Yamaha Fz1n Service Manual
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CHASSIS 3-26 WARNING EWA13110 After bleeding the hydraulic brake system, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D1006 ADJUSTING THE SHIFT PEDAL 1. Adjust: Shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. b. Turn the shift rod “2” in direction “a” or “b” to obtain the correct shift pedal position. c. Tighten both locknuts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D1007 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: ECA13550 A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci- fied limits. 1. Stand the vehicle on a level surface. WARNING EW2D1005 Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Spin the rear wheel several times and find the tightest position of drive chain. 3. Check: Drive chain slack “a”Out of specification → Adjust. 4. Adjust: Drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut “1” b. Loosen both locknuts “2” c. Turn both adjusting bolts “3” in direction “a” or “b” until the specified drive chain slack is obtained. NOTE: To maintain the proper wheel alignment, adjust both sides evenly. Direction “a” Shift pedal is raised. Direction “b” Shift pedal is lowered. Drive chain slack 25–35 mm (0.98–1.38 in) Direction “a” Drive chain is tightened. Direction “b” Drive chain is loosened.
CHASSIS 3-27 d. Tighten both locknuts to specification. e. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D1008 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rub- ber O-rings between each side plate. Steam cleaning, high-pressure washing, certain sol- vents, and the use of a coarse brush can dam- age these O-rings. Therefore, use only kerosene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain sol- vents that could damage the O-rings. EAS21510 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: Steering headGrasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. 3. Remove: Upper bracket Refer to STEERING HEAD on page 4-57. 4. Adjust: Steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. b. Loosen the lower ring nut “4” and then tighten it to specification with a steering nut wrench “5”. NOTE: Set the torque wrench at a right angle to the steering nut wrench. c. Loosen the lower ring nut “4” completely, and then tighten it to specification. WARNING EWA13140 Do not overtighten the lower ring nut. Locknut 16 Nm (1.6 m·kg, 12 ft·lb) Wheel axle nut150 Nm (15 m·kg, 108 ft·lb) Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains Steering nut wrench90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque)52 Nm (5.2 m·kg, 38 ft·lb) Lower ring nut (final tightening torque)18 Nm (1.8 m·kg, 13 ft·lb)
CHASSIS 3-28 d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD on page 4-57. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer “1”. NOTE: Make sure the lock washer tabs “a” sit correctly in the ring nut slots “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: Upper bracketRefer to STEERING HEAD on page 4-57. 6. Measure: Steering head tension ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Make sure all of the cables and wires are prop- erly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie “1” loosely around the end of the handlebar as shown. c. Hook a spring gauge “2” onto the plastic locking tie. d. Hold the spring gauge at a 90 ° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run. e. Repeat the above procedure on the oppo- site handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. Steering head tension 200–500 g
CHASSIS 3-29 WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube “1”Damage/scratches → Replace. Oil seal “2” Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to FRONT FORK on page 4-48. EAS21580 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. NOTE: Each front fork leg is equipped with a spring preload adjusting bolt, the right front fork leg is equipped with a reboumd damping force adjusting screw and left front fork leg with a compression damping force adjusting screw. WARNING EWA13150 Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: ECA13570 Grooves are provided to indicate the adjustment position. Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). Spring preload adjusting posi- tionsMinimum 8 Standard 6 Maximum 0
