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Table of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
2007
FZ1-N(W)
FZ1-S(W)
FZ1-SA
SERVICE MANUAL
5D0-28197-E0
email: info@motomatrix.co.uk

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Table of Contents

   Summary of Contents for Yamaha FZ1-N 2007

  • Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2007 FZ1-N(W) FZ1-S(W) FZ1-SA SERVICE MANUAL 5D0-28197-E0 email: info@motomatrix.co.uk...
  • Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20040 FZ1-N(W)/FZ1-S(W)/FZ1-SA SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, October 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. email: info@motomatrix.co.uk...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information 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.
  • Page 4: How To Use This Manual

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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.
  • Page 5 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20100 16.Replace the part 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.
  • Page 6 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 7: Table Of Contents

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING email: info@motomatrix.co.uk...
  • Page 8 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 9: General Information

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ..............1-25 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-25 REPLACEMENT PARTS...............1-25 GASKETS, OIL SEALS AND O-RINGS..........1-25...
  • Page 10: Identification

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IDENTIFICATION 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.
  • Page 11: Features

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS20170 FEATURES EAS5D01032 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
  • Page 12: Fi System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS5D01013 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 46.1 psi).
  • Page 13: Instrument Functions

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES EAS5D01014 kilometers and miles, press the “SELECT” INSTRUMENT FUNCTIONS button for at least one second. Multi-function meter unit Tachometer 1. Coolant temperature display/air intake tem- perature display 1.
  • Page 14 “TRIP A” and “TRIP B” in off for approximately 3 seconds. If this occurs, the following order: have a Yamaha dealer check the electrical cir- TRIP A → TRIP B → ODO → TRIP A cuit. When the fuel amount in the fuel tank decreases to 3.4 L (0.90 US gal) (0.75...
  • Page 15 • When the key is turned to “ON”, the coolant to a Yamaha dealer and have the standard temperature is automatically displayed, even keys re-registered. if the air intake temperature was displayed If the display indicates any error codes, note prior to turning the key to “OFF”.
  • Page 16 10.Front wheel sensor rotor 5. Rear brake caliper The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
  • Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced.
  • Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES e. Less slippery road surface a. Friction force between the tire and road surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d.
  • Page 19 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem condition and allows normal braking even if the ABS is not operating properly.
  • Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES ABS block diagram 8. Rear brake caliper 1. Rear brake master cylinder 9. Front brake caliper 2. Hydraulic unit 10.ABS ECU 3. Hydraulic pump 11.Rear wheel sensor 4.
  • Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 7. Wheel sensor rotor 4. At low speed 8. Voltage 5. At high speed 9. Time 6. Wheel sensor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is oper- ating properly.
  • Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 6. To the front brake master cylinder 1. To the rear brake master cylinder 7. To the rear brake caliper 2. Hydraulic pump 8. To the ABS ECU 3.
  • Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 3. Spool 1. Orifice 4. Flow control valve 2. Solenoid valve • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 3.
  • Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 16.ABS test coupler 1.
  • Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis These operations are performed once every 8/1000th of a second. When a failure is detected in the ABS, a malfunction code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.
  • Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Composition and operation The ABS motor relay is activated by signals transmitted from the ABS ECU and operates simulta- neously when the ABS starts to reduce the hydraulic pressure of the brake fluid. If the solenoid relay is turned off, the ABS motor relay is also deactivated and the motor stops operating if there is a mal- function.
  • Page 27 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 15.ABS ECU 1. Brake master cylinder 16.ABS warning light 2. Brake light switch 17.Brake fluid pressure 3. ABS motor 18.Time 4. Hydraulic pump 19.Repressurizing 5. Buffer chamber 6.
  • Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Emergency braking (ABS activated) 1. Depressurized state When the front wheel is about to lockup, port D “11” of the solenoid valve is opened by the “depressurization”...
  • Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 9. Port B 10.Orifice 11.Port D 12.Solenoid valve 13.Port C 14.Brake caliper 15.ABS ECU 16.ABS warning light 17.Brake fluid pressure 18.Time 19.Repressurizing 2. Pressurized state Port D “11” is closed by the “pressurization” signal transmitted from the ABS ECU. Before this occurs, the spool of the flow control valve has compressed the return spring and closed port B “9”.
  • Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES 12.Solenoid valve 1. Brake master cylinder 13.Port C 2. Brake light switch 14.Brake caliper 3. ABS motor 15.ABS ECU 4. Hydraulic pump 16.ABS warning light 5. Buffer chamber 17.Brake fluid pressure 6.
  • Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES Instances when the ABS warning light comes on 1. The ABS warning light comes on when the main switch is turned to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems.
  • Page 32 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES c. Goes off a. ABS warning light d. Preparation b. Comes on 4. The ABS warning light “1” flashes and a malfunction code “2” is indicated on the multi-function display when the test coupler adapter “3”...
  • Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FEATURES • Diagnosis indication The place where the ABS diagnosis code is displayed is also used for the indication of the FI diag- nosis code, odometer, trip meter and fuel trip. As the priority level of indication, the diagnosis code for FI is the first and the diagnosis code for ABS is the second.
  • Page 34: Important Information

    EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 35: Bearings And Oil Seals

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
  • Page 36: Checking The Connections

