Yamaha Fz1n Service Manual

HANDLEBAR
4-46
4. Tighten: Lower handlebar holder nuts
5. Install:  Clutch lever holder “1”
Clutch cable
NOTE:
Align the slit in the clutch lever holder with the 
punch mark a in the handlebar.
6. Install: Left handlebar switch
NOTE:
Align the projections “a” on the left handlebar 
switch with the hole “b” in the handlebar.
7. Install: Handlebar grip “1”
 Grip end “2”
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a. Apply a thin coat of rubber adhesive onto  the left end of the handlebar.
b. Side the handlebar...

HANDLEBAR
4-47
NOTE:
 Align the projections a on the handlebar switch with the holes b in the handlebar.
 Threre should be 1–3 mm (0.04–0.12 in) of 
clearance “c” between the handlebar grip 
and the grip end.
10. Install:  Front brake master cylinder assembly
 Front brake master cylinder holder “1”
CAUTION:
ECS2D1010
 Install the brake master cylinder bracket with the “UP” mark facing up.
 First, tighten the upper bolt, then the 
lower bolt.
NOTE:
Align the end of the brake master cylinder 
holder...

FRONT FORK
4-48
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty RemarksFront wheel
Front brake calipers Refer to CHECKING THE TIRES 
on page 3-32 and CHECKING THE 
WHEELS on page 3-34.
1 Front fender 1
2 Cap bolt 1 Loosen.
3 Upper bracket pinch bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1 For installation, reverse the removal 
procedure. 

FRONT FORK
4-49
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks1 Cap bolt 1
2O-ring 1
3 Damper adjusting rod 1
4Nut 1
5 Washer 1
6 Spacer 1
7Fork spring 1
8 Dust seal 1
9 Oil seal clip 1
10 Oil seal 1
11 Washer 1
12 Damper rod assembly bolt 1
13 Copper washer 1
14 Damper rod assembly 1
15 Inner tube 1
16 Outer tube 1 For assembly, reverse the disassem-
bly procedure. 

FRONT FORK
4-50
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
NOTE:
Each front fork leg is eqipped with a spring 
preload adjusting bolt, the right fork leg is 
equipped with a rebound damping force 
adjusting screan and left front fprk is equipped 
with a compression damping force adjusting 
screw. Pay attention not to mistake the right 
and left.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there...

FRONT FORK
4-51
3. Remove: Oil seal clip “1”(with a flat-head screwdriver)
CAUTION:
ECA14180
Do not scratch the inner tube.
4. Remove: Damper rod assembly bolt
 Damper rod assembly
CAUTION:
EC2D1080
For the damper rod assembly, the right side 
is used for the rebound operation and left 
side for the compression. Pay attention not 
to mistake the right and left.
NOTE:
The left side (for the compression) damper rod 
assembly has the four holes of oil path, unlike 
the right side.
NOTE:
While holding...

FRONT FORK
4-52
3. Check: Damper rod “1”Damage/wear  → Replace.
Obstruction  → Blow out all of the oil pas-
sages with compressed air.
 Damper adjusting rod Bends/damage  → Replace.
CAUTION:
ECA14200
 The front fork leg has a built-in damper 
adjusting rod and a very sophisticated 
internal construction, which are particu-
larly sensitive to foreign material.
 When disassembling and assembling the 
front fork leg, do not allow any foreign 
material to enter the front fork.
EAS23030
ASSEMBLING THE...

FRONT FORK
4-53
4. Install: Dust seal “1”
 Oil seal clip “2”
 Oil seal “3”
 Washer “4”
CAUTION:
ECA14220
Make sure the numbered side of the oil seal 
faces up.
NOTE:
 Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
 Lubricate the outer surface of the inner tube  with fork oil.
 Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
5. Install:  Oil seal “1”
(with the fork seal driver...

FRONT FORK
4-54
9. Fill:Front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA14230
 Be sure to use the recommended fork oil.  Other oils may have an adverse effect on 
front fork performance.
 When disassembling and assembling the 
front fork leg, do not allow any foreign 
material to enter the front fork.
NOTE:
Be sure to bleed the front fork.
10. After filling the front fork leg, slowly stroke  the damper rod “1” up and down (at least 
ten times) to distribute the...

FRONT FORK
4-55
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a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring and spacer.
NOTE:
Install the spring with the smaller pitch “a” fac-
ing up “A”.
d. Press down in the spacer with the fork spring compressor “1”
e. Pull up the rod puller and install the rod 
holder “2” between the damper adjusting 
rod locknut “3” and the spacer “4”.
NOTE:
Use the side of the rod holder that is marked 
“B”. f. Remove the rod puller and the rod puller...