Yamaha Fz1n Service Manual

CLUTCH
5-53
10. Install:Pull lever
NOTE:
Install the pull lever with the “O“ mark facing 
toward lower side.
11. Install:Clutch cover
 Clutch cover gasket 
NOTE:
 Install the pull rod so that the teeth a face towards the rear of the vehicle. Then, install 
the clutch cover.
 Apply oil onto the bearing.
 Apply molybdenum disulfide grease onto the  pull rod.
 When installing the clutch cover, push the  pull lever and check that the punch mark “a” 
on the pull lever aligns with the mark “b” on 
the...

SHIFT SHAFT
5-54
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty RemarksClutch assembly Refer to CLUTCH on page 5-44.
Shift arm and shift rod Refer to ENGINE REMOVAL on  page 5-2.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4Collar 1
5 Shift shaft spring 1
6 Washer 1
7 Stopper screw 1
8 Stopper lever 1
9 Washer 1
10 Oil seal 1
11 Bearing 1
12 Bearing 1
13 Stopper lever spring 1 

SHIFT SHAFT
5-55
For installation, reverse the removal 
procedure.
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks 

SHIFT SHAFT
5-56
ET2D1011
REMOVING THE SHIFT SHAFT
1. Remove: Clutch assembly
Refetr to CLUTCH on page 5-44
2. Remove:  Shift arm
 Shift rod
Refetr to ENGINE REMOVAL on page 5-
2
3. Remove:  Circlip “1”
 Washer “2”(left side of the engine)
4. Remove  Shift shaft “1”
 Shift shaft spring “2”
Collar
 Washer
5. Remove:  Stopper lever spring “1”
 Stopper screw “2”
 Stopper lever “3”
 Washer
EAS25420
CHECKING THE SHIFT SHAFT
1. Check: Shift shaft “1”
Bends/damage/wear  → Replace.
 Shift shaft...

SHIFT SHAFT
5-57
 Stopper lever spring “3”
2. Install:  Washer
Collar
 Shift shaft spring “1”
 Shift shaft “2”
NOTE:
 Mesh the stopper lever with the shift drum segment assembly.
 Lubricate the oil seal lips with lithium soap  base grease.
 Install the end of the shift shaft spring onto 
the shift shaft spring stopper.
3. Install:  Washer “1”
 Circlip “2” 
4. Install:  Shift rod
 Shift arm
Refer to ENGINE REMOVAL on page 5-
2.
5. Install:
 Clutch assemblyRefer to CLUTCH on page 5-44. 

OIL PUMP
5-58
EAS24920
OIL PUMP
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE 
OIL on page 3-12.
EXUP cables Refer to ENGINE REMOVAL on  page 5-2.
O
2 sensor Refer to ENGINE REMOVAL on  page 5-2.
Muffler Refer to ENGINE REMOVAL on  page 5-2.
Exhaust pipe assembly Refer to ENGINE REMOVAL on  page 5-2.
Clutch assembly Refer to CLUTCH on page 5-44.
Water pump inlet pipe Refer to OIL COOLER on page 6- 4.
Water pump outlet pipe Refer to...

OIL PUMP
5-59
2 Oil level switch 1
3 Oil level switch lead holder 1
4Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2
7Drain pipe 1
8Oil strainer 1
9 Oil pipe 1
10 Oil delivery pipe 1
11 Relief valve assembly 1
12 Oil/water pump assembly drive chain  guide 1
13 Collar 1
14 Oil/water pump assembly drive  sprocket 1
15 Washer 1
16 Oil/water pump assembly drive chain 1
17 Dowel pin 1
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks 

OIL PUMP
5-60
18 Oil/water pump assembly 1For assembly, reverse the removal 
procedure.
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks 

OIL PUMP
5-61
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks1 Oil/water pump driven sprocket 1
2Collar 1
3 Oil pump housing 1
4 Bearing 1
5Pin 2
6 Oil pump outer roter 1
7 Oil pump inner roter 1
8Pin 1 For assembly, reverse the disassem-
bly procedure. 

OIL PUMP
5-62
EAS24930
REMOVING THE OIL PAN
1. Remove: Oil level switch “1”
 Oil pan “2”
 Oil pan gasket
 Dowel pins
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.
ET2D1012
CHECKING THE SPROCKET AND CHAIN
1. Check:
 Oil/water pump assembly drive sprocket “1”Cracks/damage/wear  → Replace the 
defective part(-s).
2. Check:  Oil/water pump assembly drive chain “1”Damag/stiffness  → Replace the oil/water...