Yamaha FZ1-N, FZ1-S Service manual

2006

FZ1-N(V)

FZ1-S(V)

SERVICE MANUAL

2D1-28197-E0

EAS20040

FZ1-N (V)/FZ1-S (V)

SERVICE MANUAL

©2005 by Yamaha Motor Co., Ltd.

First edition, December 2005

All rights reserved.

Any reproduction or unauthorized use without

the written permission of Yamaha Motor Co.,

Ltd. is expressly prohibited.

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal­ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal­ers and will appear in future editions of this manual where applicable.

NOTE:

• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS20080

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death
the vehicle operator, a bystander or a person checking or repairing the vehicle.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

to

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section
title is shown at the top of each page “1”.

• Sub-section titles appear in smaller print than the section title “2”.

• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.

• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disas­sembly step “4”.

• Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.

• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.

• Jobs requiring more information (such as special tools and technical data) are described sequen­tially “7”.

EAS20100

SYMBOLS

The following symbols are used in this manual
for easier understanding.

NOTE:

The following symbols are not relevant to every
vehicle.

123

456

T

.

R

.

78

16.Replace the part

91011

E

G

12 13 14

B

LS

15 16

LT

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum-disulfide oil

12.Wheel-bearing grease

13.Lithium-soap-based grease

14.Molybdenum-disulfide grease

15.Apply locking agent (LOCTITE®)

New

M

M

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

1

2

3

4

5

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

6

7

8

9

GENERAL INFORMATION

IDENTIFICATION ..........................................................................................1-1

VEHICLE IDENTIFICATION NUMBER...................................................1-1

MODEL LABEL.......................................................................................1-1

FEATURES ...................................................................................................1-2

FI SYSTEM ...................................................................................................1-3

INSTRUMENT FUNCTIONS.........................................................................1-4

IMPORTANT INFORMATION .......................................................................1-8

PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-8

REPLACEMENT PARTS ........................................................................1-8

GASKETS, OIL SEALS AND O-RINGS..................................................1-8

LOCK WASHERS/PLATES AND COTTER PINS...................................1-8

BEARINGS AND OIL SEALS ................................................................. 1-9

CIRCLIPS ...............................................................................................1-9

1

CHECKING THE CONNECTIONS .............................................................1-10

SPECIAL TOOLS .......................................................................................1-11

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is
stamped into the right side of the steering
head pipe.

EAS20150

MODEL LABEL

The model label “1” is affixed to the frame. This
information will be needed to order spare
parts.

IDENTIFICATION

1-1

FEATURES

EAS20170

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti­mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera­ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con­ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man­ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.

1. Ignition coil

2. Air filter case

3. Intake air temperature sensor

4. Fuel delivery hose

5. Fuel tank

6. Fuel pump

7. Intake air pressure sensor

8. Throttle position sensor

9. Sub-throttle position sensor

10.Fuel injector

11.Catalytic converter

12.Crankshaft position sensor

13.Coolant temperature sensor

1-2

14.Spark plug

15.Cylinder identification sensor

16.Battery

17.ECU

18.Atomospheric pressure sensor

19.Relay unit (fuel pump relay)

20.Engine trouble warning light

21.Lean angle sensor

22.Air cut-off valve

23.O

sensor

2

FI SYSTEM

ET2D1001

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm

when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus­ing the fuel to be injected into the intake manifold only during the time the passage remain open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is ener­gized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature
sensor, coolant temperature sensor, speed sensor and O

sensor enable the ECU to determine the

2

injection duration. The injection timing is determined through the signals from the crankshaft posi­tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times
in accordance with the driving conditions.

Illustration is for reference only.

2

, 46.1 psi). Accordingly,

1. Fuel pump

2. Fuel injector

3. Ignition coil

4. ECU (engine control unit)

5. Intake air temperature sensor

6. Throttle position sensor

7. Sub-throttle position sensor

8. O

sensor

2

9. Catalytic converter

10.Coolant temperature sensor

11.Crankshaft position sensor

12.Intake air pressure sensor

13.Throttle body

14.Air filter case
A. Fuel system

B. Air system
C. Control system

1-3

INSTRUMENT FUNCTIONS

ET2D1002

INSTRUMENT FUNCTIONS

Multi-function meter unit

1. Coolant temperature display/air intake tem­perature display

2. Speedometer

3. Tachometer

4. Odometer/tripmeter/fuel reserve tripmeter

5. “SELECT” button

6. “RESET” button

7. Clock

8. Fuel meter

EW2D1005

WARNING

Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.