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog Pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: •...
  • Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques.
  • Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-13 90890-01426 YU-38411 Rod holder 4-62, 4-67 90890-01434 Damper rod holder double ended YM-01434 Rod puller 4-65 90890-01437 Universal damping rod bleeding tool set...
  • Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor 5-23, 5-29 90890-04019 YM-04019 Valve spring compressor attachment 5-23, 5-29 90890-04108 Valve spring compressor adapter (22 mm) YM-04108 Valve spring compressor attachment 5-23, 5-29...
  • Page 40 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 Ignition checker 8-140 90890-06754 Opama pet-4000 spark checker YU-34487 Yamaha bond No.1215 5-64, 6-11 (Three Bond No.1215®) 90890-85505 Digital circuit tester 7-8, 7-9 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Pivot shaft wrench...
  • Page 41: Special Tools

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pivot shaft wrench adapter 90890-01476 Pocket tester 1-27, 5-41, 8- 90890-03112 129, 8-130, 8- Analog pocket tester 131, 8-134, 8- YU-03112-C 136, 8-137, 8- 138, 8-139, 8-...
  • Page 42 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 90890-03153 YU-03153 Camshaft wrench 5-11, 5-16 90890-04143 YM-04143 Test coupler adapter 1-23, 4-53, 4-54 90890-03149 1-33 email: info@motomatrix.co.uk...
  • Page 43: Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-8 ELECTRICAL SPECIFICATIONS...............2-10 TIGHTENING TORQUES................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-12 ENGINE TIGHTENING TORQUES ............2-13 CHASSIS TIGHTENING TORQUES ............2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE ....................2-20 CHASSIS ....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-23...
  • Page 44: General Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2D14 (EUR) (FZ1-N) 2D15 (FRA, BEL) (FZ1-N) 2D16 (AUS) (FZ1-NW) 3C3A (EUR) (FZ1-S) 3C3B (FRA, BEL) (FZ1-S) 3C3C (AUS) (FZ1-SW) 5D01 (EUR) (FZ1-SA) 5D02 (FRA, BEL) (FZ1-SA) Dimensions...
  • Page 45: Engine Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm (60.90 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 11.50 : 1 Standard compression pressure (at sea level)
  • Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS 65/43 × 25/32 (1.181) Reduction ratio Max impeller shaft tilt limit 0.15 mm (0.0059 in) Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 12.20–13.00 cm...
  • Page 47 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Valve face width B (intake) 1.760–2.900 mm (0.0693–0.1142 in) Valve face width B (exhaust) 1.760–2.900 mm (0.0693–0.1142 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake)
  • Page 48 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS Spring rate K1 (intake) 17.53 N/mm (100.10 lb/in) (1.79 kgf/mm) Spring rate K2 (intake) 22.86 N/mm (130.53 lb/in) (2.33 kgf/mm) Spring rate K1 (exhaust) 21.52 N/mm (122.88 lb/in) (2.19 kgf/mm) Spring rate K2 (exhaust) 27.99 N/mm (159.82 lb/in) (2.85 kgf/mm) Installed compression spring force (intake)
  • Page 49 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Oil ring Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) End gap (installed) 0.10–0.40 mm (0.0039–0.0157 in) Connecting rod...
  • Page 50 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE SPECIFICATIONS 37/21 (1.762) 35/23 (1.522) 27/20 (1.350) 29/24 (1.208) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit...
  • Page 51: Chassis Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 25.00 ° Caster angle Trail 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel...
  • Page 52 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS SPECIFICATIONS Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.20 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Recommended fluid DOT 4 Rear brake Type...
  • Page 53: Electrical Specifications

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) 5.0 °/1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDF20/DENSO Transistorized coil ignition...
  • Page 54 Turn signal blinking frequency 75.0–95.0 cycles/min 10 W × 2.0 +3.4 W Wattage Oil level gauge Model/manufacturer 5VY/SOMIC ISHIKAWA Servo motor Model/manufacturer 2D1/YAMAHA Fuses Main fuse 50.0 A Headlight fuse 15.0 A (FZ1-N(W)) 25.0 A (FZ1-S(W), FZ1-SA) Taillight fuse 10.0 A Signaling system fuse 10.0 A...
  • Page 55: Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual.
  • Page 56: Engine Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head nut See NOTE Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft caps bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size EXUP pulley and shaft arm nut 7 Nm (0.7 m·kg, 5.1 ft·lb) EXUP valve pulley cover bolt 14 Nm (1.4 m·kg, 10 ft·lb) EXUP cable nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Exhaust pipe and exhaust pipe...
  • Page 58 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Left Shift rod locknut (rear) 7 Nm (0.7 m·kg, 5.1 ft·lb) thread Shift rod joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Shift arm bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Neutral switch...
  • Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES 2-16 email: info@motomatrix.co.uk...
  • Page 60: Chassis Tightening Torques

