Yamaha Fz1n Service Manual

FRONT BRAKE
4-26
NOTE:
Tighten the brake disc bolts in stages and in a 
crisscross pattern.
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust-ment steps until the br ake disc deflection is 
within specification.
f. If the brake disc deflection cannot be  brought within specification, replace the 
brake disc.
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6. Install: Front wheelRefer to FRONT WHEEL on page 4-8.
EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to...

FRONT BRAKE
4-27
NOTE:
The arrow mark “a” on the brake pad spring 
must point in the direction of disc rotation.
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3. Install: Brake pad pins
 Brake pad clips
 Brake caliper
4. Check:  Brake fluid levelBelow the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
5. Check:  Brake lever operation
Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE...

FRONT BRAKE
4-28
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the right side pistons from the brake caliper.
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EAS22390
CHECKING THE FRONT BRAKE CALIPERS
1. Check: Brake caliper pistons “1”Rust/scratches/wear  → Replace the brake 
caliper pistons.
 Brake caliper cylinders “2” Scratches/wear  → Replace the brake cali-
per assembly.
 Brake caliper body “3” Cracks/damage  → Replace the brake cali-
per assembly.
 Brake fluid delivery...

FRONT BRAKE
4-29
“a” touches the projection “b” on the brake 
caliper.
2. Remove: Brake caliper
3. Install:  Brake pads
 Brake pad spring
 Brake pad pin
 Brake pad clips
 Brake caliper
 Brake hose holder
Refer to REPLACING THE FRONT 
BRAKE PADS on page 4-26.
4. Fill:
 Brake master cylinder reservoir(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13090
 Use only the designated brake fluid. Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and...

FRONT BRAKE
4-30
2. Remove: Union bolt “1”
 Copper washers “2”
Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
EAS22500
CHECKING THE FRONT BRAKE MASTER 
CYLINDER
1. Check: Brake master cylinder
Damage/scratches/wear  → Replace.
 Brake fluid delivery passages (brake master cylinder body)
Obstruction  → Blow out with compressed 
air.
2. Check:
 Brake master cylinder kitDamage/scratches/wear  → Replace.
3. Check:...

FRONT BRAKE
4-31
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
NOTE:
 While holding the brake hose, tighten the union bolt as shown.
 Turn the handlebar to the left and right to  make sure the brake hose does not touch 
other parts (e.g., wire harness, cables, 
leads). Correct if necessary.
CAUTION:
EC2D1004
Attach the brake hose so that its angle is 
23 ° to 33 ° against the straight line in paral-
lel with the ceiling...

REAR BRAKE
4-32
EAS22550
REAR BRAKE
Removing the rear brake pads
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Rear brake caliper 1
4 Brake pad shim 4
5Brake pad 2
6 Bleed screw 1
7 Brake pad spring 1 For installation, reverse the removal 
procedure. 

REAR BRAKE
4-33
Removing the rear brake master cylinder
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain. Refer to BLEEDING THE HYDRAU-
LIC BRAKE SYSTEM on page 3-
25.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir tank 1
5 Brake fluid reservoir hose 1
6 Hose joint 1
7 Bushing 1
8 Union bolt 1
9 Copper washer 2
10 Brake hose 1
11 Brake master cylinder 1 For installation, reverse the removal 
procedure. 

REAR BRAKE
4-34
Disassembling the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks1 Brake master cylinder kit 1
2 Hose joint 1
3 Bushing 1
4 Brake master cylinder body 1 For assembly, reverse the disassem-
bly procedure. 

REAR BRAKE
4-35
Removing the rear brake caliper
Order Job/Parts to remove Q’ty Remarks1 Union bolt 1
2 Copper washer 2
3Brake hose 1
4 Barke caliper 1 For installation, reverse the removal 
procedure.