Yamaha FZ1-X Manuals

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

Yamaha FZ1-X Service Manual

Yamaha FZ1-X Service Manual (546 pages)

2008 Motorcycle

Brand: Yamaha | Category: Motorcycle | Size: 37.54 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
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
  - Important Information
    35
    
    Preparation for Removal and Disassembly
    35
    
    Replacement Parts
    35
    
    Gaskets, Oil Seals and O-Rings
    35
    
    Lock Washers/Plates and Cotter Pins
    35
    
    Bearings and Oil Seals
    36
    
    Circlips
    36
  - Checking the Connections
    37
  - Special Tools
    42
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  53
- Electrical Specifications
  56
- Tightening Torques
  59
- Lubrication Points and Lubricant Types
  67
  - Engine
    67
  - Chassis
    68
- Lubrication System Chart and Diagrams
  70
  - Engine Oil Lubrication Chart
    70
  - Lubrication Diagrams
    72
- Cooling System Diagrams
  82
- Cable Routing
  86
Periodic Checks and Adjustments

119
- Periodic Maintenance
  
  122
  - Introduction
    122
- Engine
  
  125
  - Adjusting the Valve Clearance
    125
  - Synchronizing the Throttle Bodies
    127
  - Adjusting the Exhaust Gas Volume
    129
  - Adjusting the Engine Idling Speed
    130
  - Adjusting the Throttle Cable Free Play
    130
  - Checking the Spark Plugs
    131
  - Measuring the Compression Pressure
    131
  - Checking the Engine Oil Level
    132
  - Changing the Engine Oil
    133
  - Measuring the Engine Oil Pressure
    134
  - Adjusting the Clutch Cable Free Play
    135
  - Replacing the Air Filter Element
    136
  - Checking the Throttle Body Joints
    137
  - Checking the Fuel Line
    137
  - Checking the Crankcase Breather Hose
    137
  - Checking the Exhaust System
    138
  - Adjusting the Exup Cables
    138
  - Checking the Exup Servo Motor
    139
  - Checking the Coolant Level
    139
  - Checking the Cooling System
    140
  - Changing the Coolant
    140
- Chassis
  
  143
  - Adjusting the Front Disc Brake
    143
    
    Adjusting the Rear Disc Brake
    143
    
    Checking the Brake Fluid Level
    144
    
    Checking the Front Brake Pads
    144
    
    Checking the Rear Brake Pads
    144
    
    Checking the Front Brake Hoses
    145
    
    Checking the Rear Brake Hose
    145
    
    Adjusting the Rear Brake Light Switch
    145
    
    Bleeding the Hydraulic Brake System
    146
    
    Adjusting the Shift Pedal
    148
    
    Adjusting the Drive Chain Slack
    148
    
    Lubricating the Drive Chain
    149
    
    Checking and Adjusting the Steering Head
    149
    
    Checking the Front Fork
    150
    
    Adjusting the Front Fork Legs
    151
    
    Adjusting the Rear Shock Absorber Assembly
    153
    
    Checking the Tires
    154
    
    Checking the Wheels
    156
    
    Checking and Lubricating the Cables
    156
    
    Lubricating the Levers
    156
    
    Lubricating the Pedal
    156
    
    Lubricating the Sidestand
    156
    
    Electrical System
    157
Chassis

161
- General Chassis
  
  164
  - Removing the Cover
    171
  - Installing the Cover
    171
- Front Wheel
  
  172
- Rear Wheel
  
  180
- Front Brake
  
  189
- Rear Brake
  
  201
  - Introduction
    207
  - Checking the Rear Brake Disc
    207
  - Replacing the Rear Brake Pads
    207
  - Removing the Rear Brake Caliper
    208
  - Disassembling the Rear Brake Caliper
    208
  - Checking the Rear Brake Caliper
    209
  - Assembling the Rear Brake Caliper
    209
  - Installing the Rear Brake Caliper
    210
  - Removing the Rear Brake Master Cylinder
    211
  - Checking the Rear Brake Master Cylinder
    211
  - Assembling the Rear Brake Master Cylinder
    211
  - Installing the Rear Brake Master Cylinder
    211
  - [D-5] Maintenance of the Hydraulic Unit
    215
  - Hydraulic Unit Operation Test
    216
  - [D-6-5] Trial Run
    220
- Handlebar
  
  221
  - Removing the Handlebar
    222
  - Checking the Handlebar
    222
  - Installing the Handlebar
    222
- Front Fork
  
  225
  - Removing the Front Fork Legs
    227
  - Disassembling the Front Fork Legs
    227
  - Checking the Front Fork Legs
    228
  - Assembling the Front Fork Legs
    229
  - Installing the Front Fork Legs
    232
- Steering Head
  
  234
  - Removing the Lower Bracket
    236
  - Checking the Steering Head
    236
  - Installing the Steering Head
    237
- Rear Shock Absorber Assembly
  
  238
- Swingarm
  
  241
  - Removing the Swingarm
    242
  - Checking the Swingarm
    242
  - Installing the Swingarm
    243
- Chain Drive
  