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper bracket pinch bolt 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut 113 Nm (11.3 m·kg, 82 ft·lb) Upper handlebar holder bolt 24 Nm (2.4 m·kg, 17 ft·lb) Lower handlebar holder nut...
  • Page 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive chain guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear fender screw 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake hose holder screw 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt (front)
  • Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle cable adjust nut 4 Nm (0.4 m·kg, 2.9 ft·lb) Clutch cable adjust nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Centerstand bracket nut (FZ1- 55 Nm (5.5 m·kg, 40 ft·lb) S(W), FZ1-SA))
  • Page 63: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond No. Cylinder head cover mating surface 1215 Yamaha bond No. Crankcase mating surface 1215 Yamaha bond No.
  • Page 64: Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Engine mount bolts (front left and right)
  • Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION POINTS AND LUBRICANT TYPES 2-22 email: info@motomatrix.co.uk...
  • Page 66: Lubrication System Chart And Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23 email: info@motomatrix.co.uk...
  • Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter 6. Main gallery 7. AC magneto drive gear shower 8.
  • Page 68: Lubrication Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25 email: info@motomatrix.co.uk...
  • Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Oil filter cartridge 4. Oil level switch 2-26 email: info@motomatrix.co.uk...
  • Page 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27 email: info@motomatrix.co.uk...
  • Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Crankshaft 4. Oil cooler 5. Relief valve 6. Oil pipe 7. Oil strainer 8. Oil pump 2-28 email: info@motomatrix.co.uk...
  • Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29 email: info@motomatrix.co.uk...
  • Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil level switch 3. Oil pump 4. Oil strainer 5. Oil pipe 6. Oil cooler 2-30 email: info@motomatrix.co.uk...
  • Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31 email: info@motomatrix.co.uk...
  • Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil delivery pipe 3. Drive axle 2-32 email: info@motomatrix.co.uk...
  • Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33 email: info@motomatrix.co.uk...
  • Page 77 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Crankshaft 2-34 email: info@motomatrix.co.uk...
  • Page 78: Cooling System Diagrams

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35 email: info@motomatrix.co.uk...
  • Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Water pump 2. Radiator 3. Radiator fan 2-36 email: info@motomatrix.co.uk...
  • Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 2-37 email: info@motomatrix.co.uk...
  • Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator 3. Oil cooler 4. Thermostat 2-38 email: info@motomatrix.co.uk...
  • Page 82: Cable Routing

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING EAS20430 CABLE ROUTING 2-39 email: info@motomatrix.co.uk...
  • Page 83 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-N(W)/FZ1-S(W)/FZ1-SA R. The clamp attaching position should be in 1. Clutch cable a range from 20 mm to 40 mm (0.79 in to 1.57 in) from the end of the brake hose 2.
  • Page 84 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-41 email: info@motomatrix.co.uk...
  • Page 85 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-N(W)/FZ1-S(W) N. To the coolant reservoir tank 1. Wire harness O. Route the radiator fan motor lead (right) so 2. Right handlebar switch lead that there is no slack as much as possible in this section.
  • Page 86 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-43 email: info@motomatrix.co.uk...
  • Page 87 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-SA O. Pass the coolant reservoir hose to the vehi- 1. Throttle cables cle inner side of the radiator inlet hose and route it to the lower outside of the vehicle of 2.
  • Page 88 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-45 email: info@motomatrix.co.uk...
  • Page 89 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-N(W)/FZ1-S(W) H. Route the hose assembly 1 by the vehicle 1. Clutch cable front side where the water pump inlet pipe is routed. For the hose tip position, route 2.
  • Page 90 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-47 email: info@motomatrix.co.uk...
  • Page 91 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-SA H. Route the water pump breather hose by 1. Clutch cable the vehicle front side where the water pump inlet pipe is routed. For the hose tip 2.
  • Page 92 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-49 email: info@motomatrix.co.uk...
  • Page 93 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING AC.Route the water pump breather hose finally in the guide after passing other hoses so that it can be positioned on the outside of the vehicle. AD.Route the coolant reservoir tank drain hose so that it is positioned at the inner- most part in hoses and leads.
  • Page 94 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-51 email: info@motomatrix.co.uk...
  • Page 95 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-N(W)/FZ1-S(W) 53.Direct ignition coil lead 1. Throttle cables 54.Speed sensor lead 2. Right handlebar switch lead 55.Lean angle sensor lead 3. Wire harness 56.Battery box 4.
  • Page 96 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-53 email: info@motomatrix.co.uk...
  • Page 97 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING AL.Clamp each lead at the positioning taping R. Pass the license plate light lead and turn section (white) and then insert it to the signal light lead under the turn signal relay. cover.
  • Page 98 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-55 email: info@motomatrix.co.uk...
  • Page 99 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-SA 53.Radiator fan motor lead (left) 1. Throttle cables 54.Oil level switch lead 2. Right handlebar switch lead 55.O sensor lead 3. Throttle cable (pull side) 56.Sidestand switch lead 4.
  • Page 100 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-57 email: info@motomatrix.co.uk...
  • Page 101 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING AJ.Installation procedure 1. Secure the main N. Route the battery positive lead under the switch lead and immobilizer lead with Vel- fuse box lead. cro strap. 2. Secure the left handlebar O.
  • Page 102 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-59 email: info@motomatrix.co.uk...
  • Page 103 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING FZ1-S(W) 1. Clutch cable 2. Left handlebar switch lead 3. Immobilizer lead 4. Main switch lead 5. Protector 6. Throttle cables 7. Right handlebar switch lead 8.
  • Page 104 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-61 email: info@motomatrix.co.uk...
  • Page 105 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 1. Fuel tank 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Clip 5. Air filter bracket 6. 3 way connector 7. Hose 8.
  • Page 106 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CABLE ROUTING 2-63 email: info@motomatrix.co.uk...
  • Page 107: Periodic Checks And Adjustments

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 ENGINE......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ........3-6 ADJUSTING THE EXHAUST GAS VOLUME.........3-8 ADJUSTING THE ENGINE IDLING SPEED ..........3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-9 CHECKING THE SPARK PLUGS............3-10 MEASURING THE COMPRESSION PRESSURE .......3-10...
  • Page 108 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys LUBRICATING THE CENTERSTAND (FZ1-S(W))/FZ1-SA)....3-35 LUBRICATING THE REAR SUSPENSION ..........3-35 ELECTRICAL SYSTEM................3-36 CHECKING AND CHARGING THE BATTERY........3-36 CHECKING THE FUSES..............3-36 REPLACING THE HEADLIGHT BULBS..........3-36 ADJUSTING THE HEADLIGHT BEAM ..........3-37 email: info@motomatrix.co.uk...
  • Page 109 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 110: Periodic Maintenance

