Yamaha Fz1n Service Manual
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REAR BRAKE 4-36 Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks1 Screw plug 1 2 Brake pad pin 1 3Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly, reverse the disassem- bly procedure.

REAR BRAKE 4-37 EAS22560 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. EAS22570 CHECKING THE REAR BRAKE DISC 1. Remove: Rear wheelRefer to REAR WHEEL on page 4-14. 2. Check: Brake discDamage/galling → Replace. 3. Measure: Brake disc deflectionOut of specification → Correct the brake disc deflection or replace the brake disc. Refer to CHECKING THE FRONT BRAKE DISCS on page 4-25. 4. Measure: Brake disc thicknessMeasure the brake disc thickness at a few different locations. Out of specification → Replace. Refer to CHECKING THE FRONT BRAKE DISCS on page 4-25. 5. Adjust: Brake disc deflectionRefer to CHECKING THE FRONT BRAKE DISCS on page 4-25. 6. Install: Rear wheelRefer to REAR WHEEL on page 4-14. EAS22580 REPLACING THE REAR BRAKE PADS 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 pad shims (onto the brake pads) Brake pads Brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Brake disc deflection limit 0.15 mm (0.0059 in) Brake disc thickness limit4.5 mm (0.18 in) Brake disc bolt 30 Nm (3.0 m·kg, 22 ft·lb) LOCTITE® Brake pad lining thickness (inner)6.0 mm (0.24 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 6.0 mm (0.24 in) Limit 1.0 mm (0.04 in)

REAR BRAKE 4-38 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 a new brake pad shim “3” onto each new brake pad “4”. e. Install new brake pads and a new brake pad spring “5”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: Brake caliper Brake pad pin Screw plug 4. 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. 5. Check: Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-25. EAS22590 REMOVING THE REAR BRAKE CALIPER NOTE: Before disassembling 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. EAS22600 DISASSEMBLING THE REAR BRAKE CALI- PER 1. Remove: Brake caliper piston “1” Brake caliper piston seals “2” Bleed screw5 Nm (0.5 m·kg, 3.6 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 BRAKE 4-39 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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 piston from the brake caliper. WARNING EWA13550 Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. Never try to pry out the brake caliper pis- ton. c. Remove the brake caliper piston seals. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22640 CHECKING THE REAR BRAKE CALIPER 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 EWA13610 Whenever a brake caliper is disassembled, replace the brake caliper piston seals. 2. Check: Brake caliper bracket “1”Cracks/damage → Replace. EAS22650 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA13620 Before installation, a ll 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. Recommended brake component replacement 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 fluidDOT4

REAR BRAKE 4-40 EAS22670 INSTALLING THE REAR BRAKE CALIPER 1. Install: Brake caliper “1” (temporarily) Copper washers “2” Brake hose “3” Union bolt “4” WARNING EWA13530 Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE ROUTING on page 2-39. CAUTION: EC2D1010 When installing the brake hose onto the brake caliper, make sure the brake pipe “a” touches the projection “b” on the brake cal- iper. 2. Remove: Brake caliper 3. Install: Brake pad shims Brake pads Brake pad spring Brake pad pin Screw plug Brake caliper Refer to REPLACING THE REAR BRAKE PADS on page 4-37. 4. Fill: Brake fluid 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 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. Brake hose union bolt 30 Nm (3.0 m·kg, 22 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) Recommended fluidDOT4

REAR BRAKE 4-41 7. Check: Brake pedal operationSoft or spongy feeling → Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-25. EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1. 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. EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: Brake master cylinderDamage/scratches/wear → Replace. Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 2. Check: Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: Brake fluid reservoir Cracks/damage → Replace. Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: Brake hoseCracks/damage/wear → Replace. EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation, a ll internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake components. ET2D1022 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: Copper washers Brake hose “1” Union bolt “2” WARNING EW2D1004 Proper brake hose routing is essential to insure safe vehicle operation. Refer to CABLE ROUTING on page 2-39. CAUTION: EC2D1005 When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection “a” as shown. Recommended fluidDOT4 Brake hose union bolt30 Nm (3.0 m·kg, 22 ft·lb)

REAR BRAKE 4-42 2. Fill: Brake fluid reservoir(with the specified amount of the recom- mended brake fluid) WARNING EW2D1005 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: EC2D1010 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-25. 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 pedal operationSoft or spongy feeling → Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-25. 6. Adjust: Brake pedal positionRefer to ADJUSTING THE REAR DISC BRAKE on page 3-22. 7. Adjust: Rear brake light operation timingRefer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3-24. Recommended fluid DOT4

HANDLEBAR 4-43 EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty RemarksFront cowling (FZ1-S) Refer to GENERAL CHASSIS on page 4-1. 1 Rear view mirror (FZ1-N) 2 2 Front brake light switch connector 2 Disconnect. 3 Front master cylinder bracket 1 4 Front brake master cylinder assembly 1 5 Right handlebar switch 1 6 Throttle cable housing 1 7 Throttle cable 2 8Grip end 2 9 Throttle grip 1 10 Clutch cable 1 11 Handlebar grip 1 12 Left handlebar switch 1 13 Clutch lever holder 1 14 Upper handlebar holder 1

HANDLEBAR 4-44 15 Handlebar 1 16 Lower handlebar holder 2For installation, reverse the removal procedure. Removing the handlebar Order Job/Parts to remove Q’ty Remarks

HANDLEBAR 4-45 EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Handlebar grip “1” NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. 3. Remove: Throttle cable housing “1” Throttle grip “2” NOTE: While removing the throttle cable housing, pull back the rubber cover “3”. EAS22880 CHECKING THE HANDLEBAR 1. Check: HandlebarBends/cracks/damage → Replace. WARNING EWA13690 Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. EAS22930 INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Install: Lower handlebar holders “1” NOTE: Temporarily tighten the nuts “2”. 3. Install: Handlebar “1” Upper handlebar holder “2” CAUTION: ECA14250 First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. NOTE: The upper handlebar holder should be installed with the punch mark “a” facing for- ward. Align the match marks “b” on the handlebar with the upper surface of the lower handlebar holders. Upper handlebar holder bolt24 Nm (2.4 m·kg, 17 ft·lb)