Yamaha Fz1n Service Manual
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ELECTRICAL SYSTEM 3-36 WARNING EWA13320 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 7. Install: Headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: ECA13690 Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 8. Install: Headlight bulb holder 9. Install: Headlight bulb cover 10. Connect: Headlight coupler 11. Connect: Headlight assembly coupler 12. Install: Headlight assembly bolts EAS21800 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. A. FZ1-N B. FZ1-S Direction “a”Headlight beam is raised. Direction “b” Headlight beam is lowered. A. FZ1-N B. FZ1-S Direction “a”Headlight beam moves to the left. Direction “b” Headlight beam moves to the right.
ELECTRICAL SYSTEM 3-37 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. FZ1-N B. FZ1-S
4 CHASSIS GENERAL CHASSIS.................................................................................... 4-1 REMOVING THE COVER....................................................................... 4-7 INSTALLING THE COVER ..................................................................... 4-7 FRONT WHEEL ............................................................................................ 4-8 REMOVING THE FRONT WHEEL ....................................................... 4-10 CHECKING THE FRONT WHEEL........................................................ 4-10 ADJUSTING THE FRONT WHEEL STATIC BALANCE ....................... 4-11 INSTALLING THE FRONT WHEEL (DISC) .......................................... 4-12 REAR WHEEL ............................................................................................ 4-14 REMOVING THE REAR WHEEL (DISC) ............................................. 4-17 CHECKING THE REAR WHEEL .......................................................... 4-17 CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-17 CHECKING AND REPLACING THE R EAR WHEEL SPROCKET ....... 4-18 ADJUSTING THE REAR WHEEL STATIC BALANCE .......................... 4-18 INSTALLING THE REAR WHEEL (DISC) ............................................ 4-18 FRONT BRAKE .......................................................................................... 4-20 INTRODUCTION .................................................................................. 4-25 CHECKING THE FRONT BRAKE DISCS ............................................ 4-25 REPLACING THE FRONT BR AKE PADS ............................................ 4-26 REMOVING THE FRONT BRAKE CALIPERS ..................................... 4-27 DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-27 CHECKING THE FRONT BRAKE CALIPERS ..................................... 4-28 ASSEMBLING THE FRONT BR AKE CALIPERS ................................. 4-28 INSTALLING THE FRONT BR AKE CALIPERS .................................... 4-28 REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-29 CHECKING THE FRONT BRAKE M ASTER CYLINDER ..................... 4-30 ASSEMBLING THE FRONT BRAKE M ASTER CYLINDER................. 4-30 INSTALLING THE FRONT BRAKE MASTER CYLINDER ................... 4-30 REAR BRAKE ............................................................................................ 4-32 INTRODUCTION .................................................................................. 4-37 CHECKING THE REAR BRAKE DISC ................................................. 4-37 REPLACING THE REAR BR AKE PADS .............................................. 4-37 REMOVING THE REAR BRAKE CALIPER.......................................... 4-38 DISASSEMBLING THE REAR BR AKE CALIPER................................ 4-38 CHECKING THE REAR BRAKE CALIPER .......................................... 4-39 ASSEMBLING THE REAR BR AKE CALIPER...................................... 4-39 INSTALLING THE REAR BR AKE CALIPER ........................................ 4-40 REMOVING THE REAR BRAKE M ASTER CYLINDER ....................... 4-41 CHECKING THE REAR BRAKE MASTER CYLINDER ....................... 4-41 ASSEMBLING THE REAR BRAKE MA STER CYLINDER ................... 4-41 INSTALLING THE REAR BRAKE MASTER CYLINDER ...................... 4-41 HANDLEBAR .............................................................................................. 4-43
