Yamaha FZ1 30Kmi Maintenance & Valve Adjustment :)

My 2006 Yamaha FZ1 has about 30,000mi on it, so it was time to do a major servicing. Over the last few weeks I tore my bike apart and did it all I got the bike back together this past weekend and it runs like buttered tits!

For the maintenance I did;
-Valve adjustment
-Fork rebuild at Traxxion Dynamics
-Front and rear wheel bearing replacement
-Clutch/throttle cable replacement
-Spark plug replacement
-Coolant flush
-Brake fluid flush
-Air filter cleaning
-Chain clean/lube/adjust

I'll finish it up with an oil change and brake pad replacement.


Here's some pics to share;



Day 1; Bike up on stands, front/rear wheels off.



Day 2; Fenders, cowlings, gas tank, airbox, forks off.


Underside of the gas tank Once you work on a bike a while all this isn't too bad.


Forks shipped off to Traxxion Dynamics for a rebuild. I had plans to do it myself but with warm weather creeping up on me, I decided to ship them off and have it done while I focused on the valve adjustment.



Spark plugs, ignition coils, and valve cover off. This is a 20-valve motor. 3 intake and 2 exhaust valves per cylinder. Intake is on the upper side, exhaust on the bottom, where the headers are.


Throttle bodies removed to access the intake valves.



Intake ports


End of day 4; Replaced the front and rear wheel bearings, replaced clutch/throttle cables.


I measured valve clearances and 8 intake and 2 exhaust valve clearances were out of spec...had to remove the camshafts to adjust clearances. I zip tied the cam gears to the chain so I wouldn't lose timing.

Intake camshaft off. The valve buckets are the round discs. The valve shim is right under the bucket.


Intake camshaft and retainers.


Valve bucket on the left and valve shim on the right. The shims are available in 0.05mm increments and swapping shims is how the clearance is adjusted. I used the micrometer to measure the shims that came off the bike. The thickness is printed on the shim but I wanted to make sure that the shim hadn't worn down while it was in the bike.


Exhaust camshaft out.


Exhaust camshaft and retainers.


My worksheet for the valve clearances


This is the crankshaft sprocket. The T mark on the left side of the sprocket has to line up with a mark on the case with cylinder #1 at top dead center. When its lined up, the marks on the intake and exhaust camshafts will line up with the marks on the retainers. When I put everything back together, the timing was off. The cam chain had slipped by one tooth on the crankshaft sprocket when I removed the chain tensioner and cam gears. It took me a little while to figure this out.


Proof that I got her back together

 

nice!

i did my old cbr600f4 1999.....but i didnt do it till 19,000 miles and it was all good!!!!

thats when all i did was rode!!!!!!!!

again.....nice job man!!!!!

 

seems like a bit more than a valve adjustment.

 

Awesome! Want to do mine next? Nice ride btw.

Here's mine... I am working on a set of the sport scoops I bought that are in shift red at the moment...


Here is my wife's FZ1 as of today. I pick up all her stuff from the painter tomorrow. It was cobalt blue also and I got a full lower fairing kit for her.. I'll post a pic of it when it is all back together.



Are you a forum member on www.fz1-forum.com?

 

Great write up and photos. Nice job. Sweet bike.

 

In the last pic of you with the bike.... what is that line/cable running over the side of the engine? Curious... I don't know if I will brave this storm myself though.

 

Thanks everyone for the kinds words!

I'm a SManZ on www.yamahafz1oa.com Haven't visited fz1-forum but I'll check it out!

Definitely would like to see a pic of the bikes when they're done! Did you get your sport scoops from Canada too?

 

Its a braided line that goes from a boss in the oil galley to a mechanical oil pressure gauge on the handlebar

 

I'm FZ1inNH on both boards. I don't frequent FZ1OA a lot, only when I need technical stuff. The other forum is a LOT more friendly and the people are great at getting to the point.

I bought my scoops from a guy who got rear-ended on his bike and went down. One of them got scuffed but they are not broken. He sold them to me for $100!!! I just need to find a place to get the Yamaha base color in a rattle can so I can paint and clear them.

Should be done today so I hope to have a reveal tonight on her FZ1. I'll put them out side by side as a comparison.

Nice work on the gauge then too! If you sign up on our forum, can you please post all the stuff you've done with some how-to threads and pics? We'd much appreciate it! Great ride!!!

 

Finished her build today. Here it is with mine as well. I have the FE Kit and Copperdog blinker pods off for the time being... This is the 1997 Toyota color for the trucks... Mystic Purple Mica Pearl. I used to own the access cab 4x4 this color.

 

Nice job. I have to do my Gen1 FZ1 pretty soon. At 25K the valves were fine but I have a feeling some adjustment is going to be necessary at 50K.

 

Thanks!

Most of the guys in the forum aren't finding much for adjustments until they hit about 36k miles with the exceptions being the "spirited" riders.

 

Very nice bikes!

Which seat is that on the blue one?

What kinds of tires are you running? I'm on Michelin Pilot Road 2CTs and am pretty happy with them so far. I did lose cornering grip at around 40`F, but they stuck tight this past weekend at 50-55`F.

I'm running the bike harder than I have in the past so I'm guessing the valve adjustment will come sooner this go around. Looking at getting a 2011/2012 GSX-R750 to take up the hooligan duties.

 

Thanks man! The seat on mine is from www.topsaddlery.com in France. I've put one on every FZ I've owned. I'm guessing my wife will order one for her bike too when we can fund it as they are pricey. It's comfortable enough that my arse doesn't get tired and I only have to stop for gas.

I still have the stock DunCraps on but I'm looking for a set of Pilot Road 3s (Finding a 190 is proving difficult!) Her bike came with a brand new set of Pilot Powers on it but she isn't aggressive so they might last a while. She will swap over to the PR3 set when those wear out. If I lived closer to TN/NC, I'd run Pilot Powers all the time!