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Yamaha FZ1
Owner's Manual Basics

The information below is "gleamed" out of the FZ1 Owner's Manual as the more important mechanical/maintenance information for the intermediate to experienced rider. It is assumed very few people would buy this level of performance without being an experienced rider and a basic wrench. 

Vital Values

Spark plug CR9E (NGK), gap is 0.7-0.8 mm or 0.028-0.031 inches, torque is 12.5 Nm or 9.0 ft-lb.

Regular unleaded gasoline,  pump octane number of (R=M)/2, of 86 or higher, or a research octane number of 91 or higher. Fuel capacity 5.5 US gal.  Reserve 1.1 US gal

Tach Indicator for Circuit Self-Diagnosis: 3000=throttle position sensor, 4000=speed sensor, 7000=EXUP system, 9000=overturn switch.

Capacity is 3.17 US quarts Oil  (3L) with oil filter replacement. Tightening torque for the oil filer cartridge is 12 ft-lb (17 Nm).

Coolant quantity is 2.54 US quarts (2.4 L). Reservoir capacity is 0.32 US quarts (0.3 L). Coolant drain bolt toque 5.1 ft-lb (7 Nm). Use a high quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Do not use DEX-COOL by Texaco.  The recommended antifreeze to water mixture is 1 to 1.

Instrument and Control Functions

To Lock the Steering
....Turn the bars all the way left. Push key inward from the Off position and while holding the key in turn to the Lock position. To unlock, push the key in and turn it to the Off position.

Odometer/Tripmeter
….When set to ODO, total mileage is indicated.
….There are two tripmeters, Trip 1 and Trip 2.
….To set a mode, push the Select button to toggle between the three meters.
….To reset, select tripmeter 1 or 2 and press Reset for one second.

To set the Clock
….Push the Select and Reset buttons together for 2 seconds.
….When hour digits flash, push Reset to set hours.
….Push Select to change to minutes.
….When minutes flash, push Reset to set minutes.
….Push Select to restart clock.

Self-Diagnosis Devices
….The FZ1 tachometer will indicate defective circuits by toggling rpm’s, i.e.; 0 rpm/3sec > circuit rpm/2.5sec > engine rpm/3 sec.
….If the tach shows error toggling/code, note the circuit rpm and identify for evaluation /repair. To avoid possible engine damage, check promptly after an error message.
….Circuit rpm chart: 3000=throttle position sensor, 4000=speed sensor, 7000=EXUP system, 9000=overturn switch.
….If the fuel level warning light circuit is defective, the warning light will flash 8 times, go off for three seconds, and repeat the cycle until repair.

Fuel Gauge
….As the needle reaches E for empty there is about 1.1 US gallons left in the tank (4 liters).

Turn Signals
….The turn signals ARE NOT self-canceling.
….To cancel the signals, push the switch in after it had returned to the center position.

Brake Lever
….The brake lever is equipped with a position adjusting dial, which will allow for adjustment of the distant between the lever and the grip, by holding the brake lever away from the grip and turning the dial.

Fuel Tank
….Capacity is 5.5 US gallons.
….Reserve is 1.1 US gallons (this is included in the 5.5 gal total capacity).
….Fill the tank to the bottom of the tank filler tube. Do not overfill or spill gas.

Recommended Fuel
….The FZ1 engine was designed to use regular unleaded gasoline, with a pump octane number of (R=M)/2, of 86 or higher, or a research octane number of 91 or higher.
….If knocking/pinging occurs, try a different brand of gas or premium of 91-93 octane.
….Yamaha indicates gasohol containing ethanol can be used if the ethanol content does not exceed 10%. They do not recommend gasohol utilizing methanol, as it can damage the fuel system, seals, and cause performance issues.

Seat Removal/Helmet Holder
….Insert the key in the seat lock and turn. Pop the seat off by lifting on the rear.

Front Fork Adjustment
….The fork is quipped with spring preload adjusting bolts, rebound damping force adjustment screws and compression damping force adjusting screws.

Fork Spring Preload
….To increase preload and harden/stiffen the front suspension, turn adjusting bolt on the top of each fork leg clockwise.
….To decrease preload and soften the suspension, turn the bolt counterclockwise.
….When adjusting, align the grooves on the adjusting mechanism with the top of the front fork cap bolt.
…Settings: 6=softest, 2+=standard, 1=hardest

Fork Rebound Damping Force

….To increase rebound damping and harden/stiffen damping, turn the adjusting screw on each fork leg clockwise.
….To decease or soften damping, turn the adjusting screw counterclockwise.
….Setting: 17clicks=softest, 7=standard, 1=hardest.

