Yamaha Fz1n Service Manual

REAR BRAKE
4-36
Disassembling the rear brake caliper
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3Brake pad 2
4 Brake pad shim 4
5 Brake pad spring 1
6 Brake caliper piston 1
7 Brake caliper piston seal 2
8 Bleed screw 1 For assembly, reverse the disassem-
bly procedure. 

REAR BRAKE
4-37
EAS22560
INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require dis-
assembly. Therefore, always follow these 
preventive measures:
 Never disassemble brake components unless absolutely necessary.
 If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after 
reassembly.
 Never use solvents on internal brake  components.
 Use only clean or new brake fluid for  cleaning...

REAR BRAKE
4-38
a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of 
the hose into an open container.
b. Loosen the bleed screw and push the  brake caliper pistons into the brake caliper 
with your finger.
c. Tighten the bleed screw.
d. Install a new brake pad shim “3” onto each  new brake pad “4”.
e. Install new brake pads and a new brake  pad spring “5”.
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3. Install: Brake caliper
 Brake pad pin
 Screw plug
4. Check: Brake fluid...

REAR BRAKE
4-39
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a. Secure the brake caliper pistons with a piece of wood “a”.
b. Blow compressed air into the brake hose 
joint opening “b” to force out the piston from 
the brake caliper.
WARNING
EWA13550
 Cover the brake caliper piston with a rag. Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
 Never try to pry out the brake caliper pis-
ton.
c. Remove the brake caliper piston seals.
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EAS22640
CHECKING...

REAR BRAKE
4-40
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install: Brake caliper “1”
(temporarily)
 Copper washers “2” 
Brake hose “3”
 Union bolt “4”
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
CAUTION:
EC2D1010
When installing the brake hose onto the 
brake caliper, make sure the brake pipe “a” 
touches the projection “b” on the brake cal-
iper.
2. Remove:  Brake caliper
3. Install:  Brake pad shims
 Brake...

REAR BRAKE
4-41
7. Check: Brake pedal operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
EAS22700
REMOVING THE REAR BRAKE MASTER 
CYLINDER
1. 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.
EAS22720
CHECKING THE REAR BRAKE MASTER 
CYLINDER
1. Check:
 Brake master cylinderDamage/scratches/wear  →...

REAR BRAKE
4-42
2. Fill: Brake fluid reservoir(with the specified amount of the recom-
mended brake fluid)
WARNING
EW2D1005
 Use only the designated brake fluid.  Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid  that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does  not enter...

HANDLEBAR
4-43
EAS22840
HANDLEBAR
Removing the handlebar
Order Job/Parts to remove Q’ty RemarksFront cowling (FZ1-S) Refer to GENERAL CHASSIS on  page 4-1.
1 Rear view mirror (FZ1-N) 2
2 Front brake light switch connector 2 Disconnect.
3 Front master cylinder bracket 1
4 Front brake master cylinder assembly 1
5 Right handlebar switch 1
6 Throttle cable housing 1
7 Throttle cable 2
8Grip end 2
9 Throttle grip 1
10 Clutch cable 1
11 Handlebar grip 1
12 Left handlebar switch 1
13 Clutch lever holder 1
14...

HANDLEBAR
4-44
15 Handlebar 1
16 Lower handlebar holder 2For installation, reverse the removal 
procedure.
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks 

HANDLEBAR
4-45
EAS22860
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
2. Remove: Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar 
and the handlebar grip, and gradually push the 
grip off the handlebar.
3. Remove: Throttle cable housing “1”
 Throttle grip “2”
NOTE:
While removing the throttle cable housing, pull 
back the rubber cover “3”.
EAS22880
CHECKING THE HANDLEBAR...