Yamaha Fz1n Service Manual

FRONT FORK
4-56
WARNING
EW2D1003
 The fork spring is compressed.
 Always use a new cap bolt O-ring.
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EAS23050
INSTALLING 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 screw and left front fork is equipped 
with a compression damping force adjusting 
screw. Pay attension not to mistake the...

STEERING HEAD
4-57
EAS23090
STEERING HEAD
Removing the lower bracket
Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page  4-8.
Front brake calipers Refer to FRONT BRAKE on page  4-20.
Front cowling (FZ1-S) Refer to GENERAL CHASSIS on  page 4-1.
Headlight and meter assembly (FZ1 -N) Refer to GENERAL CHASSIS on 
page 4-1.
Handlebar Refer to HANDLEBAR on page 4- 43.
Front fork legs Refer to FRONT FORK on page 4- 48.
1 Main switch connector 2 Disconnect.
2 Steering stem nut 1
3...

STEERING HEAD
4-58
5 Front brake hose joint bracket 1
6Horn 1
7 Horn bracket 1
8 Lock washer 1
9 Upper ring nut 1
10 Rubber washer 1
11 Lower ring nut 1
12 Lower bracket 1
13 Lower bearing 1
14 Lower bearing dust seal 1
15 Lower bearing inner race 1
16 Bearing cover 1
17 Upper bearing inner race 1
18 Upper bearing 1
19 Bearing outer race 2 For installation, reverse the removal 
procedure.
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks 

STEERING HEAD
4-59
EAS23110
REMOVING THE LOWER BRACKET
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: Upper ring nut “1”
 Rubber washer
 Lower ring nut “2”
 Lower bracket
NOTE:
Hold the lower ring nut with the ring nut wrench 
“3”, and then remove the upper ring nut with 
the steering nut wrench “4”.
WARNING
EWA13730
Securely support the lower bracket so that 
there is no danger of it falling....

STEERING HEAD
4-60
4. Check: Upper bracket
 Lower bracket
(along with the steering stem)
Bends/cracks/damage  → Replace.
EAS23140
INSTALLING THE STEERING HEAD
1. Lubricate:
 Upper bearing
 Lower bearing
 Bearing races
2. Install:  Lower ring nut “1”
 Rubber washer “2”
 Upper ring nut “3”
 Lock washer “4”Refer to INSTALLING THE STEERING 
HEAD on page 4-60.
3. Install:  Front brake hose joint bracket
 Front brake hose joint
4. Install:
 Upper bracket
 Steering stem nut
NOTE:
Temporarily...

REAR SHOCK ABSORBER ASSEMBLY
4-61
EAS23160
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Side cover (left and right) Refer to GENERAL CHASSIS on  page 4-1.
Brake fluid reservoir tank bolt Refer to REAR BRAKE on page 4- 32.
1 Self-locking nut/bolt 1/1
2 Self-locking nut/bolt 1/1
3 Self-locking nut/bolt 1/1
4 Self-locking nut/bolt/collar 1/1/1
5 Rear shock absorber assembly 1
6...

REAR SHOCK ABSORBER ASSEMBLY
4-62
For installation, reverse the removal 
procedure.
Removing the rear shock absorber assembly
Order Job/Parts to remove Q’ty Remarks 

REAR SHOCK ABSORBER ASSEMBLY
4-63
EAS23180
HANDLING THE REAR SHOCK ABSORBER
WARNING
EWA13740
This rear shock absorber contains highly 
compressed nitrogen gas. Before handling 
the rear shock absorber, read and make 
sure you understand the following informa-
tion. The manufacturer cannot be held 
responsible for property damage or per-
sonal injury that may result from improper 
handling of the rear shock absorber.
 Do not tamper or attempt to open the rear shock absorber.
 Do not subject the rear...

REAR SHOCK ABSORBER ASSEMBLY
4-64
Gas leaks/oil leaks → Replace the rear 
shock absorber assembly.
Spring Damage/wear  → Replace the rear shock 
absorber assembly.
 Bushings Damage/wear  → Replace.
Dust seals
Damage/wear  → Replace.
Bolts Bends/damage/wear  → Replace.
EAS23260
CHECKING THE CONNECTING ARM AND 
RELAY ARM
1. Check:
 Connecting arms “1”
 Relay arm “2”Damage/wear  → Replace.
2. Check:  Bearings
 Oil sealsDamage/pitting  → Replace.
3. Check: Coller
Damage/scratches  → Replace....

SWINGARM
4-65
EAS23330
SWINGARM
Removing the swingarm
Order Job/Parts to remove Q’ty RemarksRear wheel Refer to REAR WHEEL on page 4- 14.
Rear brake caliper Refer to REAR BRAKE on page 4- 32.
Rear shock absorber Refer to REAR SHOCK  ABSORBER ASSEMBLY on page 
4-61.
Drive sprocket Refer to ENGINE REMOVAL on  page 5-2.
1 Rear fender cover 1
2 Drive chain guard 1
3 Brake hose holder 1
4 Drive chain adjusting bolt/locknut 2/2
5 Pivot shaft nut/washer 1/1
6 Pivot shaft 1
7 Swingarm 1