The multi-function meter unit is equipped with
the following:

• a speedometer (which shows the riding
speed)

• a tachometer (which shows engine speed)

• an odometer (which shows the total distance
traveled)

• two tripmeters (which show the distance trav­eled since they were last set to zero)

• a fuel reserve tripmeter (which shows the
distance traveled since the left segment of
the fuel meter started flashing)

•a clock

• a fuel meter

• a coolant temperature display

• an air intake temperature display

• a self-diagnosis device

• an LCD and tachometer brightness control
mode

NOTE:

• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.

• For the U.K. only: To switch the speedometer
and odometer/tripmeter displays between

kilometers and miles, press the “SELECT”
button for at least one second.

Tachometer

1. Tachometer

2. Tachometer red zone

The electric tachometer allows the rider to
monitor the engine speed and keep it within
the ideal power range.
When the key is turned to “ON”, the tachome­ter needle will sweep once across the r/min
range and then return to zero r/min in order to
test the electrical circuit.

EC2D1007

CAUTION:

Do not operate the engine in the tachome­ter red zone.
Red zone: 12000 r/min and above

Clock mode

1. Clock

2. Speedometer

The clock is displayed when the key is turned
to “ON”. In addition, the clock can be displayed
for 10 seconds by pushing the “SELECT” but­ton when the main switch is in the “OFF” or
“LOCK” position.
To set the clock

1. Turn the key to “ON”.

2. Push the “SELECT” button and “RESET”
button together for at least two seconds.

1-4

3. When the hour digits start flashing, push
the “RESET” button to set the hours.

4. Push the “SELECT” button, and the minute
digits will start flashing.

5. Push the “RESET” button to set the min­utes.

6. Push the “SELECT” button and then
release it to start the clock.

Odometer and tripmeter modes

1. Odometer/tripmeter/fuel reserve tripmeter

Push the “SELECT” button to switch the dis­play between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
the following order:
TRIP A → TRIP B → ODO → TRIP A
When the fuel amount in the fuel tank
decreases to 3.4 L (0.90 US gal) (0.75
Imp.gal), the left segment of the fuel meter will
start flashing, and the odometer display will
automatically change to the fuel reserve trip­meter mode “FTRIP” and start counting the
distance traveled from that point. In that case,
push the “SELECT” button to switch the dis­play between the various tripmeter and odom­eter modes in the following order:
F-TRIP → TRIP A → TRIP B → ODO → F­TRIP
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second. If you do not
reset the fuel reserve tripmeter manually, it will
reset itself automatically and the display will
return to the prior mode after refueling and
traveling 5 km (3 mi).

Fuel meter

INSTRUMENT FUNCTIONS

1. Fuel meter

The fuel meter indicates the amount of fuel in
the fuel tank. The display segments of the fuel
meter disappear towards “E” (Empty) as the
fuel level decreases. When only one segment
is left near “E”, refuel as soon as possible.

NOTE:

This fuel meter is equipped with a self-diagno­sis system. If the electrical circuit is defective,
the following cycle will be repeated until the
malfunction is corrected: “E” (Empty), “F” (Full)
and symbol “ ” will flash eight times, then go
off for approximately 3 seconds. If this occurs,
have a Yamaha dealer check the electrical cir­cuit.

Coolant temperature mode

1. Coolant temperature display

The coolant temperature display indicates the
temperature of the coolant.
Push the “RESET” button to switch the coolant
temperature display to the air intake tempera­ture display.

NOTE:

When the coolant temperature display is
selected, “C” is displayed for one second, and
then the coolant temperature is displayed.

EC2D1011

CAUTION:

Do not operate the engine if it is over­heated.

1-5

INSTRUMENT FUNCTIONS

Air intake temperature mode

1. Air intake temperature display

The air intake temperature display indicates
the temperature of the air drawn into the air fil­ter case. Push the “RESET” button to switch
the coolant temperature display to the air
intake temperature display.

NOTE:

• Even if the air intake temperature is set to be

displayed, the coolant temperature warning
light comes on when the engine overheats.

• When the key is turned to “ON”, the coolant

temperature is automatically displayed, even
if the air intake temperature was displayed
prior to turning the key to “OFF”.

