Yamaha Fz1n Service Manual

ELECTRIC STARTER
5-43
7. Check: Gear teethDamage/wear  → Replace the gear.
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
Brush seat “1”
NOTE:
Align the tab “a” on the brush seat with the tab 
“b” in the starter motor rear cover.
2. Install: Armature “1”
3. Install:  Starter motor yoke “1”
 O-rings “2” 
 Starter motor rear cover “3”
 Starter motor assembling bolts
NOTE:
Align the match marks “a” on the starter motor 
yoke with the match marks “b” on the front and 
starter motor rear covers....

CLUTCH
5-44
EAS25060
CLUTCH
Removing the clutch cover
Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE 
OIL on page 3-12.
1Clutch cable 1
2Clutch cover 1
3 Clutch cover gasket 1
4 Dowel pin 2
5 Oil filler cap 1 For installation, reverse the removal 
procedure. 

CLUTCH
5-45
Removing the pull lever shaft
Order Job/Parts to remove Q’ty Remarks1 Circlip 2
2Pull lever 1
3Pull lever spring 1
4 Pull lever shaft 1
5 Oil seal 1
6 Bearing 2 For installation, reverse the removal 
procedure. 

CLUTCH
5-46
Removing the clutch
Order Job/Parts to remove Q’ty Remarks1 Compression spring 6
2 Pressure plate 1
3Pull rod 1
4 Bearing 1
5 Friction plate 1 1
6 Clutch plate 1 7
7 Friction plate 2 7
8 Wire circlip 1
9 Clutch plate 2 1
10 Friction plate 3 1
11 Clutch damper spring 1
12 Clutch damper spring seat 1
13 Clutch boss nut 1
14 Washer 1
15 Clutch boss assembly 1
16 Thrust plate 1
17 Clutch housing 1
18 Bearing 1 

CLUTCH
5-47
For assembly, reverse the removal 
procedure.
Removing the clutch
Order Job/Parts to remove Q’ty Remarks 

CLUTCH
5-48
EAS25080
REMOVING THE CLUTCH
1. Remove: Clutch cover “1”
Gasket
NOTE:
Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove 
them.
2. Remove:
 Compression spring bolts “1”
 Compression springs
 Pressure plate “2”
 Pull rod “3”
3. Remove:  Friction plate 1 “1” 4. Remove:
 Clutch plate 1 “1”
 Friction plate 2
5. Straighten the clutch boss nut rib “1”.
6. Loosen:  Clutch boss nut “1”
NOTE:
While holding the...

CLUTCH
5-49
 Thrust plate
8. Remove:
 Wire circlip “1”
NOTE:
There is a built-in damper between the clutch 
boss and the clutch plate. It is not necessary to 
remove the wire circlip “1” and disassemble the 
built-in damper unless there is serious clutch 
chattering.
9. Remove: Clutch plate 2 “1”
 Friction plate 3 “2”
10. Remove:  Clutch damper spring “1”
 Clutch damper spring seat “2”
ET2D1010
CHECKING THE FRICTION PLATES
The following procedure applies to all of the 
friction plates. 1. Check:
...

CLUTCH
5-50
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the 
clutch springs.
1. Check: Clutch springDamage  → Replace the clutch springs as a 
set.
2. Measure:  Clutch spring free length “a”
Out of specification  → Replace the clutch 
springs as a set.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:  Clutch housing dogsDamage/pitting/wear  → Deburr the clutch 
housing dogs or replace the clutch hous-
ing.
NOTE:
Pitting on the clutch  housing dogs will cause 
erratic...

CLUTCH
5-51
 Pull lever shaft pinion gear teeth “1”
 Pull rod teeth “2”Damage/wear  → Replace the pull rod and 
pull lever shaft pinion gear as a set.
2. Check:  Pull rod bearingDamage/wear  → Replace.
EAS25240
INSTALLING THE CLUTCH
1. Install:
 Clutch damper spring seat “1”
 Clutch damper spring “2”
2. Install:  Friction plate 3 “1”
 Clutch plate 2 “2”
NOTE:
Lubricate the engine oil. 3. Install:
 Wire circlip “1”
4. Install:  Clutch housing “1”
NOTE:
Align the projection of clutch housing “a”...

CLUTCH
5-52
 Lock the threads on the clutch boss nut by staking them with a drift punch at the point 
aligned with the groove in the axle.
 While holding the clutch boss assembly “1”  with the clutch holding tool “3”, tighten the 
clutch boss nut.
6. Lubricate  Friction plates
 Clutch plates(with the recommended lubricant)
7. Install:  Friction plate 2
 Clutch plate 1 “1” 8. Install:
 Friction plate 1 “1”
NOTE:
Install the last friction plate shifting half phase.
9. Install: Bearing
 Pull rod...