REMOVING THE HANDLEBAR .................................... ....................... 4-45 CHECKING THE HANDLEBAR............................................................ 4-45 INSTALLING THE HANDLEBAR .......................................................... 4-45 FRONT FORK ............................................................................................. 4-48 REMOVING THE FRONT FORK LEGS ............................................... 4-50 DISASSEMBLING THE FRONT FORK LEGS ..................................... 4-50 CHECKING THE FRONT FORK LEGS ................................................ 4-51 ASSEMBLING THE FRONT FO RK LEGS ........................................... 4-52 INSTALLING THE FRONT FORK LEGS .............................................. 4-56 STEERING HEAD ....................................................................................... 4-57 REMOVING THE LOWER BRACKET .................................................. 4-59 CHECKING THE STEERING HEAD .................................................... 4-59 INSTALLING THE STEERING HEAD................................................... 4-60 REAR SHOCK ABSORBER ASSEMBLY .................................................. 4-61 HANDLING THE REAR SHOC K ABSORBER ..................................... 4-63 DISPOSING OF A REAR SHOCK ABSORBER................................... 4-63 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................. 4-63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-63 CHECKING THE CONNECTING ARM AND RELAY ARM .................. 4-64 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ............... 4-64 SWINGARM ................................................................................................ 4-65 REMOVING THE SWINGARM ............................................................. 4-67 CHECKING THE SWINGARM ............................................................. 4-67 INSTALLING THE SWINGARM ............................................................ 4-68 CHAIN DRIVE ............................................................................................. 4-69 REMOVING THE DRIVE CHAIN .......................................................... 4-70 CHECKING THE DRIVE CHAIN .......................................................... 4-70 CHECKING THE DRIVE SPROCKET .................................................. 4-71 CHECKING THE REAR WHEEL SPROCKET ..................................... 4-71 CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-71 INSTALLING THE DRIVE CHAIN ......................................................... 4-71
GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks1 Passenger seat 1 2 Rider seat 1 3 Battery band 1 4 Battery cover 1 5 Battery negative lead 1 6 Battery positive lead 1 7 Battery 1 8 Battery seat 1 For installation, reverse the removal procedure.
GENERAL CHASSIS 4-2 Removing the headlight and meter assembly (FZ1-N) Order Job/Parts to remove Q’ty Remarks1 Headlight side cover bolt (left and right) 4 2 Headlight coupler 1 Disconnect. 3 Headlight sub-wire har ness coupler 1 Disconnect. 4 Headlight assembly 1 5 Headlight bracket 2 6 Headlight side cover (left and right) 2 7 Meter cover 1 8 Meter coupler 1 9 Meter assembly 1 10 Headlight and meter stay 1 For installation, reverse the removal procedure.
GENERAL CHASSIS 4-3 Removing the front cowling (FZ1-S) Order Job/Parts to remove Q’ty Remarks1 Inner panel 2 2 Headlight assembly coupler 1 Disconnect. 3 Meter coupler 1 Disconnect. 4 Front cowling assembly 1 5 Rear view mirror 2 6 Cowling stay 1 7 Meter assembly 1 8 Headlight unit 1 For installation, reverse the removal procedure.
GENERAL CHASSIS 4-4 Removing the rear fender (FZ1-N) Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on page 4-1. 1 Licence plate light lead coupler 1 Disconnect. 2 Turn signal light l ead coupler 1 Disconnect. 3 Mud guard assembly 1 4 Rear fender 1 5 Tail/brake light le ad coupler 1 Disconnect. 6Tail cover 1 7 Rear fender bracket 1 8 Tail/brake light 1 For installation, reverse the removal procedure.
GENERAL CHASSIS 4-5 Removing the rear fender (FZ1-S) Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on page 4-1. 1 Licence plate light lead coupler 1 Disconnect. 2 Turn signal light lead coupler 1 Disconnect. 3 Mud guard assembly 1 4 Rear fender 1 5 Tail/brake light lead coupler 1 Disconnect. 6 Tail/brake light cover 1 7 Rear fender side cover (left and right) 2 8 Rear fender bracket 1 9 Tail/brake light 1 10 Tail cover 1 For installation, reverse the removal procedure.