• When the air intake temperature display is

selected, “A” is displayed for one second,
and then the air intake temperature is dis­played.

Self-diagnosis device

light will flash, and then the display will indicate
a two-digit error code (e.g., 51, 52, 53).

NOTE:

If the display indicates error code 52, this could
be caused by transponder interference. If this
error code appears, try the following.

1. Use the code re-registering key to start the
engine.

NOTE:

Make sure there are no other immobilizer keys
close to the main switch, and do not keep more
than one immobilizer key on the same key ring!
Immobilizer system keys may cause signal
interference, which may prevent the engine
from starting

2. If the engine starts, turn it off and try start­ing the engine with the standard keys.

3. If one or both of the standard keys do not
start the engine, take the vehicle, the code
re-registering key and both standard keys
to a Yamaha dealer and have the standard
keys re-registered.

If the display indicates any error codes, note
the code number, and then have a Yamaha
dealer check the vehicle.

EC2D1012

CAUTION:

If the display indicates an error code, the
vehicle should be checked as soon as pos­sible in order to avoid engine damage.

1. Error code display

This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
display will indicate a two-digit error code (e.g.,
11, 12, 13).
This model is also equipped with a self-diagno­sis device for the immobilizer system.
If any of the immobilizer system circuits are
defective, the immobilizer system indicator

LCD and tachometer brightness control
mode

1. Tachometer panel

2. Tachometer needle

3. LCD

4. Brightness level

This function allows you to adjust the bright­ness of the LCD and the tachometer panel and
needle to suit the outside lighting conditions.
To set the brightness

1-6

1. Turn the key to “OFF”.

2. Push and hold the “SELECT” button.

3. Turn the key to “ON”, and then release the
“SELECT” button after five seconds.

4. Push the “RESET” button to select the
desired brightness level.

5. Push the “SELECT” button to confirm the
selected brightness level. The display will
return to the odometer or tripmeter mode.

INSTRUMENT FUNCTIONS

1-7

EAS20180

IMPORTANT INFORMATION

EAS20190

PREPARATION FOR REMOVAL AND DISAS­SEMBLY

1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning
equipment.
Refer to "SPECIAL TOOLS" on page 1-11.

3. When disassembling, always keep mated
parts together. This includes gears, cylin­ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced
as an assembly.

IMPORTANT INFORMATION

EAS20210

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur­faces, oil seal lips and O-rings must be
cleaned.

2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil
seal lips with grease.

4. During disassembly, clean all of the parts
and place them in trays in the order of dis­assembly. This will speed up assembly and
allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS20200

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace­ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

1. Oil

2. Lip

3. Spring

4. Grease

EAS20220

LOCK WASHERS/PLATES AND COTTER
PINS

After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.

1-8

EAS20230

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.

ECA13300

CAUTION:

Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.

IMPORTANT INFORMATION

EAS20240

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

1-9

EAS20250

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.

1. Disconnect:

• Lead

• Coupler

• Connector

2. Check:

• Lead

• Coupler

• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.

CHECKING THE CONNECTIONS

Pocket tester

90890-03112

Analog Pocket tester

YU-03112-C

NOTE:

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform
steps (1) to (3).

• As a quick remedy, use a contact revitalizer
available at most part stores.

3. Check:

• All connections
Loose connection → Connect properly.

NOTE:

If the pin “1” on the terminal is flattened, bend
it up.

4. Connect:

• Lead

• Coupler

• Connector

NOTE:

Make sure all connections are tight.

5. Check:

• Continuity
(with the pocket tester)

1-10

SPECIAL TOOLS

EAS20260

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri­ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.

