Yamaha Fz1n Service Manual

							
FRONT BRAKE
4-26
NOTE:
Tighten the brake disc bolts in stages and in a 
crisscross pattern.
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust-ment steps until the br ake disc deflection is 
within specification.
f. If the brake disc deflection cannot be  brought within specification, replace the 
brake disc.
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6. Install: Front wheelRefer to FRONT WHEEL on page 4-8.
EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake 
calipers.
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Measure:  Brake pad wear limit “a”
Out of specification  → Replace the brake 
pads as a set. 2. Install:
 Brake pads
 Brake pad spring
NOTE:
Always install new brake pads and a brake pad 
spring as a set.
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a. Connect a clear plastic hose “1” tightly to  the bleed screw “2”. Put the other end of 
the hose into an open container.
b. Loosen the bleed screw and push the  brake caliper pistons into the brake caliper 
with your finger.
c. Tighten the bleed screw.
d. Install new brake pads and a new brake  pad spring.
Brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
Brake pad lining thickness 
(inner)4.5 mm (0.18 in)
Limit 0.5 mm (0.02 in)
Brake pad lining thickness 
(outer)
4.5 mm (0.18 in)
Limit
0.5 mm (0.02 in)
Bleed screw5 Nm (0.5 m·kg, 3.6 ft·lb) 
						

							
FRONT BRAKE
4-27
NOTE:
The arrow mark “a” on the brake pad spring 
must point in the direction of disc rotation.
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3. Install: Brake pad pins
 Brake pad clips
 Brake caliper
4. Check:  Brake fluid levelBelow the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
5. Check:  Brake lever operation
Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
NOTE:
Before removing the brake caliper, drain the 
brake fluid from the entire brake system.
1. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hose “3”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22360
DISASSEMBLING THE FRONT BRAKE 
CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Remove:
 Brake caliper pistons “1”
 Brake caliper piston seals “2”
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a. Secure the brake caliper pistons with a  piece of wood “a”.
b. Blow compressed air into the brake hose  joint opening “b” to force out the left side 
pistons from the brake caliper.
WARNING
EWA13570
 Never try to pry out the brake caliper pis-
tons.
 Do not loosen the bolts “3”.
Brake caliper bolt40 Nm (4.0 m·kg, 29 ft·lb) 
						

							
FRONT BRAKE
4-28
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the right side pistons from the brake caliper.
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EAS22390
CHECKING THE FRONT BRAKE CALIPERS
1. Check: Brake caliper pistons “1”Rust/scratches/wear  → Replace the brake 
caliper pistons.
 Brake caliper cylinders “2” Scratches/wear  → Replace the brake cali-
per assembly.
 Brake caliper body “3” Cracks/damage  → Replace the brake cali-
per assembly.
 Brake fluid delivery passages (brake caliper body)
Obstruction  → Blow out with compressed 
air.
WARNING
EWA13600
Whenever a brake caliper is disassembled, 
replace the piston seals.
EAS22410
ASSEMBLING THE FRONT BRAKE CALI-
PERS
WARNING
EWA13620
 Before installation, all internal brake com- ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake  components as they will cause the piston 
seals to swell and distort.
 Whenever a brake caliper is disassem- bled, replace the brake caliper piston 
seals.
EAS22440
INSTALLING THE FRONT BRAKE CALI-
PERS
The following procedure applies to both of the 
brake calipers.
1. Install: Brake caliper “1”
(temporarily)
 Copper washers 
Brake hose “2”
 Union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Brake fluid Every two years and  whenever the brake is 
disassembled
Recommended brake fluidDOT4
Brake hose union bolt30 Nm (3.0 m·kg, 22 ft·lb) 
						