  244
  - Removing the Drive Chain
    245
  - Checking the Drive Chain
    245
  - Checking the Drive Sprocket
    246
  - Checking the Rear Wheel Sprocket
    246
  - Checking the Rear Wheel Drive Hub
    246
  - Installing the Drive Chain
    246
Engine

247
- Engine Removal
  
  250
  - Installing the Engine
    256
- Camshafts
  
  258
  - Removing the Camshafts
    260
  - Checking the Camshafts
    261
  - Checking the Timing Chain and Camshaft Sprocket
    262
  - Checking the Timing Chain Guides
    262
  - Checking the Timing Chain Tensioner
    262
  - Installing the Camshafts
    264
- Cylinder Head
  
  268
  - Removing the Cylinder Head
    268
  - Checking the Cylinder Head
    268
  - Installing the Cylinder Head
    268
- Valves and Valve Springs
  
  271
  - Removing the Valves
    272
  - Checking the Valves and Valve Guides
    273
  - Checking the Valve Seats
    274
  - Checking the Valve Springs
    276
  - Checking the Valve Lifters
    277
  - Installing the Valves
    277
- Generator
  
  279
  - Removing the Generator
    281
  - Installing the Generator
    281
- Starter Clutch
  
  283
  - Removing the Starter Clutch
    284
  - Checking the Damper
    284
  - Checking the Starter Clutch
    284
  - Installing the Starter Clutch
    285
- Crankshaft Position Sensor
  
  286
  - Removing the Crankshaft Position Sensor
    287
  - Installing the Crankshaft Position Sensor
    287
- Electric Starter
  
  288
  - Checking the Starter Motor
    290
  - Assembling the Starter Motor
    291
  - Installing the Starter Motor
    291
- Clutch
  
  292
  - Removing the Clutch
    295
  - Checking the Friction Plates
    296
  - Checking the Clutch Plates
    296
  - Checking the Clutch Springs
    297
  - Checking the Clutch Housing
    297
  - Checking the Clutch Boss
    297
  - Checking the Pressure Plate
    297
  - Checking the Pull Lever Shaft and Pull Rod
    298
  - Installing the Clutch
    298
- Shift Shaft
  
  301
  - Removing the Shift Shaft
    302
  - Checking the Shift Shaft
    302
  - Checking the Stopper Lever
    302
  - Installing the Shift Shaft
    302
- Oil Pump
  
  304
  - Removing the Oil Pan
    307
  - Checking the Sprocket and Chain
    307
  - Checking the Oil Pump
    307
  - Checking the Relief Valve
    308
  - Checking the Oil Delivery Pipes
    308
  - Checking the Oil Strainer
    308
  - Checking the Oil Nozzles
    308
  - Assembling the Oil Pump
    308
  - Installing the Oil/Water Pump Assembly
    309
  - Installing the Oil Pan
    310
- Crankcase
  
  311
  - Disassembling the Crankcase
    313
  - Checking the Crankcase
    313
  - Checking the Bearing and Oil Seals
    313
  - Assembling the Crankcase
    313
- Crankshaft
  
  315
  - Removing the Connecting Rods and Pistons
    317
  - Removing the Crankshaft Assembly
    317
  - Checking the Cylinder and Piston
    318
  - Checking the Piston Rings
    318
  - Checking the Piston Pins
    319
  - Checking the Big End Bearings
    320
  - Installing the Connecting Rod and Piston
    323
  - Checking the Crankshaft
    326
  - Checking the Crankshaft Drive Sprocket
    326
  - Checking the Crankshaft Journal Bearings
    326
  - Installing the Crankshaft
    328
- Transmission
  
  330
  - Removing the Transmission
    335
  - Checking the Shift Forks
    335
  - Checking the Shift Drum Assembly
    336
  - Checking the Transmission
    336
Cooling System

339
- Radiator
  
  341
  - Checking the Radiator
    341
  - Installing the Radiator
    341
- Oil Cooler
  
  342
  - Checking the Oil Cooler
    343
  - Installing the Oil Cooler
    343
- Thermostat
  
  344
- Water Pump
  
  348
  - Disassembling the Water Pump
    349
  - Checking the Water Pump
    349
  - Assembling the Water Pump
    349
  - Fuel System
    351
    
    Fuel Tank
    352
    
    Fuel Tank
    353
    
    Throttle Bodies
    355
    
    Air Induction System
    363
  - Electrical System
    367
    
    Ignition System
    370
    
    Passenger Seat
    372
    
    Electric Starting System
    374
    
    Charging System
    380
    
    Lighting System
    384
    
    Signaling System
    390
    
    Fuel Injection System
    400
    
    Fuel Pump System
    444
    
    Immobilizer System
    448
    
    Meter Coupler
    477
    
    Meter Assembly
    481
    
    Rectifier/Regulator
    482
    
    Electrical Components
    500
  - Troubleshooting
    527
    
    Wiring List
    534
    
    Wiring Diagram
    534
    
    Wiring Diagrams
    539

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