NOTE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool name/Tool No. Illustration

Piston pin puller set
90890-01304
Piston pin puller
YU-01304

Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01

Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984

Steering nut wrench
90890-01403
Spanner wrench
YU-33975

Reference

pages

5-71

6-3

6-3

3-27, 4-59

Ring nut wrench
90890-01268
Spanner wrench
YU-01268

Damper rod holder
90890-01423
Damping rod holder
YM-01423

4-59

4-51, 4-52

1-11

SPECIAL TOOLS

Tool name/Tool No. Illustration

Oil filter wrench
90890-01426
YU-38411

Rod holder
90890-01434
Damper rod holder double ended
YM-01434

Rod puller
90890-01437
Universal damping rod bleeding tool set
YM-A8703

Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding tool set
YM-A8703

Reference

pages

3-13

4-50, 4-55

4-54

4-54

Fork spring compressor
90890-01441
YM-01441

Fork seal driver
90890-01442
Adjust table fork seal driver (36-46 mm)
YM-01442

Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456

4-50, 4-55

4-53

3-7

1-12

SPECIAL TOOLS

Tool name/Tool No. Illustration

Compression gauge
90890-03081
Engine compression tester
YU-33223

Valve spring compressor
90890-04019
YM-04019

Valve spring compressor attachment
90890-04108
Valve spring compressor adapter (22 mm)
YM-04108

Valve spring compressor attachment
90890-04114
Valve spring compressor adapter
YM-04114

Reference

pages

3-11

5-23, 5-29

5-23, 5-29

5-23, 5-29

Middle driven shaft bearing driver
90890-04058
Bearing driver (40 mm)
YM-04058

Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A

Universal clutch holder
90890-04086
YM-91042

6-12

6-12

5-47, 5-51

1-13

SPECIAL TOOLS

Tool name/Tool No. Illustration

Valve guide remover (ø4)
90890-04111
Valve guide remover (4.0 mm)
YM-04111

Valve guide remover (ø4.5)
90890-04116
Valve guide remover (4.5 mm)
YM-04116

Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112

Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117

Reference

pages

5-25

5-25

5-25

5-25

Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113

Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118

Ignition checker
90890-06754
Opama pet-4000 spark checker
YU-34487

5-25

5-25

8-104

1-14

SPECIAL TOOLS

Tool name/Tool No. Illustration

Yamaha bond No.1215
(Three Bond No.1215®)
90890-85505

Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927

Pivot shaft wrench
90890-01518
Frame spanner socket
YM-01518

Pivot shaft wrench adapter
90890-01476

Reference

pages

5-67, 6-12

7-9, 7-10

5-7

5-7

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

Oil pressure gauge
90890-03153
Pressure gauge
YU-03153

Oil pressure gauge adapter
90890-03139

1-10, 5-41, 8­95, 8-96, 8-97,
8-100, 8-102, 8­103, 8-104, 8­105, 8-106, 8­107, 8-108, 8­109, 8-110, 8­111, 8-112

3-14

3-14

1-15

SPECIAL TOOLS

Tool name/Tool No. Illustration

Vacuum/pressure pump gauge set
90890-06756

Valve lapper
90890-04101
Valve lapping tool
YM-A8998

Fuel pressure adapter
90890-03176
YM-03176

Pressure gauge
90890-03153
YU-03153

Reference

pages

7-8

3-5

7-8

3-14, 7-8

Camshaft wrench
90890-04143
YM-04143

5-11, 5-16

1-16

SPECIAL TOOLS

1-17

SPECIFICATIONS

GENERAL SPECIFICATIONS......................................................................2-1

ENGINE SPECIFICATIONS..........................................................................2-1

CHASSIS SPECIFICATIONS .......................................................................2-8

ELECTRICAL SPECIFICATIONS...............................................................2-10

TIGHTENING TORQUES............................................................................2-12

GENERAL TIGHTENING TORQUE SPECIFICATIONS.......................2-12

ENGINE TIGHTENING TORQUES ......................................................2-13

CHASSIS TIGHTENING TORQUES ....................................................2-17

LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-20

ENGINE................................................................................................2-20

CHASSIS..............................................................................................2-22

2

LUBRICATION SYSTEM CHART AND DIAGRAMS .................................2-23

ENGINE OIL LUBRICATION CHART ...................................................2-23

LUBRICATION DIAGRAMS..................................................................2-25

COOLING SYSTEM DIAGRAMS ...............................................................2-35

CABLE ROUTING ......................................................................................2-39

GENERAL SPECIFICATIONS

EAS20280

GENERAL SPECIFICATIONS

Model

Model 2D11 (EUR)

2D13 (AUS)
3C31 (EUR)
3C33 (AUS)
3C37 (EUR)

Dimensions

Overall length 2140 mm (84.3 in)
Overall width 770 mm (30.3 in)
Overall height 1060 mm (41.7 in) (FZ1-N)

Seat height 815 mm (32.1 in)
Wheelbase 1460 mm (57.5 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 3000 mm (118.1 in)