Compression Damping Force
….To increase compression damping force and harden/stiffen the compression damping, turn the adjusting screw on the bottom, rear of each fork leg clockwise.
….To decrease compression damping and soften compression, turn the adjusting screw counterclockwise.
….Settings: 12clicks=softest, 6=standard, 1=hardest.

Adjustment Fastener Cautions
….Do not force the adjusting mechanisms beyond the max or min.
….Individual bikes by have a different number of clicks.

Shock Adustments
….The nitrogen filled monoshock has a spring preload adjusting ring, a rebound damping force adjusting knob and a compression damping force adjusting screw. The shock is nitrogen filled at the factory and the nitrogen has to be checked and replenished by a dealer with capabilities to service nitrogen shocks.

Shock Spring Preload
….There is a spring preload wrench in the tool kit under the seat used to turn the preload ring at the top of the shock, which is in front of the back tire.
….To increase/harden the rear suspension turn the preload ring counterclockwise.
….To decrease/soften preload, turn clockwise.
….Settings: 1=softest, 6=standard, 11=hardest

Shock Rebound Damping Force
….To increase rebound damping force or harden the rebound turn the adjusting knob at the bottom of the shock counterclockwise.
….To decrease/soften rebound damping, turn the knob clockwise.
….Settings: 20clicks clockwise=soft, 10clicks=standard, 3clicks=hard.

Shock Compression Damping Force
….To increase/harden the compression damping, turn the adjusting screw at the top of the shock clockwise.
….To decrease/soften compression damping, turn the adjusting screw counterclockwise.
….Setting: 1click clockwise=softest, 7 clicks=standard, 12 clicks=hardest.

The EXUP System in the Exhaust
….The FZ1 like the R1, is equipped with Yamaha’s EXUP (Exhaust Ultimate Power Valve) System.
….The EXUP boosts engine power by means of a valve that regulated the diameter of the exhaust pipe.
….TheEXUP system valve is constantly adjusting in accordance with the engine speed by a computer-controlled servomoter.
….The EXUP system was set and extensively tested at the Yamaha factory, thus chaning these settings without technical knowledge can result in poor performance or even damage to the engine.
….If the bikes self-diagnosis system on the tach cycles on 7000rpm to indicate problems with the EXUP system, have a dealer check it.

Spark Plugs
….Specified spark plug is CR9E (NGK) or U27ESR-N (DENSO)
….Plug gap is 0.7-0.8 mm or 0.028-0.031 inches
….Plug torque is 12.5 Nm or 9.0 ft-lb.
….Without a torque wrench, tighten ¼ to ½ turn past finger tight.

Engine Oil
….Place cycle on centerstand.
….It is generally best to check the oil after it sits several minutes after being hot.
….Looking at the oil level in the sight window on the right side of the bike, the oil level should be between the minimum and maximum level marks.

To Change the Engine Oil
….Generally recommended after engine is hot.
….Place an oil pan under the engine to collect used oil.
….Remove the oil drain bolt on the lower right side of the engine, and let the oil drain into the oil pan.
….Remove the oil filter cartridge using a socket/extenstion/rachet and an oil filter wrench. Oil filter cap wrenches are available at auto stores. Be careful to minimize oil from dropping down on the header pipes. A funnel made from heavy foil will work to channel the oil coming from the filter port down into the drain pan.
….Apply a thin coat of fresh oil to the O-ring of the new oil filter cartridge and install using the oil filter wrench again. Tightening torque for the oil filer cartridge is 12 ft-lb (17 Nm). If you do not have a torque wrench firm the filter up ¼ to ½ turns from finger tight.
….Install the engine oil drain bolt and torque to 31 ft-lb (43 Nm). If you do not have a torque wrench, snug up the drain bolt to moderately firm. Be careful not to strip threads or cross-thread.
….Add the correct amount of engine oil of choice and tighten the oil filler cap.
….Oil capacity is 3.17 US quarts (3L) with oil filter replacement. Without oil filter replacement 2.96 US quarts (2.8 L). With a totally dry engine, 3.91 US quarts (3.7 L).
….Start the engine and let idle a little to check for leakage.
….Turn engine off and check oil level. Correct is necessary.

Factory Oil Cautions
….The engine oil also lubricates the clutch (wet clutch).
….To help prevent clutch slippage, do not mix any chemical additives with the oil or use oils of a higher grade than "CD".
….Do not use oils labeled "Energy Conserving II" or higher.

To Check the Coolant Level
….Place cycle on center stand.
….Check when engine is cool. The level should be between minimum and maximum lines.
….The coolant level can be observed from the right side, while looking in at the shock area.
….Coolant reservoir capacity is 0.32 US qt (0.3 L).