    • The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. • From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READ-...
  • Page 111 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 • Check chain slack, alignment and condition. Every 1000 km and after wash- Drive chain •...
  • Page 112 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys PERIODIC MAINTENANCE ODOMETER READ- Annual ING (X 1000 km) ITEM CHECK OR MAINTENANCE JOB check 10 20 30 40 Moving parts √ √ √ √ √ • Lubricate. and cables •...
  • Page 113: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EAS20470 • Valve clearance ENGINE Out of specification → Adjust. Valve clearance (cold) EAS20490 ADJUSTING THE VALVE CLEARANCE Intake valve The following procedure applies to all of the 0.11–0.20 mm (0.0043–0.0079 valves.
  • Page 114 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 6. Adjust: • Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. Valve lapper 90890-04101 NOTE: •...
  • Page 115: Synchronizing The Throttle Bodies

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Example: • The valve lifter must turn smoothly when If the valve pad is marked “158”, the pad rotated by hand. thickness is 1.58 mm (0.062in) d.
  • Page 116 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 2. Remove: 8. Adjust: • Rider and passenger seat • Throttle body synchronization Refer to "GENERAL CHASSIS" on page 4- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. With throttle body #3 as standard, adjust •...
  • Page 117: Adjusting The Exhaust Gas Volume

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 9. Measure: • Engine idling speed Out of specification → Adjust. Make sure that the vacuum pressure is within specification. 10. Stop the engine and remove the measuring equipment.
  • Page 118: Adjusting The Engine Idling Speed

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 8. Simultaneously press the “SELECT” and Throttle cable free play (at the “RESET” buttons to return to the cylinder flange of the throttle grip) selection (step 5). 3.0–5.0 mm (0.12–0.20 in) 9.
  • Page 119: Checking The Spark Plugs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 6. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.6–0.7 mm (0.0236–0.0276 in) c. Tighten the locknut. EWA5D01003 WARNING After adjusting the throttle cable free play,...
  • Page 120: Checking The Engine Oil Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ECA13340 NOTE: CAUTION: The difference in compression pressure Before removing the spark plugs, use com- between cylinders should not exceed 100 kPa pressed air to blow away any dirt accumu- (1 kg/cm², 1 bar, 14.22 psi).
  • Page 121: Changing The Engine Oil

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Type SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13360 CAUTION: • Engine oil also lubricates the clutch and 4.
  • Page 122: Measuring The Engine Oil Pressure

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 5. If the oil filter cartridge is also to be 8. Fill: replaced, perform the following procedure. • Crankcase (with the specified amount of the recom- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 123: Adjusting The Clutch Cable Free Play

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE EWA12980 only as a reference when measuring the WARNING engine oil pressure. The engine, muffler and engine oil are Engine oil pressure Possible causes extremely hot. •...
  • Page 124: Replacing The Air Filter Element

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 2. Adjust • Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting dial “1” in direction “b” or “c” until the specified clutch cable free play is obtained.
  • Page 125: Checking The Throttle Body Joints

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 4. Install: 1. Remove: • Air filter case cover • Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4- ECA14400 CAUTION: Never operate the engine without the air fil- •...
  • Page 126: Checking The Exhaust System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 2. Check: Exhaust pipe nut • Crankcase breather hose “1” 20 Nm (2.0 m·kg, 14 ft·lb) Cracks/damage → Replace. Exhaust pipe and exhaust pipe Loose connection → Connect properly. bracket bolt ECA13450 20 Nm (2.0 m·kg, 14 ft·lb)
  • Page 127: Checking The Exup Servo Motor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 2. Check: • EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Activate the diagnostic mode and select the diagnostic code number “53”. Refer to "FUEL INJECTION SYSTEM" on page 8-31. b.
  • Page 128: Checking The Cooling System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 2. Check: • Coolant level The coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level.
  • Page 129 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE 7. Drain: 4. Drain: • Coolant • Coolant (from the water pump inlet pipe and outlet (from the coolant reservoir) pipe) 5. Remove: 8. Check: • Radiator cap “1” •...
  • Page 130 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE Handling notes for coolant NOTE: Coolant is potentially harmful and should Before checking the coolant level, wait a few be handled with special care. minutes until the coolant has settled. EWA13040 WARNING 18.
  • Page 131: Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position EAS21160 ADJUSTING THE FRONT DISC BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Adjust: a. Loosen the locknut “1”. •...
  • Page 132: Checking The Brake Fluid Level

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21240 will significantly lower the boiling point of CHECKING THE BRAKE FLUID LEVEL the brake fluid and could cause vapor 1. Stand the vehicle on a level surface. lock.
  • Page 133: Checking The Front Brake Hoses

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EAS21280 2. Check: CHECKING THE FRONT BRAKE HOSES • Brake hose clamp “2” The following procedure applies to all of the Loose Connection → Tighten the clamp brake hoses and brake hose clamps.
  • Page 134: Bleeding The Hydraulic Brake System

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYS- EWA13100 WARNING Bleed the hydraulic brake system when- ever: • The system is disassembled. • A brake hose is loosened, disconnected or replaced.
  • Page 135 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Bleeding the ABS brake EWA14010 WARNING Bleed the ABS whenever: • the system is disassembled. A.
  • Page 136: Adjusting The Shift Pedal

