Yamaha FZ1-N 2007 Manuals

Manuals and User Guides for Yamaha FZ1-N 2007. We have 1 Yamaha FZ1-N 2007 manual available for free PDF download: Service Manual

Yamaha FZ1-N 2007 Service Manual

Yamaha FZ1-N 2007 Service Manual (522 pages)

Brand: Yamaha | Category: Motorcycle | Size: 35.61 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- 1 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
    34
    
    Preparation for Removal and Disassembly
    34
    
    Replacement Parts
    34
    
    Gaskets, Oil Seals and O-Rings
    34
    
    Lock Washers/Plates and Cotter Pins
    34
    
    Bearings and Oil Seals
    35
    
    Circlips
    35
  - Checking the Connections
    36
  - Special Tools
    41
Specifications

43
- General Specifications
  44
- Engine Specifications
  45
- Chassis Specifications
  51
- Electrical Specifications
  53
- Tightening Torques
  55
- Lubrication Points and Lubricant Types
  63
  - Engine
    63
  - Chassis
    64
- Lubrication System Chart and Diagrams
  66
  - Engine Oil Lubrication Chart
    66
  - Lubrication Diagrams
    68
- Cooling System Diagrams
  78
- Cable Routing
  82
Periodic Checks and Adjustments

107
- Periodic Maintenance
  
  110
  - Introduction
    110
- Engine
  
  113
  - Adjusting the Valve Clearance
    113
  - Synchronizing the Throttle Bodies
    115
  - Adjusting the Exhaust Gas Volume
    117
  - Adjusting the Engine Idling Speed
    118
  - Adjusting the Throttle Cable Free Play
    118
  - Checking the Spark Plugs
    119
  - Measuring the Compression Pressure
    119
  - Checking the Engine Oil Level
    120
  - Changing the Engine Oil
    121
  - Measuring the Engine Oil Pressure
    122
  - Adjusting the Clutch Cable Free Play
    123
  - Replacing the Air Filter Element
    124
  - Checking the Throttle Body Joints
    125
  - Checking the Fuel Line
    125
  - Checking the Crankcase Breather Hose
    125
  - Checking the Exhaust System
    126
  - Adjusting the Exup Cables
    126
  - Checking the Exup Servo Motor
    127
  - Checking the Coolant Level
    127
  - Checking the Cooling System
    128
  - Changing the Coolant
    128
- Chassis
  
  131
  - Adjusting the Front Disc Brake
    131
    
    Adjusting the Rear Disc Brake
    131
    
    Checking the Brake Fluid Level
    132
    
    Checking the Front Brake Pads
    132
    
    Checking the Rear Brake Pads
    132
    
    Checking the Front Brake Hoses
    133
    
    Checking the Rear Brake Hose
    133
    
    Adjusting the Rear Brake Light Switch
    133
    
    Bleeding the Hydraulic Brake System
    134
    
    Adjusting the Shift Pedal
    136
    
    Adjusting the Drive Chain Slack
    136
    
    Lubricating the Drive Chain
    137
    
    Checking and Adjusting the Steering Head
    137
    
    Checking the Front Fork
    138
    
    Adjusting the Front Fork Legs
    139
    
    Adjusting the Rear Shock Absorber Assembly
    140
    
    Checking the Tires
    141
    
    Checking the Wheels
    143
    
    Checking and Lubricating the Cables
    143
    
    Lubricating the Levers
    144
    
    Lubricating the Pedal
    144
    
    Lubricating the Sidestand
    144
Chassis

149
- General Chassis
  
  158
  - Removing the Cover
    158
  - Installing the Cover
    158
- Front Wheel
  
  159
- Rear Wheel
  
  167
- Front Brake
  
  176
- Rear Brake
  
  188
  - Introduction
    194
  - Checking the Rear Brake Disc
    194
  - Replacing the Rear Brake Pads
    194
  - Removing the Rear Brake Caliper
    195
  - Disassembling the Rear Brake Caliper
    195
  - Checking the Rear Brake Caliper
    196
  - Assembling the Rear Brake Caliper
    196
  - Installing the Rear Brake Caliper
    197
  - Removing the Rear Brake Master Cylinder
    198
  - Checking the Rear Brake Master Cylinder
    198
  - Assembling the Rear Brake Master Cylinder
    198
  - Installing the Rear Brake Master Cylinder
    198
  - [D-5] Maintenance of the Hydraulic Unit
    202
  - Hydraulic Unit Operation Test
    203
  - [D-6-5] Trial Run
    206
- Handlebar
  
  207
  - Removing the Handlebar
    208
  - Checking the Handlebar
    208
  - Installing the Handlebar
    208
- Front Fork
  
  211
  - Removing the Front Fork Legs
    213
  - Disassembling the Front Fork Legs
    213
  - Checking the Front Fork Legs
    214
  - Assembling the Front Fork Legs
    215
  - Installing the Front Fork Legs
    218
- Steering Head
  
  220
  - Removing the Lower Bracket
    222
  - Checking the Steering Head
    222
  - Installing the Steering Head
    223
- Rear Shock Absorber Assembly
  
