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Yamaha FZ1-NV Manuals
Manuals and User Guides for Yamaha FZ1-NV. We have
1
Yamaha FZ1-NV manual available for free PDF download: Service Manual
Yamaha FZ1-NV Service Manual (451 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 18.29 MB
Table of Contents
Table of Contents
7
How to Use this Manual
4
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Fi System
12
Instrument Functions
13
Important Information
17
Preparation for Removal and Disassembly
17
Replacement Parts
17
Gaskets, Oil Seals and O-Rings
17
Lock Washers/Plates and Cotter Pins
17
Bearings and Oil Seals
18
Circlips
18
Checking the Connections
19
Special Tools
24
Specifications
27
General Specifications
28
Engine Specifications
29
Chassis Specifications
35
Electrical Specifications
37
Tightening Torques
39
General Tightening Torque Specifications
39
Engine Tightening Torques
40
Chassis Tightening Torques
44
Lubrication Points and Lubricant Types
47
Engine
47
Chassis
49
Lubrication System Chart and Diagrams
50
Engine Oil Lubrication Chart
50
Lubrication Diagrams
52
Cooling System Diagrams
62
Cable Routing
66
Periodic Checks and Adjustments
83
Periodic Maintenance
86
Introduction
86
Engine
89
Adjusting the Valve Clearance
89
Synchronizing the Throttle Bodies
91
Adjusting the Exhaust Gas Volume
93
Adjusting the Engine Idling Speed
94
Adjusting the Throttle Cable Free Play
94
Checking the Spark Plugs
95
Measuring the Compression Pressure
95
Checking the Engine Oil Level
96
Changing the Engine Oil
97
Measuring the Engine Oil Pressure
98
Adjusting the Clutch Cable Free Play
99
Replacing the Air Filter Element
100
Checking the Throttle Body Joints
101
Checking the Fuel Line
101
Checking the Crankcase Breather Hose
101
Checking the Exhaust System
102
Adjusting the Exup Cables
102
Checking the Exup Servo Motor
103
Checking the Coolant Level
103
Checking the Cooling System
104
Changing the Coolant
104
Chassis
107
Adjusting the Front Disc Brake
107
Adjusting the Rear Disc Brake
107
Checking the Brake Fluid Level
108
Checking the Front Brake Pads
108
Checking the Rear Brake Pads
108
Checking the Front Brake Hoses
109
Checking the Rear Brake Hose
109
Adjusting the Rear Brake Light Switch
109
Bleeding the Hydraulic Brake System
110
Adjusting the Shift Pedal
111
Adjusting the Drive Chain Slack
111
Lubricating the Drive Chain
112
Checking and Adjusting the Steering Head
112
Checking the Front Fork
113
Adjusting the Front Fork Legs
114
Adjusting the Rear Shock Absorber Assembly
116
Checking the Tires
117
Checking the Wheels
119
Checking and Lubricating the Cables
119
Lubricating the Levers
119
Lubricating the Pedal
119
Lubricating the Sidestand
119
Chassis
123
General Chassis
132
Removing the Cover
132
Installing the Cover
132
Front Wheel
135
Removing the Front Wheel
135
Checking the Front Wheel
135
Adjusting the Front Wheel Static Balance
136
Installing the Front Wheel (Disc)
137
Rear Wheel
142
Removing the Rear Wheel (Disc)
142
Checking the Rear Wheel
142
Checking the Rear Wheel Drive Hub
142
Checking and Replacing the Rear Wheel Sprocket
143
Adjusting the Rear Wheel Static Balance
143
Installing the Rear Wheel (Disc)
143
Front Brake
145
Introduction
150
Checking the Front Brake Discs
150
Replacing the Front Brake Pads
151
Removing the Front Brake Calipers
152
Disassembling the Front Brake Calipers
152
Checking the Front Brake Calipers
153
Assembling the Front Brake Calipers
153
Installing the Front Brake Calipers
153
Removing the Front Brake Master Cylinder
154
Checking the Front Brake Master Cylinder
155
Assembling the Front Brake Master Cylinder
155
Installing the Front Brake Master Cylinder
155
Rear Brake
157
Introduction
162
Checking the Rear Brake Disc
162
Replacing the Rear Brake Pads
162
Removing the Rear Brake Caliper
163
Disassembling the Rear Brake Caliper
163
Checking the Rear Brake Caliper
164
Assembling the Rear Brake Caliper
164
Installing the Rear Brake Caliper
165
Removing the Rear Brake Master Cylinder
166
Checking the Rear Brake Master Cylinder
166
