Yamaha Fz1n Service Manual
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REAR WHEEL 4-16 Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks1Coller 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly, reverse the disassem- bly procedure.
REAR WHEEL 4-17 EAS22040 REMOVING THE REAR WHEEL (DISC) 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 rear wheel is elevated. 2. Remove: Brake caliper “1” NOTE: Do not depress the brake pedal when remov- ing the brake caliper. 3. Loosen: Locknut “1” Adjusting bolt “2” 4. Remove: Wheel axle nut “1” Wheel axle “2” Rear wheel NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket. 5. Remove: Left collar “1” Rear wheel drive hub “2” Rear wheel drive hub damper Right collar EAS22090 CHECKING THE REAR WHEEL 1. Check: Wheel axle Rear wheel Wheel bearings Oil sealsRefer to FRONT WHEEL on page 4-8. 2. Check: Tire Rear wheelDamage/wear → Replace. Refer to CHECKING THE TIRES on page 3-32 and CHECKING THE WHEELS on page 3-34. 3. Measure: Radial wheel runout Lateral wheel runout Refer to FRONT WHEEL on page 4-8. EAS22110 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: Rear wheel drive hub “1”Cracks/damage → Replace. Rear wheel drive hub dampers “2”
REAR WHEEL 4-18 Damage/wear → Replace. EAS22120 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: Rear wheel sprocketMore than 1/4 tooth “a” wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket. 2. Replace: Rear wheel sprocket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: Rear wheel static balanceRefer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4-11. EAS22160 INSTALLING THE REAR WHEEL (DISC) 1. Lubricate: Wheel axle Wheel bearings Oil seal lips 2. Adjust: Drive chain slackRefer to ADJUSTING THE DRIVE CHAIN SLACK on page 3-26. 3. Tighten: Wheel axle nut Brake caliper bolts b. Correct 1. Drive chain roller 2. Rear wheel sprocket Rear wheel sprocket self-lock- ing nut 100 Nm (10 m·kg, 72 ft·lb) Recommended lubricantLithium-soap-based grease Drive chain slack25–35 mm (0.98–1.38 in) Wheel axle nut150 Nm (15 m·kg, 108 ft·lb) Brake caliper bolt (front) 27 Nm (2.7 m·kg, 20 ft·lb) Brake caliper bolt (rear) 22 Nm (2.2 m·kg, 16 ft·lb)
REAR WHEEL 4-19 WARNING EWA13500 Make sure the brake hose is routed prop- erly.
FRONT BRAKE 4-20 EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6Brake pad 2 7 Bleed screw 1 For installation, reverse the removal procedure.
FRONT BRAKE 4-21 Removing the front brake master cylinder Order Job/Parts to remove Q’ty RemarksBrake fluid Drain. Refer to BLEEDING THE HYDRAU- LIC BRAKE SYSTEM on page 3- 25. 1 Right rearview mirror (FZ1-N) 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir dia- phragm holder 1 4 Brake master cylinder diaphragm 1 5Brake lever 1 6 Front brake light switch lead coupler 1 Disconnect. 7 Front brake light switch 1 8 Union bolt 1 9 Copper washer 2 10 Master cylinder bracket 1 11 Master cylinder assembly 1 For assembly, reverse the disassem- bly procedure.
FRONT BRAKE 4-22 Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly, reverse the disassem- bly procedure.
FRONT BRAKE 4-23 Removing the front brake calipers Order Job/Parts to remove Q’ty RemarksBrake fluid Drain. Refer to BLEEDING THE HYDRAU- LIC BRAKE SYSTEM on page 3- 25. 1 Union bolt 1 2 Copper washer 2 3Brake hose 1 4 Brake caliper 1 For installation, reverse the removal procedure.
FRONT BRAKE 4-24 Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly, reverse the disassem- bly procedure.
FRONT BRAKE 4-25 EAS22220 INTRODUCTION WARNING EWA14100 Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. Avoid brake fluid coming into contact with the eyes as it can cause serious injury. FIRST AID FOR BRAKE FLUID ENTERING THE EYES: Flush with water for 15 minutes and get immediate medical attention. EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs. 1. Remove: Front wheelRefer to FRONT WHEEL on page 4-8. 2. Check: Brake discDamage/galling → Replace. 3. Measure: Brake disc deflectionOut of specification → Correct the brake disc deflection or replace the brake disc. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the vehicle on a suitable stand so that the front wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is sta- tionary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection 1.5 mm (0.06 in) below the edge of the brake disc. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Measure: Brake disc thicknessMeasure the brake disc thickness at a few different locations. Out of specification → Replace. 5. Adjust: Brake disc deflection ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. Brake disc deflection limit0.1 mm (0.004 in) Brake disc thickness limit4.0 mm (0.16 in)