							
FRONT BRAKE
4-29
“a” touches the projection “b” on the brake 
caliper.
2. Remove: Brake caliper
3. Install:  Brake pads
 Brake pad spring
 Brake pad pin
 Brake pad clips
 Brake caliper
 Brake hose holder
Refer to REPLACING THE FRONT 
BRAKE PADS on page 4-26.
4. Fill:
 Brake master cylinder reservoir(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13090
 Use only the designated brake fluid. Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid  that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does  not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
5. Bleed: Brake systemRefer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
6. Check:  Brake fluid level
Below the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
7. Check:  Brake lever operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
EAS22490
REMOVING THE FRONT BRAKE MASTER 
CYLINDER
NOTE:
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake 
system.
1. Disconnect:  Brake switch couplers “1”(from the brake switch)
Brake caliper bolt40 Nm (4.0 m·kg, 29 ft·lb)
Brake hose holder bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
Recommended fluidDOT4 
						

							
FRONT BRAKE
4-30
2. Remove: Union bolt “1”
 Copper washers “2”
Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
EAS22500
CHECKING THE FRONT BRAKE MASTER 
CYLINDER
1. Check: Brake master cylinder
Damage/scratches/wear  → Replace.
 Brake fluid delivery passages (brake master cylinder body)
Obstruction  → Blow out with compressed 
air.
2. Check:
 Brake master cylinder kitDamage/scratches/wear  → Replace.
3. Check:
 Brake master cylinder reservoirCracks/damage  → Replace.
 Brake master cylinder reservoir diaphragm
Damage/wear  → Replace.
4. Check: Brake hoses
Cracks/damage/wear  → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
WARNING
EWA13520
 Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake 
components.
EAS22530
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1. Install:  Brake master cylinder “1”
 Brake master cylinder bracket “2”
NOTE:
 Install the brake master cylinder holder with the “UP” mark “a” facing up.
 Align the end of the brake master cylinder  holder with the punch mark “b” on the han-
dlebar.
 First, tighten the upper bolt, then the lower  bolt.
 There should be more than 11 mm (0.43 in) 
for clearance between the right handlebar 
switch and the brake master cylinder bracket.
Also, the punch mark should be seen.
2. Install:  Copper washers 
Brake hose
 Union bolt
Recommended fluidDOT4
Brake master cylinder bracket 
bolt10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							
FRONT BRAKE
4-31
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
NOTE:
 While holding the brake hose, tighten the union bolt as shown.
 Turn the handlebar to the left and right to  make sure the brake hose does not touch 
other parts (e.g., wire harness, cables, 
leads). Correct if necessary.
CAUTION:
EC2D1004
Attach the brake hose so that its angle is 
23 ° to 33 ° against the straight line in paral-
lel with the ceiling plane of the master cyl-
inder.
3. Fill:  Brake master cylinder reservoir(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13540
 Use only the designated brake fluid. Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid 
that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.  When refilling, be careful that water does 
not enter the brake master cylinder reser-
voir. Water will significantly lower the 
boiling point of the brake fluid and could 
cause vapor lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
4. Bleed:
 Brake systemRefer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
5. Check:  Brake fluid levelBelow the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
6. Check:  Brake lever operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
Brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb)
Recommended fluidDOT4 
						

							
REAR BRAKE
4-32
EAS22550
REAR BRAKE
Removing the rear brake pads
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Rear brake caliper 1
4 Brake pad shim 4
5Brake pad 2
6 Bleed screw 1
7 Brake pad spring 1 For installation, reverse the removal 
procedure. 
						

							
REAR BRAKE
4-33
Removing the rear 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 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir tank 1
5 Brake fluid reservoir hose 1
6 Hose joint 1
7 Bushing 1
8 Union bolt 1
9 Copper washer 2
10 Brake hose 1
11 Brake master cylinder 1 For installation, reverse the removal 
procedure. 
						

							
REAR BRAKE
4-34
Disassembling the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks1 Brake master cylinder kit 1
2 Hose joint 1
3 Bushing 1
4 Brake master cylinder body 1 For assembly, reverse the disassem-
bly procedure. 
						

							
REAR BRAKE
4-35
Removing the rear brake caliper
Order Job/Parts to remove Q’ty Remarks1 Union bolt 1
2 Copper washer 2
3Brake hose 1
4 Barke caliper 1 For installation, reverse the removal 
procedure.