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EWA14020 NOTE: WARNING Place the vehicle on a suitable stand so that After bleeding the ABS, check the brake the rear wheel is elevated. operation. 2. Spin the rear wheel several times and find ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 137: Lubricating The Drive Chain

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS 4. Adjust: Locknut • Steering head 16 Nm (1.6 m·kg, 12 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring e. Tighten the wheel axle nut to specification. nut “2”, and the rubber washer “3”.
  • Page 138: Checking The Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.
  • Page 139: Adjusting The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS 2. Check: • Securely support the vehicle so that there • Inner tube “1” is no danger of it falling over. Damage/scratches → Replace. • Oil seal “2” Spring preload Oil leakage →...
  • Page 140: Adjusting The Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Rebound damping (Right side front fork) • When assembling the front forks, be care- ECA5D01014 ful not to assemble them to the opposite CAUTION: position because there are two kinds of forks (for the rebound side and for the •...
  • Page 141: Checking The Tires

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS Spring preload a. Turn the adjusting screw “1” in direction “a” ECA13590 or “b”. CAUTION: Direction “a” Never go beyond the maximum or minimum Rebound damping is increased adjustment positions.
  • Page 142 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS EWA13180 EWA13190 WARNING WARNING • The tire pressure should only be checked It is dangerous to ride with a worn-out tire. and regulated when the tire temperature When the tire tread reaches the wear limit, equals the ambient air temperature.
  • Page 143: Checking The Wheels

    Never attempt to make any repairs to the given if a tire combination other than one wheel. approved by Yamaha is used on this vehi- NOTE: cle. After a tire or wheel has been changed or replaced, always balance the wheel.
  • Page 144: Lubricating The Levers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers.
  • Page 145 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to "ELECTRICAL COMPONENTS" on page 8-123. EAS21770 CHECKING THE FUSES Refer to "ELECTRICAL COMPONENTS" on page 8-123.
  • Page 146 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM 6. Remove: • Headlight assembly coupler • Headlight bulb “1” 12. Install: • Headlight assembly bolts EAS21800 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 147 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM A. FZ1-N(W) B. FZ1-S(W)/FZ1-SA ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-38 email: info@motomatrix.co.uk...
  • Page 148 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SYSTEM 3-39 email: info@motomatrix.co.uk...
  • Page 149 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE COVER...............4-7 INSTALLING THE COVER ..............4-7 FRONT WHEEL ....................4-8 REMOVING THE FRONT WHEEL ............4-11 CHECKING THE FRONT WHEEL............4-11 [D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR .................4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-13 INSTALLING THE FRONT WHEEL ............4-14...
  • Page 150 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys INSTALLING THE REAR BRAKE MASTER CYLINDER......4-47 ABS (ANTI-LOCK BRAKE SYSTEM) ............4-49 [D-5] MAINTENANCE OF THE HYDRAULIC UNIT......4-51 HYDRAULIC UNIT OPERATION TEST ..........4-52 [D-6-5] TRIAL RUN ................4-55 HANDLEBAR....................4-56 REMOVING THE HANDLEBAR ............4-57 CHECKING THE HANDLEBAR............4-57 INSTALLING THE HANDLEBAR ............4-57...
  • Page 151 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
  • Page 152 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks Passenger seat Rider seat Battery band Battery cover Battery negative lead Battery positive lead Battery Battery seat...
  • Page 153 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the headlight and meter assembly (FZ1-N(W)) Order Job/Parts to remove Q’ty Remarks Headlight side cover bolt (left and right) Headlight coupler Disconnect. Headlight sub-wire harness coupler Disconnect.
  • Page 154 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the front cowling (FZ1-S(W)/FZ1-SA) Order Job/Parts to remove Q’ty Remarks Inner panel Headlight assembly coupler Disconnect. Meter coupler Disconnect. Front cowling assembly Rear view mirror Cowling stay Meter assembly Headlight unit...
  • Page 155 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the rear fender (FZ1-N(W)) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Licence plate light lead coupler Disconnect.
  • Page 156 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the rear fender (FZ1-S(W)/FZ1-SA) Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Licence plate light lead coupler Disconnect.
  • Page 157 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Fuel tank Refer to "FUEL TANK" on page 7-1. Intake air temperature sensor lead coupler Disconnect.
  • Page 158: General Chassis

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys GENERAL CHASSIS EAS21840 REMOVING THE COVER 1. Remove: • Tail cover • Rear fender NOTE: To remove the quick fastener, push its center with a screwdriver, then pull the fastener out. EAS21850 INSTALLING THE COVER 1.
  • Page 159: Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs (FZ1-N(W)/FZ1-S(W)) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel axle pinch bolt Front wheel axle Collar Dust cover...
  • Page 160 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Removing the front wheel sensor and sensor rotor (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Front wheel sensor Front wheel axle pinch bolt Front wheel axle Collar Sensor housing...
  • Page 161 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-10 email: info@motomatrix.co.uk...
  • Page 162: Removing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL EAS21900 Refer to "CHECKING THE TIRES" on page REMOVING THE FRONT WHEEL 3-32 and "CHECKING THE WHEELS" on 1. Stand the vehicle on a level surface. page 3-34.
  • Page 163: [d-3] Maintenance Of The Front Wheel Sensor And Sensor Rotor