CHASSIS 3-30 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping (Right side front fork) CAUTION: EC2D1006 Never go beyond the maximum or mini-mum adjustment positions. When assembling the front forks, be care- ful not to assemble them to the opposite position because there are two kinds of forks (for the rebound side and for the compression side). 1. Adjust: Rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping (Left side front fork) CAUTION: ECA13590 Never go beyond the maximum or mini-mum adjustment positions. When assembling the front forks, be care- ful not to assemble them to the opposite position because there are two kinds of forks (for the rebound side and for the compression side). 1. Adjust: Compression damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” (turn in) Rebound damping is increased (suspension is harder). Direction “b” (turn out) Rebound damping is decreased (suspension is softer). Rebound damping adjusting positions Minimum 26 clicks in direction: “b”* Standard 15 clicks in direction: “b”* Maximum 1 clicks in direction: “b”* * With the adjusting screw fully turned-in direction “a” Direction “a” (turn in) Compression damping is increased (suspension is harder). Direction “b” (turn out) Compression damping is decreased (suspension is softer). Compression damping adjusting positionsMinimum 26 clicks in direction: “b”* Standard 5 clicks in direction: “b”* Maximum 1 clicks in direction: “b”* * With the adjusting screw fully turned-in direction “a”
CHASSIS 3-31 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21620 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. b. Turn the adjusting ring “1” in direction “a” or “b”. c. Align the desired position on the adjusting ring with the stopper “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Rebound damping CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). Spring preload adjusting posi- tionsMinimum 1 Standard 3 Maximum 7 Direction “a” Rebound damping is increased (suspension is harder). Direction “b” Rebound damping is decreased (suspension is softer). Rebound damping adjusting position Minimum12 clicks in direction: “b”* Standard 6 clicks in direction: “b”* Maximum 1 clicks in direction: “b”* * With the adjusting screw fully turned-in direction “a”
CHASSIS 3-32 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: Tire pressureOut of specification → Regulate. WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. WARNING EWA13190 It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: Tire surfacesDamage/wear → Replace the tire. Tire air pressure (measured on cold tires): Basic weight (with oil and a full fuel tank) FZ1-N 214kg (472lb) FZ1-S 220kg (485lb) Loading condition* 0–90 kg (0–198 lb) Front 250 kPa (2.5 kg/cm 2, 2.5 bar, 36 psi) Rear 290 kPa (2.9 kg/cm 2, 2.9 bar, 42 psi) Loading condition* FZ1-N 90–196 kg (198–432 lb) FZ1-S 90–190 kg (198–419 lb) Front 250 kPa (2.5 kg/cm 2, 2.5 bar, 36 psi) Rear 290 kPa (2.9 kg/cm 2, 2.9 bar, 42 psi) High speed riding: Front 250 kPa (2.5 kg/cm 2, 2.5 bar, 36 psi) Rear 290 kPa (2.9 kg/cm 2, 2.9 bar, 42 psi) Maximum load* FZ1-N 196 kg (432 lb) FZ1-S 190 kg (419 lb) * Total weight of rider, passenger, cargo and accessories.
CHASSIS 3-33 WARNING EWA14080 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. WARNING EWA14090 After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark “1”: Install the tire with the mark pointing in the direction of wheel rotation. Align the mark “2” with the valve installation point. 1. Tire tread depth 2. Side wall 3. Wear indicator Minimum tire tread depth 1.6 mm (0.06 in) A. Tire B. Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Front tire Size120/70 ZR17 M/C (58W) Manufacturer/model DUNLOP/D221FA MICHELIN/PILOT ROAD S Rear tire Size190/50 ZR17 M/C (73W) Manufacturer/model DUNLOP/D221G MICHELIN/PILOT ROAD D
CHASSIS 3-34 EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: WheelDamage/out-of-round → Replace. WARNING EWA13260 Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: Outer cable Damage → Replace. 2. Check: Cable operation Rough movement → Lubricate. NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21730 LUBRICATING THE CENTERSTAND (FZ1-S) Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Engine oil or a suitable cable lubricant Recommended lubricantLithium - soap - based grease Recommended lubricantLithium - soap - based grease Recommended lubricantLithium - soap - based grease Recommended lubricantLithium - soap - based grease Recommended lubricantMolybdenum disulfide grease
ELECTRICAL SYSTEM 3-35 EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to ELECTRICAL COMPONENTS on page 8-89. EAS21770 CHECKING THE FUSES Refer to ELECTRICAL COMPONENTS on page 8-89. EAS21780 REPLACING THE HEADLIGHT BULBS 1. Remove: Headlight side cover bolts “1” (FZ1-N) 2. Disconnect: Headlight sub-wire harness coupler “2” (FZ1-N) 3. Disconnect: Headlight coupler “1” 4. Remove: Headlight bulb cover “1” (FZ1-S) 5. Remove: Headlight bulb holder “1” 6. Remove: Headlight bulb “1” A. FZ1-N B. FZ1-S A. FZ1-N B. FZ1-S