Coolant recommendations
….Use a 30% coolant to 70% water mixture at minimum. Most riders use a 50-50 mixture of coolant and water.
….Do not use hard water or salt water on the cooling system. Use either distilled or soft tap water.
….The radiator fan is automatically switched on and off according to the coolant temperature in the radiator.

Coolant Replacement|
….It is a good idea to change coolant yearly, or at least every two years.
….Place cycle on centerstand and let the engine cool.
….Remove the right upper cowling panel that sit over the radiator fill cap.
….Place a container under the engine to collect the used coolant.
….Remove the radiator cap.
….Remove the coolant drain bolt with is under the water pump sitting to the bike’s right of the oil filter and behind the header pipes.
….After the coolant completely drains, thorough flush the cooling system with clean tap water.
….Install the coolant drain bolt and toque to 5.1 ft-lb (7 Nm). Be sure to check the drain bolt washer and replace if necessary.
….Pour the recommended coolant into the radiator until it is full.
….Total coolant quantity is 2.54 US quarts (2.4 L). Reservoir capacity is 0.32 US quarts (0.3 L).
….Use a high quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Do not use DEX-COOL by Texaco.
….The recommended antifreeze to water mixture is 1 to 1.
….Install the radiator cap, start the engine, idle for several minutes and turn off.
….Remove the radiator cap to check coolant level in the radiator. Add enough coolant to reach the top of the radiator and re-install the radiator cap.
….Check the coolant level in the reservoir, and if necessary add coolant to the maximum level mark, and install the cap.
….Restart the engine and check for leaks.
….Install the cowling panel.

Cleaning the Air Filter Element
....Clean the air filter element at least every 4000 miles.
....Remove the seat.
....Remove the fuel tank bolts.
....Lift the fuel tank and position it away from the air filter case under the tank, but do not disconnect the fuel hoses.
....Make sure the fuel tank is well supported.  Do not tilt or pull the fuel tank excessively, as the fuel may dislodge.
....Remove the two side panels.
....Pull the rubber cover over the air box off its hooks.
....Remove the air filter case cover by removing the screws.
....Pull the air filter element out of the air-box.
....To clean the filter element, lightly tap it with the hand to remove most of the dust and dirt.  
....Blow the remaining dirt out/off with compressed air, if available.
....Insert the filter back into the air filter case.  
....Install the air filter case cover by replacing the screws.
....Place the rubber cover in the original position.
....Install the side panels.
....Install the fuel tank by installing the bolts.
....Be sure not to pinch the fuel hoses when reinstalling the tank.  Also inspect the fuel hoses.  Be sure to place the tank breather hose in the original position. 
....DO NO operate the engine without the air filter element installed, as piston/cylinder wear may be excessive.

Adjusting the Carburetors
....Yamaha recommends al carburetor adjustments be left to their dealers :)))))))))))))))))))) as they have the necessary professional knowledge and experience :))))))))))))))))))))))))) to adjust a high performance racing engine :))))))))))))))))))))))

Adjusting the Throttle Cable Free Play
....The throttle cable free play should measure 3-5mm (0.1-0.2 in) at the throttle grip. Periodically do a check of throttle free-play.  Yamaha recommends to have a Yamaha dealer adjust it.

Adjusting the Valve Clearance
....Valve clearance changes with use, resulting in improper air/fuel mixture and/or engine noise.  to prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the specified intervals of every 26k miles or every 42k km.

Tires
....Tire pressure should be checked on cold tires.
....Adjust tire pressure according to load and riding type.
....Up to 200 lb; front 36psi, rear 39psi
....Over 200 lb; front 36psi, rear 42psi
....High-speed riding; front 36psi, rear 42psi.
....Total Max Load is 415lb.
....Minimum tire tread is 1.0mm or 0.04 inch.
....Factory Tires:  front, Bridgestone, BT020F, 120/70ZR17 (58W); rear, Bridgestone, BT020R, 180/55ZR17 (73W)
....Tire air valve: TR412; Valve Core, #9000A

MORE TO COME LATER

Late May 2001, at the Saverton, MO, Lock and Dam on the Mississippi River ten miles downstream from Hannibal, MO.  Z's FZ1 with three little mods.  The "mudflap" was cut off the first day of ownership.  A Memphis Shades Hell Cat shield was installed to give some wind protection and stop the wind blast to the chest and head.  Aluminum foot pegs from Fastlap were mounted to homemade aluminum plates and installed at the lower frame motor mount bolts, to offer a second forward foot position and to act as case guards for tip-overs.  Other little, functional mods are rolling around in my head, and we shall see what June, 2k1 brings.

Use the FZ1 Sitemap  to navigate all of the FZ pages.

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