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL Keep them away from dirt and do not sub- ject them to shocks. • The ABS wheel sensor cannot be disas- sembled. Do not attempt to disassemble it.
  • Page 164: Adjusting The Front Wheel Static Balance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL • Brake hose holder “4” NOTE: The wheel sensor rotor of the vehicle is NOTE: inserted under pressure by a special process When installing the front wheel sensor, check and cannot be replaced as a single unit.
  • Page 165: Installing The Front Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL b. Turn the front wheel 90° so that the heavy spot is positioned as shown. c. Turn the front wheel 90° so that the “X ”...
  • Page 166 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT WHEEL 4. Lower the front wheel so that it is on the ground. 5. Tighten: • Wheel axle Wheel axle nut 72 Nm (7.2 m·kg, 52 ft·lb) •...
  • Page 167: Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel (FZ1-N(W)/FZ1-S(W)) Order Job/Parts to remove Q’ty Remarks Rear brake caliper Locknut Loosen. Adjusting bolt Loosen. Wheel axle nut Washer Rear wheel axle Adjusting block (left)
  • Page 168 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the rear wheel sensor and sensor rotor (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor protector Rear wheel sensor Rear wheel sensor lead stay Rear brake caliper Lock nut Loosen.
  • Page 169 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Removing the brake disc and rear wheel sprocket Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar (left and right) Dust cover Oil seal Bearing Rear wheel drive hub...
  • Page 170 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-19 email: info@motomatrix.co.uk...
  • Page 171: Removing The Rear Wheel

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22040 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. EWA13120 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 rear wheel is elevated.
  • Page 172: Checking And Replacing The Rear Wheel Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL EAS22120 CHECKING AND REPLACING THE REAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ WHEEL SPROCKET EAS22200 1. Check: [D-4] MAINTENANCE OF THE REAR • Rear wheel sprocket WHEEL SENSOR AND SENSOR ROTOR More than 1/4 tooth “a”...
  • Page 173 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL 3. Remove: • Rear wheel sensor protector • Rear wheel sensor “4” 2. Install: • Rear wheel Refer to "INSTALLING THE REAR WHEEL" on page 4-23. 4.
  • Page 174: Adjusting The Rear Wheel Static Balance

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL • Rear wheel sensor coupler “5” 4. Check: • Check the clearance “a” between the rear ECA14500 CAUTION: wheel sensor and sensor rotor. Out of specification → Check the existence To route the rear wheel sensor lead, refer to of foreign matters in the wheel sensor "CABLE ROUTING"...
  • Page 175 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL • Brake caliper bolts Wheel axle nut 150 Nm (15 m·kg, 108 ft·lb) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) 22 Nm (2.2 m·kg, 16 ft·lb) EWA13500 WARNING...
  • Page 176: Front Brake

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw...
  • Page 177 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Right rear view mirror (FZ1-N(W)) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm...
  • Page 178 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 179 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Union bolt Copper washer Brake hose Brake caliper...
  • Page 180 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...
  • Page 181: Introduction

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22220 INTRODUCTION EWA14100 WARNING Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. •...
  • Page 182: Replacing The Front Brake Pads

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE NOTE: Brake pad lining thickness Tighten the brake disc bolts in stages and in a (inner) crisscross pattern. 4.5 mm (0.18 in) Limit Brake disc bolt 0.5 mm (0.02 in) 18 Nm (1.8 m·kg, 13 ft·lb) Brake pad lining thickness...
  • Page 183: Removing The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE NOTE: NOTE: The arrow mark “a” on the brake pad spring Before removing the brake caliper, drain the must point in the direction of disc rotation. brake fluid from the entire brake system.
  • Page 184: Checking The Front Brake Calipers

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE c. Remove the brake caliper piston seals. EAS22410 d. Repeat the previous steps to force out the ASSEMBLING THE FRONT BRAKE CALI- right side pistons from the brake caliper. PERS EWA13620 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 185: Removing The Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE ECA14170 • When refilling, be careful that water does CAUTION: not enter the brake fluid reservoir. Water will significantly lower the boiling point of When installing the brake hose onto the the brake fluid and could cause vapor brake caliper “1”, make sure the brake pipe “a”...
  • Page 186: Checking The Front Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE EAS22520 ASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 187 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT BRAKE • When refilling, be careful that water does Brake hose union bolt not enter the brake master cylinder reser- 30 Nm (3.0 m·kg, 22 ft·lb) voir.
  • Page 188: Rear Brake

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Rear brake caliper Brake pad shim Brake pad Bleed screw Brake pad spring...
  • Page 189 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder (FZ1-N(W)/FZ1-S(W)) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 190 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake master cylinder (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-25. Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 191 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Hose joint Bushing Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 192 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal proce- dure.
  • Page 193 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad pin Brake pad Brake pad shim Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro-...
  • Page 194: Introduction

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to "CHECKING THE FRONT BRAKE preventive measures: DISCS"...
  • Page 195: Removing The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE a. Connect a clear plastic hose “1” tightly to Refer to "CHECKING THE BRAKE FLUID the bleed screw “2”. Put the other end of LEVEL" on page 3-23. the hose into an open container.
  • Page 196: Checking The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE Scratches/wear → Replace the brake cali- per assembly. • Brake caliper body “3” Cracks/damage → Replace the brake cali- per assembly. • Brake fluid delivery passages (brake caliper body) Obstruction →...
  • Page 197: Installing The Rear Brake Caliper

