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Yamaha Fz1n Service Manual

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    Page
    of 451
    							
    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) 
    						
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