Yamaha FZ1 Repair Manual 2001-2005

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Item # M399  ISBN: 0892879181




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This repair and service manual covers Yamaha FZ1 2001-2005 and FZS1000 (U.K. 2001-2003).

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE | GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage

CHAPTER TWO | TROUBLESHOOTING
Operating requirements | Starting the engine | Engine will not start | Engine performance | Engine noises | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Fuel system | Electrical testing | Lighting system | Charging system | Ignition system | Starting system | Front suspension and steering | Brake system

CHAPTER THREE | LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type | Tune-up procedures | Air filter | Spark plugs | Idle speed adjustment | Carburetor synchronization | Engine compression test | Ignition timing inspection | Valve clearance | Fuel hose inspection | Control cable lubrication (non-nylon lined cables only) | Throttle cables | Starting enrichment (choke) cable | Clutch cable adjustment | Gearshift pedal adjustment | EXUP system | Engine oil and filter | Cooling system | Emission control systems | Battery | Tires and wheels | Front fork oil change | Drive chain | Brake system | Headlight aim inspection | Sidestand and ignition cut-off switch inspection | Steering bearing inspection | Front suspension inspection | Rear suspension inspection | Fastener inspection | Wheel bearing inspection | Lights and horn inspection

CHAPTER FOUR | ENGINE TOP END
Engine service notes | Cylinder head cover | Camshafts | Camshaft chain tensioner | Camshaft chain, timing sprocket and chain guide | Cylinder head | Valve lifters and shims | Valves and valve components

CHAPTER FIVE | ENGINE LOWER END
Servicing engine in frame | Engine service notes | Engine | Oil pan, oil strainer and pressure relief valve | Oil pump/water pump | Starter clutch | Crankcase | Piston and connecting rod assembly | Crankshaft | Break-in procedure

CHAPTER SIX | CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cover | Clutch | Starter clutch and starter reduction gears | External gearshift mechanism | Clutch cable replacement

CHAPTER SEVEN | TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM
Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection

CHAPTER EIGHT | FUEL, CARBURETOR, EMISSION CONTROL AND EXHAUST SYSTEMS
Fuel tank | Air filter housing | Carburetor | Pilot screw | Carburetor separation | Carburetor fuel level | Carburetor jetting | Carburetor synchronization | Throttle cable replacement | Starter (choke) cable replacement | Fuel pump assembly | Fuel filter replacement | Crankcase breather system | Evaporative emission control system (California models only) | Air induction system (AIS) | Exhaust system | EXUP system

CHAPTER NINE | ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Battery | Charging system | Alternator rotor and stator | Ignition system | Starting circuit cutoff system | Starter | Starter relay | Lighting system | Combination meter | Speed sensor | Cooling system switches and sensors | Turn signal relay | Fuel level gauge | Fuel pump relay | Throttle position sensor | Oil level sensor | Horn | Switches | Fuses | Wiring diagrams

CHAPTER TEN | COOLING SYSTEM
Cooling system inspection | Hoses and hose clamps | Coolant reservoir | Radiator | Cooling fan | Thermostat | Water pump | Oil cooler and crankcase inlet fitting | One-way valve

CHAPTER ELEVEN | WHEELS, TIRES AND DRIVE CHAIN
Front wheel | Rear wheel | Drive hub assembly and rear sprocket | Front wheel hub | Rear wheel hub | Wheel runout and balance | Tire changing | Tire repairs | Drive chain

CHAPTER TWELVE | FRONT SUSPENSION AND STEERING
Handlebar | Handlebar left hand grip replacement | Front fork | Front fork oil refilling | Steering head and stem | Steering head bearing race replacement | Steering stem bearing race replacement

CHAPTER THIRTEEN | REAR SUSPENSION
Shock absorber | Swing arm | Shock linkage | Bearing replacement

CHAPTER FOURTEEN | BRAKES
Brake fluid selection | Preventing brake fluid damage | Brake service | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Brake hose replacement | Brake disc | Rear brake pedal | Brake bleeding | Bleeding the system | Brake fluid draining | Flushing the brake system

CHAPTER FIFTEEN | BODY AND FRAME
Seat | Frame side covers | Windshield | Front cowl panels | Mirrors | Front cowl (fairing) | Headlight module | Front fender | Rear cowl | Sidestand | Centerstand

COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and illustrations guide you through every job, from basic maintenance and troubleshooting, to complete teardown and rebuild.

From the Publisher:

This detailed, comprehensive manual covers the Yamaha FZ1 2001-2005 and FZS1000 (UK) 2001-2003.

The expert text gives complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide you through every step. The book includes all you will need to know to keep your Yamaha FZ1 running right. Throughout this book where differences occur among the models, they are clearly identified.

A shop manual is a reference. You want to be able to find information fast. As in all Clymer books, this one is designed with you in mind. All chapters are thumb tabbed. Important items are extensively indexed. All procedures, tables, photos, etc., in this manual are for the reader who may be working on the bike for the first time. All the most frequently used specifications and capacities are summarized in the Quick Reference Data pages at the front of the book.

Keep the book handy in your tool box. It will help you better understand how your bike runs, lower repair costs and generally improve your satisfaction with the motorcycle.

Yamaha FZ1 Repair Manual 2001-2005