Yamaha Fz1n Service Manual

ENGINE REMOVAL
5-3
Removing the exhaust pipe
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
1 EXUP pulley cover 1
2 EXUP servo motor cover 1
3 EXUP cables 2
4 EXUP servo motor 1
5O
2 sensor 1
6 Exhaust pipe assembly 1
7 Exhaust pipe gasket 4
8 Muffler 1
9 Muffler gasket 1
10 Muffler cover 1
11 Muffler end cover 1 For installation, reverse the removal 
procedure. 

ENGINE REMOVAL
5-4
Disassembling the exhaust valve pipe
Order Job/Parts to remove Q’ty Remarks1Nut 1
2Pulley 1
3Spring 1
4 Spring seat 1 For assembly, reverse the disassem-
bly procedure. 

ENGINE REMOVAL
5-5
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty RemarksFuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on  page 4-1.
Throttle body assembly Refe r to THROTTLE BODIES on 
page 7-4.
Engine oil Drain. Refer to CHANGING THE ENGINE 
OIL on page 3-12.
Oil cooler Refer to OIL COOLER on page 6- 4.
Air cut-off valve Refer to AIR INDUCTION SYS- TEM on page 7-13.
Starter motor Refer to ELECTRIC STARTER on  page 5-40.
1 Battery negative lead 1
2...

ENGINE REMOVAL
5-6
6 Crankshaft position sensor lead coupler 1 Disconnect.
7 Oil level switch connector 1 Disconnect.
8 Neutral switch connector 1 Disconnect.
9 Cylinder identification  sensor coupler 1 Disconnect.
10 Speed sensor coupler 1 Disconnect. For assembly, reverse the removal 
procedure.
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty Remarks 

ENGINE REMOVAL
5-7
Removing the engine
Order Job/Parts to remove Q’ty Remarks1 Right front engine mounting bolt 1 1
2 Left front engine mounting bolt 1
3 Upper self-locking nut 1
4 Upper engine mounting bolt 1
5 Lower self-locking nut 1
6 Lower engine mounting bolt 1
7 Engine mounting adjust bolt 2
8 Engine 1 For assembly, reverse the removal 
procedure. 

ENGINE REMOVAL
5-8
EAS23720
INSTALLING THE ENGINE
1. Install: Right front engine mounting bolt 2 “1”
Refer to CYLINDER HEAD on page 5-19.
2. Tighten:  Right front engine mounting bolt 2
3. Install:  Engine mounting adjust bolts(temporarily tighten)
4. Install:
 Engine
5. Install:  Lower engine mounting bolt “1”
 Upper engine mounting bolt “2”
 Self-locking nuts
NOTE:
Do not fully tighten the bolts and nuts.
6. Install: Left front engine mounting bolt “1”
(temporarily tighten)
 Right front...

ENGINE REMOVAL
5-9
8. Tighten: Lower self-locking nut “1”
 Upper self-locking nut “2”
NOTE:
First tighten the lower self-locking nut, and 
then tighten the upper self-locking nut.
9. Tighten: Left front engine mounting bolt ”1”
 Right front engine mounting bolt 1 ”2”
Upper self-locking nut51 Nm (5.1 m·kg, 37 ft·lb)
Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb)
Left front engine mounting bolt45 Nm (4.5 m·kg, 33 ft·lb)
Right front engine mounting 
bolt 1
45 Nm (4.5 m·kg, 33 ft·lb) 

CAMSHAFTS
5-10
EAS23760
CAMSHAFTS
Removing the cylinder head cover
Order Job/Parts to remove Q’ty RemarksFuel tank Refer to FUEL TANK on page 7-1.
Throttle body assembly Refer to THROTTLE BODIES on  page 7-4.
Radiator assembly Refer to RADIATOR on page 6-1.
Air cut-off valve Refer to AIR INDUCTION SYS- TEM on page 7-13.
1 Ignition coil 4
2 Spark plug 4
3 Cylinder head cover 1
4 Cylinder head cover gasket 1
5 Timing chain guide (top side) 1
6 Cylinder identification sensor 1
7O-ring 1 For assembly,...

CAMSHAFTS
5-11
Removing the camshafts
Order Job/Parts to remove Q’ty RemarksPickup rotor cover Refer to CRANKSHAFT POSITION  SENSOR on page 5-38.
1 Camshaft sprocket bolt 4 Loosen.
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Intake camshaft cap 3
5 Dowel pin 6 Refer to REMOVING THE CAM- SHAFTS on page 5-12.
6 Exhaust camshaft cap 3
7 Dowel pin 6 Refer to REMOVING THE CAM- SHAFTS on page 5-12.
8 Intake camshaft 1
9 Exhaust camshaft 1
10 Camshaft sprocket 2 For assembly, reverse the...

CAMSHAFTS
5-12
EAS23810
REMOVING THE CAMSHAFTS
1. Remove: Pickup rotor cover
Refer to CRANKSHAFT POSITION SEN-
SOR on page 5-38.
2. Align:
 “T” mark “a” on the pickup rotor(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark “a” on the 
pickup rotor with the crankcase mating sur-
face “b”.
NOTE:
TDC on the compression stroke can be found 
when the camshaft lobes are turned...