Weight

With oil and fuel 214.0 kg (472 lb) (FZ1-N)

Maximum load 196 kg (432 lb) (FZ1-N)

EAS20290

ENGINE SPECIFICATIONS

3C39 (AUS)

1205 mm (47.4 in) (FZ1-S)

220.0 kg (485 lb) (FZ1-S)

190 kg (419 lb) (FZ1-S)

Engine

Engine type Liquid cooled 4-stroke, DOHC
Displacement 998.0 cm³ (60.90 cu.in)
Cylinder arrangement Forward-inclined parallel 4-cylinder
Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in)
Compression ratio 11.50 : 1
Standard compression pressure (at sea level) 1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8

kgf/cm²/350 r/min)

Starting system Electric starter

Fuel

Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 18.0 L (4.76 US gal) (3.96 Imp.gal)
Fuel reserve amount 3.4 L (0.90 US gal) (0.75 Imp.gal)

Engine oil

Lubrication system Wet sump
Type SAE10W30 or SAE10W40 or SAE15W40 or

SAE20W40 or SAE20W50
Recommended engine oil grade API service SE, SF, SG type or higher
Engine oil quantity

Total amount 3.80 L (4.02 US qt) (3.34 Imp.qt)
Without oil filter cartridge replacement 2.90 L (3.07 US qt) (2.55 Imp.qt)
With oil filter cartridge replacement 3.10 L (3.28 US qt) (2.73 Imp.qt)

Oil filter

Oil filter type Paper

Oil pump

Oil pump type Trochoid

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ENGINE SPECIFICATIONS

Inner-rotor-to-outer-rotor-tip clearance 0.010–0.100 mm (0.0004–0.0039 in)
Limit 0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housing clearance 0.090–0.150 mm (0.0035–0.0059 in)
Limit 0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor

clearance 0.06–0.13 mm (0.0024–0.0051 in)
Limit 0.20 mm (0.0079 in)
Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20

Relief valve operating pressure 600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80

Cooling system

Radiator capacity (including all routes) 2.25 L (2.38 US qt) (1.98 Imp.qt)
Coolant reservoir capacity (up to the maximum

level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator cap opening pressure 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23

Radiator core

Width 222.6 mm (8.76 in)
Height 360.0 mm (14.17 in)
Depth 22.0 mm (0.87 in)

Water pump

Water pump type Single suction centrifugal pump
Reduction ratio 65/43 × 25/32 (1.181)
Max impeller shaft tilt limit 0.15 mm (0.0059 in)

Spark plug (s)

Manufacturer/model NGK/CR9EK
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)

Cylinder head

Volume 12.20–13.00 cm³ (0.74–0.79 cu.in)
Warpage limit* 0.10 mm (0.0039 in)

kgf/cm²)

kgf/cm²)

kgf/cm²)

Camshaft

Drive system Chain drive (right)
Camshaft cap inside diameter 22.500–22.521 mm (0.8858–0.8867 in)
Camshaft journal diameter 22.459–22.472 mm (0.8842–0.8847 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Camshaft lobe dimensions

Intake A 32.500–32.600 mm (1.2795–1.2835 in)
Limit 32.400 mm (1.2756 in)
Intake B 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.850 mm (0.9783 in)
Exhaust A 30.699–30.799 mm (1.2086–1.2126 in)
Limit 30.599 mm (1.2047 in)
Exhaust B 22.950–23.050 mm (0.9035–0.9075 in)
Limit 22.850 mm (0.8996 in)

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ENGINE SPECIFICATIONS

Camshaft runout limit 0.030 mm (0.0012 in)

Timing chain

Model/number of links RH2020/122
Tensioning system Automatic

Valve, valve seat, valve guide

Valve clearance (cold)

Intake 0.11–0.20 mm (0.0043–0.0079 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)

Valve dimensions

Valve head diameter A (intake) 23.40–23.60 mm (0.9213–0.9291 in)
Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in)

Valve face width B (intake) 1.760–2.900 mm (0.0693–0.1142 in)
Valve face width B (exhaust) 1.760–2.900 mm (0.0693–0.1142 in)

Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)

Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)
Valve margin thickness D (exhaust) 0.50–0.90 mm (0.0197–0.0354 in)

Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in)
Limit 3.945 mm (0.1553 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)

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