
    101
  - Checking the Exhaust System
    102
  - Adjusting the Exup Cables
    102
  - Checking the Exup Servo Motor
    103
  - Checking the Coolant Level
    103
  - Checking the Cooling System
    104
  - Changing the Coolant
    104
- Chassis
  
  107
  - Adjusting the Front Disc Brake
    107
    
    Adjusting the Rear Disc Brake
    107
    
    Checking the Brake Fluid Level
    108
    
    Checking the Front Brake Pads
    108
    
    Checking the Rear Brake Pads
    108
    
    Checking the Front Brake Hoses
    109
    
    Checking the Rear Brake Hose
    109
    
    Adjusting the Rear Brake Light Switch
    109
    
    Bleeding the Hydraulic Brake System
    110
    
    Adjusting the Shift Pedal
    111
    
    Adjusting the Drive Chain Slack
    111
    
    Lubricating the Drive Chain
    112
    
    Checking and Adjusting the Steering Head
    112
    
    Checking the Front Fork
    113
    
    Adjusting the Front Fork Legs
    114
    
    Adjusting the Rear Shock Absorber Assembly
    116
    
    Checking the Tires
    117
    
    Checking the Wheels
    119
    
    Checking and Lubricating the Cables
    119
    
    Lubricating the Levers
    119
    
    Lubricating the Pedal
    119
    
    Lubricating the Sidestand
    119
Chassis

123
- General Chassis
  
  132
  - Removing the Cover
    132
  - Installing the Cover
    132
- Front Wheel
  
  135
  - Removing the Front Wheel
    135
  - Checking the Front Wheel
    135
  - Adjusting the Front Wheel Static Balance
    136
  - Installing the Front Wheel (Disc)
    137
- Rear Wheel
  
  142
- Front Brake
  
  145
- Rear Brake
  
  157
  - Introduction
    162
  - Checking the Rear Brake Disc
    162
  - Replacing the Rear Brake Pads
    162
  - Removing the Rear Brake Caliper
    163
  - Disassembling the Rear Brake Caliper
    163
  - Checking the Rear Brake Caliper
    164
  - Assembling the Rear Brake Caliper
    164
  - Installing the Rear Brake Caliper
    165
  - Removing the Rear Brake Master Cylinder
    166
  - Checking the Rear Brake Master Cylinder
    166
  - Assembling the Rear Brake Master Cylinder
    166
  - Installing the Rear Brake Master Cylinder
    166
- Handlebar
  
  168
  - Removing the Handlebar
    170
  - Checking the Handlebar
    170
  - Installing the Handlebar
    170
- Front Fork
  
  173
  - Removing the Front Fork Legs
    175
  - Disassembling the Front Fork Legs
    175
  - Checking the Front Fork Legs
    176
  - Assembling the Front Fork Legs
    177
  - Installing the Front Fork Legs
    181
- Steering Head
  
  182
  - Removing the Lower Bracket
    184
  - Checking the Steering Head
    184
  - Installing the Steering Head
    185
- Rear Shock Absorber Assembly
  
  186
- Swingarm
  
  190
  - Removing the Swingarm
    192
  - Checking the Swingarm
    192
  - Installing the Swingarm
    193
- Chain Drive
  
  194
  - Removing the Drive Chain
    195
  - Checking the Drive Chain
    195
  - Checking the Drive Sprocket
    196
  - Checking the Rear Wheel Sprocket
    196
  - Checking the Rear Wheel Drive Hub
    196
  - Installing the Drive Chain
    196
Engine

197
- Engine Removal
  
  200
  - Installing the Engine
    206
- Camshafts
  
  208
  - Removing the Camshafts
    210
  - Checking the Camshafts
    211
  - Checking the Timing Chain and Camshaft Sprocket
    212
  - Checking the Timing Chain Guides
    212
  - Checking the Timing Chain Tensioner
    212
  - Installing the Camshafts
    214
- Cylinder Head
  
  217
  - Removing the Cylinder Head
    218
  - Checking the Cylinder Head
    218
  - Installing the Cylinder Head
    218
- Valves and Valve Springs
  
  221
  - Removing the Valves
    222
  - Checking the Valves and Valve Guides
    223
  - Checking the Valve Seats
    224
  - Checking the Valve Springs
    226
  - Checking the Valve Lifters
    227
  - Installing the Valves
    227
- Generator
  
  229
  - Removing the Generator
    231
  - Installing the Generator
    231
- Starter Clutch
  
  233
  - Removing the Starter Clutch
    234
  - Checking the Damper
    234
  - Checking the Starter Clutch
    234
  - Installing the Starter Clutch
    235
- Crankshaft Position Sensor
  
  236
  - Removing the Crankshaft Position Sensor
    237
  - Installing the Crankshaft Position Sensor
    237
- Electric Starter
  
  238
  - Checking the Starter Motor
    240
  - Assembling the Starter Motor
    241
  - Installing the Starter Motor
    241
- Clutch
  
  242
  - Removing the Clutch
    246
  - Checking the Friction Plates
    247
  - Checking the Clutch Plates
    247
  - Checking the Clutch Springs
    248
  - Checking the Clutch Housing
    248
  - Checking the Clutch Boss
    248
  - Checking the Pressure Plate
    248
  - Checking the Pull Lever Shaft and Pull Rod
    248
  - Installing the Clutch
    249
- Shift Shaft
  
  252
  - Removing the Shift Shaft
    254
  - Checking the Shift Shaft
    254
  - Checking the Stopper Lever
    254
  - Installing the Shift Shaft
    254
- Oil Pump
  
  256
  - Removing the Oil Pan
    260
  - Checking the Sprocket and Chain
    260
  - Checking the Oil Pump
    260
  - Checking the Relief Valve
    261
  - Checking the Oil Delivery Pipes
    261
  - Checking the Oil Strainer
    261
  - Checking the Oil Nozzles
    261
  - Assembling the Oil Pump
    261
  - Installing the Oil/Water Pump Assembly
    262
  - Installing the Oil Pan
    263
- Crankcase
  
  264
  - Disassembling the Crankcase
    266
  - Checking the Crankcase
    266
  - Checking the Bearing and Oil Seals
    266
  - Assembling the Crankcase
    266
- Crankshaft
  
  268
  - Removing the Connecting Rods and Pistons
    270
  - Removing the Crankshaft Assembly
    270
  - Checking the Cylinder and Piston
    271
  - Checking the Piston Rings
    271
  - Checking the Piston Pins
    272
  - Checking the Big End Bearings
    273
  - Installing the Connecting Rod and Piston
    276
  - Checking the Crankshaft
    279
  - Checking the Crankshaft Drive Sprocket
    279
  - Checking the Crankshaft Journal Bearings
    279
  - Installing the Crankshaft
    281
- Transmission
  
  283
  - Removing the Transmission
    288
  - Checking the Shift Forks
    288
  - Checking the Shift Drum Assembly
    289
    
    Oil Cooler
    297
    
    Water Pump
    302
    
    Fuel Tank
    308
    
    Throttle Bodies
    310
    
    Air Induction System
    319
    
    General Information
    322
    
    Ignition System
    325
    
    Electric Starting System
    329
    
    Charging System
    335
    
    Lighting System
    339
    
    Signaling System
    345
  - Cooling System
    351
    
    Fuel Injection System
    355
    
    Self-Diagnostic Function Table
    362
    
    Fuel Pump System
    399
    
    Immobilizer System
    403
    
    Electrical Components
    413
  - Electrical System
    439
  - Fuel System
    439
  - Troubleshooting
    440

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