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Yamaha FZ1-N 2007 User Manual

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

Table of Contents

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Yamaha FZ1-N 2007 Specifications

General IconGeneral
Bore x Stroke77.0 mm x 53.6 mm
Compression Ratio11.5:1
Fuel SystemFuel Injection
IgnitionTCI
Transmission6-speed
Front Tire120/70 ZR17
Fuel Tank Capacity18 L
Seat Height815 mm
Final DriveChain
Maximum Torque106 Nm @ 8, 000 rpm
StarterElectric
Length2, 140 mm
Width770 mm
Height1, 060 mm
Wheelbase1, 460 mm
Ground Clearance135 mm
Front SuspensionTelescopic fork
Rear SuspensionSwingarm
Front BrakesDual 320mm discs
Rear Brakes245 mm disc
Rear Tire190/50 ZR17
Maximum Power150 hp @ 11, 000 rpm
FrameAluminum Deltabox
Engine Type4-stroke, liquid-cooled, DOHC, 20-valve, inline-four

Summary

GENERAL INFORMATION

IDENTIFICATION

Details about vehicle identification numbers and model labels.

FEATURES

Overview of the fuel injection system and its components.

INSTRUMENT FUNCTIONS

Explanation of the multi-function meter and tachometer displays.

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

Steps for preparing parts before removal and disassembly.

REPLACEMENT PARTS

Guidelines on using genuine Yamaha parts and recommended lubricants.

GASKETS, OIL SEALS AND O-RINGS

Instructions for replacing and lubricating these components during engine overhaul.

LOCK WASHERS/PLATES AND COTTER PINS

Guidelines for replacing lock washers and cotter pins after removal.

BEARINGS AND OIL SEALS

Proper installation and lubrication of bearings and oil seals.

CIRCLIPS

Procedures for checking and installing circlips correctly.

CHECKING THE CONNECTIONS

How to check leads, couplers, and connectors for stains, rust, and moisture.

SPECIAL TOOLS

List of specialized tools required for tune-up and assembly, with part numbers.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Covers model, dimensions, weight, and maximum load of the vehicle.

ENGINE SPECIFICATIONS

Detailed technical data for the engine, including displacement, bore, fuel, oil, and cooling system.

CHASSIS SPECIFICATIONS

Technical data for chassis components like frame, wheels, tires, suspension, and drive chain.

ELECTRICAL SPECIFICATIONS

Details on voltage, ignition system, battery, lighting, and fuses.

TIGHTENING TORQUES

Specifies tightening torques for standard fasteners and special components.

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

Information on recommended checks and adjustments for vehicle reliability.

INTRODUCTION

Explains the importance of preventive maintenance for vehicle operation.

ENGINE

Procedures for checks and adjustments related to the engine.

CHASSIS

Procedures for checks and adjustments related to the chassis.

ENGINE

ADJUSTING THE VALVE CLEARANCE

Step-by-step procedure for measuring and adjusting valve clearance on a cold engine.

SYNCHRONIZING THE THROTTLE BODIES

Procedure for synchronizing throttle bodies, including vacuum pressure checks.

ADJUSTING THE EXHAUST GAS VOLUME

Instructions for adjusting CO density level and exhaust gas volume via diagnostic mode.

ADJUSTING THE ENGINE IDLING SPEED

Steps to adjust engine idling speed using the idle adjusting screw.

ADJUSTING THE THROTTLE CABLE FREE PLAY

Procedure for checking and adjusting throttle cable free play at the grip and engine sides.

CHECKING THE SPARK PLUGS

Procedure for checking spark plug type, condition, and gap.

MEASURING THE COMPRESSION PRESSURE

Method for measuring cylinder compression pressure to check engine performance.

CHECKING THE ENGINE OIL LEVEL

How to check engine oil level and add oil if it's below the minimum mark.

CHANGING THE ENGINE OIL

Steps for draining old engine oil and replacing the oil filter cartridge.

MEASURING THE ENGINE OIL PRESSURE

Procedure for measuring engine oil pressure at specified conditions.

ADJUSTING THE CLUTCH CABLE FREE PLAY

Steps to adjust clutch cable free play using handlebar and engine side adjusters.

REPLACING THE AIR FILTER ELEMENT

Procedure for removing and installing the air filter case and element.

CHECKING THE THROTTLE BODY JOINTS

How to check throttle body joints and intake manifolds for cracks or damage.

CHECKING THE FUEL LINE

Procedure for inspecting fuel, vacuum, and breather hoses for damage or leaks.

CHECKING THE CRANKCASE BREATHER HOSE

How to check the crankcase breather hose for cracks or loose connections.

CHECKING THE EXHAUST SYSTEM

Inspecting exhaust pipes and mufflers for cracks or damage, and checking gasket seals.

ADJUSTING THE EXUP CABLES

Procedure for adjusting EXUP cable free play.

CHECKING THE COOLING SYSTEM

Inspecting radiator, hoses, oil cooler, and water pump for damage or leaks.

CHANGING THE COOLANT

Steps for draining, filling, and checking the cooling system and radiator cap.

CHASSIS

ADJUSTING THE FRONT DISC BRAKE

How to adjust the front brake lever position and check for brake drag.