Assembling the Rear Brake Master Cylinder
166
Installing the Rear Brake Master Cylinder
166
Handlebar
168
Removing the Handlebar
170
Checking the Handlebar
170
Installing the Handlebar
170
Front Fork
173
Removing the Front Fork Legs
175
Disassembling the Front Fork Legs
175
Checking the Front Fork Legs
176
Assembling the Front Fork Legs
177
Installing the Front Fork Legs
181
Steering Head
182
Removing the Lower Bracket
184
Checking the Steering Head
184
Installing the Steering Head
185
Rear Shock Absorber Assembly
186
Handling the Rear Shock Absorber
188
Disposing of a Rear Shock Absorber
188
Removing the Rear Shock Absorber Assembly
188
Checking the Rear Shock Absorber Assembly
188
Checking the Connecting Arm and Relay Arm
189
Installing the Rear Shock Absorber Assembly
189
Swingarm
190
Removing the Swingarm
192
Checking the Swingarm
192
Installing the Swingarm
193
Chain Drive
194
Removing the Drive Chain
195
Checking the Drive Chain
195
Checking the Drive Sprocket
196
Checking the Rear Wheel Sprocket
196
Checking the Rear Wheel Drive Hub
196
Installing the Drive Chain
196
Engine
197
Engine Removal
200
Installing the Engine
206
Camshafts
208
Removing the Camshafts
210
Checking the Camshafts
211
Checking the Timing Chain and Camshaft Sprocket
212
Checking the Timing Chain Guides
212
Checking the Timing Chain Tensioner
212
Installing the Camshafts
214
Cylinder Head
217
Removing the Cylinder Head
218
Checking the Cylinder Head
218
Installing the Cylinder Head
218
Valves and Valve Springs
221
Removing the Valves
222
Checking the Valves and Valve Guides
223
Checking the Valve Seats
224
Checking the Valve Springs
226
Checking the Valve Lifters
227
Installing the Valves
227
Generator
229
Removing the Generator
231
Installing the Generator
231
Starter Clutch
233
Removing the Starter Clutch
234
Checking the Damper
234
Checking the Starter Clutch
234
Installing the Starter Clutch
235
Crankshaft Position Sensor
236
Removing the Crankshaft Position Sensor
237
Installing the Crankshaft Position Sensor
237
Electric Starter
238
Checking the Starter Motor
240
Assembling the Starter Motor
241
Installing the Starter Motor
241
Clutch
242
Removing the Clutch
246
Checking the Friction Plates
247
Checking the Clutch Plates
247
Checking the Clutch Springs
248
Checking the Clutch Housing
248
Checking the Clutch Boss
248
Checking the Pressure Plate
248
Checking the Pull Lever Shaft and Pull Rod
248
Installing the Clutch
249
Shift Shaft
252
Removing the Shift Shaft
254
Checking the Shift Shaft
254
Checking the Stopper Lever
254
Installing the Shift Shaft
254
Oil Pump
256
Removing the Oil Pan
260
Checking the Sprocket and Chain
260
Checking the Oil Pump
260
Checking the Relief Valve
261
Checking the Oil Delivery Pipes
261
Checking the Oil Strainer
261
Checking the Oil Nozzles
261
Assembling the Oil Pump
261
Installing the Oil/Water Pump Assembly
262
Installing the Oil Pan
263
Crankcase
264
Disassembling the Crankcase
266
Checking the Crankcase
266
Checking the Bearing and Oil Seals
266
Assembling the Crankcase
266
Crankshaft
268
Removing the Connecting Rods and Pistons
270
Removing the Crankshaft Assembly
270
Checking the Cylinder and Piston
271
Checking the Piston Rings
271
Checking the Piston Pins
272
Checking the Big End Bearings
273
Installing the Connecting Rod and Piston
276
Checking the Crankshaft
279
Checking the Crankshaft Drive Sprocket
279
Checking the Crankshaft Journal Bearings
279
Installing the Crankshaft
281
Transmission
283
Removing the Transmission
288
Checking the Shift Forks
288
Checking the Shift Drum Assembly
289
Oil Cooler
297
Water Pump
302
Fuel Tank
308
Throttle Bodies
310
Air Induction System
319
General Information
322
Ignition System
325
Electric Starting System
329
Charging System
335
Lighting System
339
Signaling System
345
Cooling System
351
Fuel Injection System
355
Self-Diagnostic Function Table
362
Fuel Pump System
399
Immobilizer System
403
Electrical Components
413
Electrical System
439
Fuel System
439
Troubleshooting
440
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