  224
- Swingarm
  
  227
  - Removing the Swingarm
    228
  - Checking the Swingarm
    228
  - Installing the Swingarm
    229
- Chain Drive
  
  230
  - Removing the Drive Chain
    231
  - Checking the Drive Chain
    231
  - Checking the Drive Sprocket
    232
  - Checking the Rear Wheel Sprocket
    232
  - Checking the Rear Wheel Drive Hub
    232
  - Installing the Drive Chain
    232
Engine

233
- Engine Removal
  
  242
  - Installing the Engine
    242
- Camshafts
  
  244
  - Removing the Camshafts
    246
  - Checking the Camshafts
    247
  - Checking the Timing Chain and Camshaft Sprocket
    248
  - Checking the Timing Chain Guides
    248
  - Checking the Timing Chain Tensioner
    248
  - Installing the Camshafts
    250
- Cylinder Head
  
  254
  - Removing the Cylinder Head
    254
  - Checking the Cylinder Head
    254
  - Installing the Cylinder Head
    254
- Valves and Valve Springs
  
  257
  - Removing the Valves
    258
  - Checking the Valves and Valve Guides
    259
  - Checking the Valve Seats
    260
  - Checking the Valve Springs
    262
  - Checking the Valve Lifters
    263
  - Installing the Valves
    263
- Generator
  
  265
  - Removing the Generator
    267
  - Installing the Generator
    267
- Starter Clutch
  
  269
  - Removing the Starter Clutch
    270
  - Checking the Damper
    270
  - Checking the Starter Clutch
    270
  - Installing the Starter Clutch
    271
- Crankshaft Position Sensor
  
  272
  - Removing the Crankshaft Position Sensor
    273
  - Installing the Crankshaft Position Sensor
    273
- Electric Starter
  
  274
  - Checking the Starter Motor
    276
  - Assembling the Starter Motor
    277
  - Installing the Starter Motor
    277
- Clutch
  
  278
  - Removing the Clutch
    281
  - Checking the Friction Plates
    282
  - Checking the Clutch Plates
    282
  - Checking the Clutch Springs
    283
  - Checking the Clutch Housing
    283
  - Checking the Clutch Boss
    283
  - Checking the Pressure Plate
    283
  - Checking the Pull Lever Shaft and Pull Rod
    284
  - Installing the Clutch
    284
- Shift Shaft
  
  287
  - Removing the Shift Shaft
    288
  - Checking the Shift Shaft
    288
  - Checking the Stopper Lever
    288
  - Installing the Shift Shaft
    288
- Oil Pump
  
  290
  - Removing the Oil Pan
    293
  - Checking the Sprocket and Chain
    293
  - Checking the Oil Pump
    293
  - Checking the Relief Valve
    294
  - Checking the Oil Delivery Pipes
    294
  - Checking the Oil Strainer
    294
  - Checking the Oil Nozzles
    294
  - Assembling the Oil Pump
    294
  - Installing the Oil/Water Pump Assembly
    295
  - Installing the Oil Pan
    296
- Crankcase
  
  297
  - Disassembling the Crankcase
    299
  - Checking the Crankcase
    299
  - Checking the Bearing and Oil Seals
    299
  - Assembling the Crankcase
    299
- Crankshaft
  
  301
  - Removing the Connecting Rods and Pistons
    303
  - Removing the Crankshaft Assembly
    303
  - Checking the Cylinder and Piston
    304
  - Checking the Piston Rings
    304
  - Checking the Piston Pins
    305
  - Checking the Big End Bearings
    306
  - Installing the Connecting Rod and Piston
    309
  - Checking the Crankshaft
    312
  - Checking the Crankshaft Drive Sprocket
    312
  - Checking the Crankshaft Journal Bearings
    312
  - Installing the Crankshaft
    314
- Transmission
  
  316
  - Removing the Transmission
    321
  - Checking the Shift Forks
    321
  - Checking the Shift Drum Assembly
    322
  - Checking the Transmission
    322
Cooling System

325
- Radiator
  
  327
  - Checking the Radiator
    327
  - Installing the Radiator
    327
- Oil Cooler
  
  328
  - Checking the Oil Cooler
    329
  - Installing the Oil Cooler
    329
- Thermostat
  
  330
- Water Pump
  
  334
  - Disassembling the Water Pump
    335
  - Checking the Water Pump
    335
  - Assembling the Water Pump
    335
  - Fuel System
    337
    
    Fuel Tank
    339
    
    Adjusting the Throttle Position Sensor
    345
    
    Adjusting Sub-Throttle Position Sensor
    345
  - Electrical System
    353
  - General Information
    353
    
    Ignition System
    356
    
    Electric Starting System
    360
    
    Charging System
    366
    
    Lighting System
    370
    
    Signaling System
    376
    
    Fuel Injection System
    386
    
    Fuel Pump System
    430
    
    Immobilizer System
    434
  - Specifications
    502
  - Troubleshooting
    505
    
    Wiring Diagram
    512

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