ADJUSTING THE REAR DISC BRAKE

Procedure for adjusting the rear brake pedal position and checking the brake light switch.

CHECKING THE BRAKE FLUID LEVEL

How to check brake fluid level and add fluid if necessary, with safety precautions.

CHECKING THE FRONT BRAKE PADS

Procedure to check front brake pad wear indicators and when to replace them.

CHECKING THE REAR BRAKE PADS

Procedure to check rear brake pad wear indicators and when to replace them.

CHECKING THE FRONT BRAKE HOSES

Inspecting front brake hoses and clamps for cracks, damage, or leaks.

CHECKING THE REAR BRAKE HOSE

Inspecting rear brake hoses and clamps for cracks, damage, or leaks.

ADJUSTING THE REAR BRAKE LIGHT SWITCH

How to adjust the rear brake light switch timing.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

Step-by-step guide for bleeding hydraulic brake systems, including ABS.

Bleeding the ABS brake

Specific procedures for bleeding the ABS hydraulic system.

ADJUSTING THE SHIFT PEDAL

How to adjust the shift pedal position for optimal engagement.

ADJUSTING THE DRIVE CHAIN SLACK

Procedure for checking and adjusting drive chain slack to prevent damage.

CHECKING AND ADJUSTING THE STEERING HEAD

How to check for steering head looseness or binding and adjust accordingly.

ADJUSTING THE FRONT FORK LEGS

Procedure for adjusting spring preload on front fork legs.

Rebound damping (Right side front fork)

Adjusting rebound damping for the right front fork leg.

Compression damping (Left side front fork)

Adjusting compression damping for the left front fork leg.

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

Adjusting spring preload and damping on the rear shock absorber.

Spring preload

Procedure for adjusting spring preload using special tools.

Rebound damping

Adjusting rebound damping on the front fork legs.

CHECKING THE TIRES

How to check tire pressure, tread depth, and wear indicators.

CHECKING THE WHEELS

Inspecting wheels for damage, out-of-round conditions, and proper tire installation.

CHECKING AND LUBRICATING THE CABLES

Checking outer cable integrity and lubricating inner cables.

LUBRICATING THE LEVERS

Lubricating pivoting points and moving parts of levers.

LUBRICATING THE PEDAL

Lubricating pivoting points and moving parts of the pedal.

LUBRICATING THE SIDESTAND

Lubricating pivoting points and moving parts of the sidestand.

LUBRICATING THE CENTERSTAND (FZ1-S(W))/FZ1-SA)

Lubricating pivoting points and moving parts of the centerstand.

LUBRICATING THE REAR SUSPENSION

Lubricating pivoting points and moving parts of the rear suspension.

ELECTRICAL SYSTEM

IGNITION SYSTEM

Circuit diagrams and troubleshooting for the ignition system.

ELECTRIC STARTING SYSTEM

Circuit diagrams and troubleshooting for the electric starting system.

CHARGING SYSTEM

Circuit diagrams and troubleshooting for the charging system.

LIGHTING SYSTEM

Circuit diagrams and troubleshooting for the lighting system.

SIGNALING SYSTEM

Circuit diagrams and troubleshooting for the signaling system.

COOLING SYSTEM

Circuit diagrams and troubleshooting for the cooling system.

FUEL INJECTION SYSTEM

Circuit diagrams, troubleshooting, ECU self-diagnostics, and fault codes.

FUEL PUMP SYSTEM

Circuit diagrams and troubleshooting for the fuel pump system.

IMMOBILIZER SYSTEM

Information on the immobilizer system, part replacement, and key registration.

ABS (ANTI-LOCK BRAKE SYSTEM)

Detailed information on ABS components, circuit diagrams, maintenance, and troubleshooting.

ELECTRICAL COMPONENTS

Detailed checks for various electrical components like switches, bulbs, fuses, relays, etc.

TROUBLESHOOTING

GENERAL INFORMATION

General guide to basic troubleshooting procedures.

STARTING FAILURES

Common causes and checks for engine starting failures.

INCORRECT ENGINE IDLING SPEED

Potential causes and adjustments for incorrect engine idling speed.

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Troubleshooting for performance issues at medium and high speeds.

FAULTY GEAR SHIFTING

Common issues and checks related to faulty gear shifting.

SHIFT PEDAL DOES NOT MOVE

Troubleshooting steps for a non-moving shift pedal.

JUMPS OUT OF GEAR

Potential causes for the transmission jumping out of gear.

FAULTY CLUTCH

Troubleshooting for clutch slips and drags.

OVERHEATING

Potential causes and checks for engine overheating.

OVER COOLING

Potential causes and checks for engine over cooling.

POOR BRAKING PERFORMANCE

Troubleshooting steps for poor brake performance.

FAULTY FRONT FORK LEGS

Diagnosis and repair for leaking oil or malfunction in front fork legs.

UNSTABLE HANDLING

Causes and checks for unstable vehicle handling.

FAULTY LIGHTING OR SIGNALING SYSTEM

Troubleshooting for issues with headlights, indicators, and other lights.

TROUBLESHOOTING AT THE ABS WARNING LIGHT

Diagnosing ABS issues based on the warning light status.

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