Yamaha Fz1n Service Manual

TRANSMISSION
5-93
4. Check: TransmissionRough movement  → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly. 

6
COOLING SYSTEM
RADIATOR.................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................. 6-3
INSTALLING THE RADIATOR ................................................................ 6-3
OIL COOLER ................................................................................................ 6-4
CHECKING THE OIL...

RADIATOR
6-1
EAS26380
RADIATOR
Removing the radiator
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on  page 4-1.
Coolant Drain. Refer to CHANGING THE COOL-
ANT on page 3-19.
1 Radiator side covers 2
2 Coolant reservoir hose 1
3 Radiator front cover 1
4 Radiator 1
5 Radiator fan motor 2
6 Radiator inlet hose 1
7 Oil cooler outlet hose 1
8 Water pump breather hose 1
9...

RADIATOR
6-2
10 Water pump inlet pipe 1
11 O-ring 1For installation, reverse the removal 
procedure.
Removing the radiator
Order Job/Parts to remove Q’ty Remarks 

RADIATOR
6-3
EAS26390
CHECKING THE RADIATOR
1. Check: Radiator fins
Obstruction  → Clean.
Apply compressed air to the rear of the 
radiator.
Damage  → Repair or replace.
NOTE:
Straighten any flattened  fins with a thin, flat-
head screwdriver.
2. Check:
 Radiator hoses
 Radiator pipes
Cracks/damage  → Replace.
3. Measure:
 Radiator cap opening pressureBelow the specified pressure  → Replace 
the radiator cap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radia-
tor cap...

OIL COOLER
6-4
EAS26410
OIL COOLER
Removing the oil cooler
Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE 
OIL on page 3-12.
1 Oil cooler inlet hose 1
2 Oil cooler bolt 1
3 Washer 1
4 Oil cooler 1
5O-ring 1
6 Water pump outlet pipe 1
7O-ring 1
8 Water jacket joint inlet hose 1
9O-ring 1
10 Water jacket joint 1
11 Stay 1
12 O-ring 1 For assembly, reverse the removal 
procedure. 

OIL COOLER
6-5
EAS26420
CHECKING THE OIL COOLER
1. Check: Oil cooler
Cracks/damage  → Replace.
2. Check:  Oil cooler inlet hose
 Oil cooler outlet hoseCracks/damage/wear  → Replace.
EAS26430
INSTALLING THE OIL COOLER
1. Clean:
 Mating surfaces of the oil cooler and the 
crankcase
(with a cloth dampened with lacquer thin-
ner)
2. Install:
 O-ring 
 Oil cooler “1”
 Washer “2” 
 Oil cooler bolt “3”
NOTE:
 Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat...

THERMOSTAT
6-6
EAS26440
THERMOSTAT
Removing the thermostat assembly
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on  page 4-1.
Coolant Drain. Refer to CHANGING THE COOL-
ANT on page 3-19.
1 Thermostat assembly outlet hose 1
2 Thermostat assembly 1
3 Thermostat assembly inlet hose 1
4 Band 2 For installation, reverse the removal 
procedure. 

THERMOSTAT
6-7
Disassembling the thermostat assembly
Order Job/Parts to remove Q’ty Remarks1 Thermostat housing cover 1
2 Thermostat 1
3 Thermostat housing 1
4O-ring 1 For assembly, reverse the disassem-
bly procedure. 

THERMOSTAT
6-8
EAS26450
CHECKING THE THERMOSTAT
1. Check: Thermostat
Does not open at 71 – 85 °C (160 – 185 °F) 
→  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “3” in a container 
“4” filled with water.
b. Slowly heat the water “2”.
c. Place a thermometer “1” in the water.
d. While stirring the water, observe the ther- mostat and thermometer’s indicated tem-
perature.
NOTE:
If the accuracy of the thermostat is in doubt, 
replace it. A faulty thermostat could cause seri-
ous...