2012 YAMAHA FZ1 S brake pads

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator lights and warning lights ..............................3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-12
Handlebar switches ......................3-13
Clutch lever ...................................3-14
Shift pedal .....................................3-14
Brake lever ...................................3-15
Brake pedal ..................................3-15
ABS (for ABS models) ..................3-15
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather hose and
overflow hose ............................3-18
Catalytic converters ......................3-19
Seats ............................................3-19
Storage compartment ...................3-21
Rear view mirrors .........................3-21
Adjusting the front fork ..................3-22 Adjusting the shock absorber
assembly ................................... 3-24
Luggage strap holders ................. 3-25
EXUP system ............................... 3-26
Sidestand ..................................... 3-26
Ignition circuit cut-off system ........ 3-27
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the emission control system ....... 6-3
General maintenance and lubrication chart .......................... 6-4
Removing and installing panels ..... 6-8
Checking the spark plugs ............... 6-9
Engine oil and oil filter cartridge ... 6-10
Coolant ......................................... 6-13
Replacing the air filter element ..... 6-14 Adjusting the engine idling
speed ........................................ 6-17
Checking the throttle grip free play ........................................... 6-17
Valve clearance ........................... 6-18
Tires ............................................. 6-18
Cast wheels ................................. 6-20
Adjusting the clutch lever free
play ........................................... 6-21
Checking the brake lever free play ........................................... 6-21
Brake light switches (for ABS models) ...................... 6-22
Brake light switches
(for non-ABS models) ............... 6-22
Checking the front and rear brake pads ........................ 6-23
Checking the brake fluid level ...... 6-23
Changing the brake fluid .............. 6-25
Drive chain slack .......................... 6-25
Cleaning and lubricating the drive chain .......................... 6-26
Checking and lubricating
the cables ................................. 6-27
Checking and lubricating the throttle grip and cable ......... 6-27
Checking and lubricating the brake and shift pedals ........ 6-28
Checking and lubricating
the brake and clutch levers ...... 6-28U1CAE1E0.book Page 1 Tuesday, September 13, 2011 5:02 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEMCHECKS PAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose and overflow
hose for obstructions, cracks or dam-
age, and check hose connections. 3-17, 3-18
Engine oil Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 6-10
Coolant Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage. 6-13
Front brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 6-23, 6-23
U1CAE1E0.book Page 1 Tuesday, September 13, 2011 5:02 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brake fluid to specified level.
Check hydraulic system for leakage. 6-23, 6-23
Clutch Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
6-21
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing. 6-17, 6-27
Control cables Make sure that operation is smooth.
Lubricate if necessary. 6-27
Drive chain Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
6-25, 6-26
Wheels and tires Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
6-18, 6-20
Brake and shift pedals Make sure that operation is smooth.
Lubricate pedal pivoting points if necessary. 6-28
Brake and clutch levers Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
6-28
Centerstand, sidestand Make sure that operation is smooth.
Lubricate pivots if necessary.
6-29
ITEM CHECKS PAGE
U1CAE1E0.book Page 2 Tuesday, September 13, 2011 5:02 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 Air filter element Replace. √
2Clutch Check operation.
Adjust.
√√√√√
3 *Front brake Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
Replace brake pads. Whenever worn to the limit
4 *Rear brake Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
Replace brake pads. Whenever worn to the limit
5 *Brake hoses Check for cracks or damage.
Check for correct routing and
clamping. √√√√√
Replace. Every 4 years
6 *Wheels Check runout and for damage. √√√√
7 *Tires Check tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary. √√√√√
8 *Wheel bearings Check bearing for looseness or
damage. √√√√
9 *Swingarm Check operation and for exces-
sive play. √√√√
U1CAE1E0.book Page 4 Tuesday, September 13, 2011 5:02 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU22392
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36890
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn tothe point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU46291
Rear brake pads
Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that a wear
indicator groove almost appears, have
a Yamaha dealer replace the brake
pads as a set.
EAU43112
Checking the brake fluid level Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
1. Brake pad wear indicator
1. Brake pad wear indicator groove
1
1. Minimum level mark
U1CAE1E0.book Page 23 Tuesday, September 13, 2011 5:02 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6Rear brake (FZ1-S)
Rear brake (FZ1-SA)
TIPThe rear brake fluid reservoir is located
behind panel C. (See page 6-8.)
WARNING
EWA16010
Improper maintenance can result in
loss of braking ability. Observe
these precautions:●
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
●
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
●
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
●
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
●
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re- sult in vapor lock, and dirt may
clog the ABS hydraulic unit
valves.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before further riding.
1. Minimum level mark
1. Minimum level mark
Specified brake fluid: DOT 4
U1CAE1E0.book Page 24 Tuesday, September 13, 2011 5:02 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
EAU44791
Front wheel (for non-ABS
models)
WARNING
EWA14840
For the ABS model, have a Yamaha
dealer remove and install the wheel.
EAU40062
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the front wheel axle pinchbolt, then the wheel axle and the
brake caliper bolts. 2. Place the vehicle on the center-
stand.
3. Remove the brake hose holder on each side by removing the bolt and
nut.
4. Remove the brake caliper on each side by removing the bolts.
NOTICE: Do not apply the brake
after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11051]
5. Pull the wheel axle out, and then remove the wheel.
EAU40071
To install the front wheel1. Lift the wheel up between the fork legs.
2. Insert the wheel axle.
3. Install the brake caliper on each side by installing the bolts.TIPMake sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.
1. Front wheel axle pinch bolt
2. Wheel axle
3. Brake caliper bolt
3
2
1
1. Brake hose holder
2. Bolt and nut
3. Brake caliper bolt
4. Brake caliper
U1CAE1E0.book Page 38 Tuesday, September 13, 2011 5:02 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-40
6
●
The drive chain cannot be disas-
sembled.
7. While supporting the brake caliperbracket, pull the wheel axle out,
and then remove the wheel.
NOTICE: Do not apply the brake
after the wheel has been re-
moved together with the brake
disc, otherwise the brake pads
will be forced shut.
[ECA11071]
EAU48402
To install the rear wheel1. Install the wheel and the brake cal- iper bracket by inserting the wheel
axle from the left-hand side.
TIP●
Make sure that the slot in the brake
caliper bracket is fit over the retain-
er on the swingarm.
●
Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
2. Install the drive chain onto the rearsprocket.
3. Install the axle nut.
4. Take the vehicle off the center- stand so that the rear wheel is on
the ground, and then put the side-
stand down.
5. Adjust the drive chain slack. (See page 6-25.) 6. Tighten the axle nut, and then
tighten the locknuts to the speci-
fied torques.
1. Wheel axle
1. Slot
2. Retainer
Tightening torques:Axle nut:150 Nm (15 m·kgf, 108 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 12 ft·lbf)
U1CAE1E0.book Page 40 Tuesday, September 13, 2011 5:02 PM