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE EAS22670 Refer to "REPLACING THE REAR BRAKE INSTALLING THE REAR BRAKE CALIPER PADS" on page 4-43. 1. Install: • Brake caliper “1” Brake caliper bolt (front) (temporarily) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear)
  • Page 198: Removing The Rear Brake Master Cylinder

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER...
  • Page 199 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR BRAKE ECA5D01025 CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: • Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM"...
  • Page 200 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Rider seat Refer to "GENERAL CHASSIS"...
  • Page 201 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit (FZ1-SA) Order Job/Parts to remove Q’ty Remarks Union bolt Copper washer Brake hose (hydraulic unit to rear brake caliper) Union bolt Copper washer Brake hose (rear brake master cylinder to...
  • Page 202: [d-5] Maintenance Of The Hydraulic Unit

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) EAS22770 • Brake hose “3” (to the rear brake caliper) [D-5] MAINTENANCE OF THE HYDRAULIC • Brake hose “4” (from the rear brake master UNIT cylinder) ECA15060...
  • Page 203: Hydraulic Unit Operation Test

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Installing the hydraulic unit EWA13940 Proceed in the reverse order of disassembly. WARNING Pay attention to the following items. The brake hoses to the front and rear brake 1.
  • Page 204 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) action that is generated in the brake lever Test coupler adapter and brake pedal when the ABS is activated. 90890-03149 • Hydraulic unit operation test 2: this test checks the function of the ABS after the sys- tem was disassembled, adjusted, or ser- viced.
  • Page 205 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) Refer to "GENERAL CHASSIS" on page 4- • Fuel tank Refer to "FUEL TANK" on page 7-1. 4. Check: • Battery voltage Battery voltage Higher than 12.8 V a.
  • Page 206: [d-6-5] Trial Run

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ABS (ANTI-LOCK BRAKE SYSTEM) NOTE: NOTE: After setting the main switch to “ON”, wait Be sure to continue to operate the brake lever (approximately 2 seconds) until the ABS warn- and brake pedal even after the pulsating action ing light goes off.
  • Page 207: Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Front cowling (FZ1-S(W)/FZ1-SA) Refer to "GENERAL CHASSIS" on page 4-1. Rear view mirror (FZ1-N(W)) Front brake light switch connector Disconnect.
  • Page 208: Removing The Handlebar

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR EAS22860 EAS22930 REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there...
  • Page 209 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR Grip end 26 Nm (2.6 m·kg, 19 ft·lb) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Side the handlebar grip over the left end of the handlebar.
  • Page 210 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys HANDLEBAR NOTE: • Align the projections "a" on the handlebar switch with the holes "b" in the handlebar. • There should be 1–3 mm (0.04–0.12 in) of clearance “c”...
  • Page 211: Front Fork

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Refer to "CHECKING THE TIRES" on page Front wheel 3-32 and "CHECKING THE WHEELS" on Front brake calipers page 3-34.
  • Page 212 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Damper adjusting rod Washer Spacer Fork spring Dust seal Oil seal clip Oil seal Washer Damper rod assembly bolt...
  • Page 213: Removing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK EAS22970 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE FRONT FORK LEGS a. Press down on the spacer with the fork The following procedure applies to both of the spring compressor “4”. front fork legs.
  • Page 214: Checking The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 3. Remove: • Oil seal clip “1” (with a flat-head screwdriver) ECA14180 CAUTION: Do not scratch the inner tube. EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
  • Page 215: Assembling The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 3. Check: NOTE: • Damper rod “1” The left side (for the compression) damper rod Damage/wear → Replace. assembly has the four holes of oil path, unlike Obstruction →...
  • Page 216 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 4. Install: NOTE: • Dust seal “1” Adjust the oil seal clip so that it fits into the • Oil seal clip “2” outer tube’s groove. •...
  • Page 217 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. NOTE: Be sure to bleed the front fork leg of any resid- ual air.
  • Page 218: Installing The Front Fork Legs

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK d. Press down in the spacer with the fork h. Set the cap bolt distance “c” to specifica- spring compressor “1” tion. e. Pull up the rod puller and install the rod holder “2”...
  • Page 219 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FRONT FORK 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder.
  • Page 220: Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front wheel Refer to "FRONT WHEEL" on page 4-8. Front brake calipers Refer to "FRONT BRAKE"...
  • Page 221 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower bearing Lower bearing dust seal Lower bearing inner race Bearing cover Upper bearing inner race Upper bearing Bearing outer race For installation, reverse the removal proce-...
  • Page 222: Removing The Lower Bracket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD Damage/pitting → Replace. EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 223: Installing The Steering Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys STEERING HEAD 4. Check: Steering stem nut • Upper bracket 113 Nm (11.3 m·kg, 82 ft·lb) • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1.
  • Page 224: Rear Shock Absorber Assembly

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. Side cover (left and right) Refer to "GENERAL CHASSIS"...
  • Page 225: Handling The Rear Shock Absorber

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that EWA13740 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2.
  • Page 226: Checking The Connecting Arm And Relay Arm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR SHOCK ABSORBER ASSEMBLY • Rear shock absorber 3. Tighten: Gas leaks/oil leaks → Replace the rear • Rear shock absorber assembly upper nut shock absorber assembly. Rear shock absorber assembly •...
  • Page 227: Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to "REAR WHEEL" on page 4-16. Rear brake caliper Refer to "REAR BRAKE" on page 4-37. Refer to "REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY"...
  • Page 228: Removing The Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM EAS23350 If swingarm vertical movement is not REMOVING THE SWINGARM smooth or if there is binding, check the 1. Stand the vehicle on a level surface. spacers, bearings, washers, and dust cov- EWA13120 ers.
  • Page 229: Installing The Swingarm

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SWINGARM 5. Check: • Connecting arms “1” • Relay arm “2” Damage/wear → Replace. 6. Check: 3. Install: • Bearings “3” • Rear shock absorber assembly • Rear wheel •...
  • Page 230: Chain Drive

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to "ENGINE REMOVAL" on page 5-1. Drive chain guard Drive chain For installation, reverse the removal proce- dure.
  • Page 231: Removing The Drive Chain

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE EAS23410 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 2.
  • Page 232: Checking The Drive Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHAIN DRIVE EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth →...
  • Page 233: Engine

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS ............5-11 CHECKING THE CAMSHAFTS ............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET..5-13 CHECKING THE TIMING CHAIN GUIDES ..........5-13 CHECKING THE TIMING CHAIN TENSIONER ........5-13 INSTALLING THE CAMSHAFTS ............5-15 CYLINDER HEAD..................5-18...
  • Page 234 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE CLUTCH PLATES.............5-47 CHECKING THE CLUTCH SPRINGS ..........5-48 CHECKING THE CLUTCH HOUSING ..........5-48 CHECKING THE CLUTCH BOSS ............5-48 CHECKING THE PRESSURE PLATE ..........5-48 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-49 INSTALLING THE CLUTCH..............5-49 SHIFT SHAFT .....................5-52 REMOVING THE SHIFT SHAFT ............5-53...
  • Page 235 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys INSTALLING THE TRANSMISSION.............5-88 email: info@motomatrix.co.uk...
  • Page 236 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket Plate For installation, reverse the removal proce-...
  • Page 237 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the exhaust pipe Order Job/Parts to remove Q’ty Remarks Rider and passenger seat Refer to "GENERAL CHASSIS" on page 4-1. EXUP pulley cover EXUP servo motor cover EXUP cables EXUP servo motor sensor...
  • Page 238 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks Pulley Spring Spring seat For assembly, reverse the disassembly pro- cedure. email: info@motomatrix.co.uk...
  • Page 239 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to "FUEL TANK" on page 7-1. Air filter case Refer to "GENERAL CHASSIS" on page 4-1. Throttle body assembly Refer to "THROTTLE BODIES"...
  • Page 240 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks For assembly, reverse the removal proce- dure. email: info@motomatrix.co.uk...
  • Page 241 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Right front engine mounting bolt 1 Left front engine mounting bolt Upper self-locking nut Upper engine mounting bolt Lower self-locking nut Lower engine mounting bolt Engine mounting adjust bolt...
  • Page 242: Engine Removal

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Right front engine mounting bolt 2 “1” Refer to "CYLINDER HEAD" on page 5-18. 2. Tighten: • Right front engine mounting bolt 2 Right front engine mounting bolt 2 7.
  • Page 243 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL 8. Tighten: • Lower self-locking nut “1” • Upper self-locking nut “2” Upper self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut.
  • Page 244: Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to "FUEL TANK" on page 7-1. Throttle body assembly Refer to "THROTTLE BODIES" on page 7-4. Radiator assembly Refer to "RADIATOR"...
  • Page 245 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Refer to "CRANKSHAFT POSITION SEN- Pickup rotor cover SOR" on page 5-37. Camshaft sprocket bolt Loosen. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Refer to "REMOVING THE CAMSHAFTS"...
  • Page 246: Removing The Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: • Pickup rotor cover Refer to "CRANKSHAFT POSITION SEN- SOR" on page 5-37. 2. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 247: Checking The Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 3. Measure: EAS23850 • Camshaft runout CHECKING THE CAMSHAFTS Out of specification → Replace. 1. Check: • Camshaft lobes Camshaft runout limit Blue discoloration/pitting/scratches → 0.03 mm (0.0012 in) Replace the camshaft.
  • Page 248: Checking The Timing Chain And Camshaft Sprocket

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 2. Check: • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprockets and the timing chain as a set. a. 1/4 tooth ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 249 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS NOTE: NOTE: Squeeze the timing chain tensioner clip, and When the timing chain tensioner rod “3” is then remove the timing chain tensioner spring pushed while holding the grip of the timing and timing chain tensioner rod.
  • Page 250: Installing The Camshafts

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS EAS24000 INSTALLING THE CAMSHAFTS 1. Align: • “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.
  • Page 251 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS • The camshaft cap bolts must be tightened • Timing chain tensioner bolts “2” evenly or damage to the cylinder head, Timing chain tensioner bolt camshaft caps, and camshafts will result. 10 Nm (1.0 m·kg, 7.2 ft·lb) •...
  • Page 252 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CAMSHAFTS 11. Measure: • Valve clearance Out of specification → Adjust. Refer to "ADJUSTING THE VALVE CLEARANCE" on page 3-4. 12. Install: • Pickup coil rotor cover "CRANKSHAFT POSITION SENSOR"...
  • Page 253 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Refer to Engine "ENGINE REMOVAL" on page 5-1. Refer to Intake camshaft "CAMSHAFTS"...
  • Page 254: Cylinder Head

    Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to "REMOVING THE CAMSHAFTS" on page 5-11. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove: a. Place a straightedge “1” and a thickness •...
  • Page 255 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD 2. Install: • Gasket “1” • Dowel pins 5. Install: • Exhaust camshaft • Intake camshaft Refer to "INSTALLING THE CAMSHAFTS" 3. Install: on page 5-15. •...