Yamaha Fz1n Service Manual

							
HANDLEBAR
4-46
4. Tighten: Lower handlebar holder nuts
5. Install:  Clutch lever holder “1”
Clutch cable
NOTE:
Align the slit in the clutch lever holder with the 
punch mark a in the handlebar.
6. Install: Left handlebar switch
NOTE:
Align the projections “a” on the left handlebar 
switch with the hole “b” in the handlebar.
7. Install: Handlebar grip “1”
 Grip end “2”
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a. Apply a thin coat of rubber adhesive onto  the left end of the handlebar.
b. Side the handlebar grip over the left end of  the handlebar.
c. Wipe off any excess rubber adhesive with a 
clean rag.
WARNING
EW2D1007
Do not touch the handlebar grip until the 
rubber adhesive has fully dried.
NOTE:
There should be 1–3 mm (0.04–0.12 in) of 
clearance “a” between the handlebar grip and 
the grip end.
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8. Install: Throttle grip “1”
 Throttle cable hoousing “2”
 Throttle cables
 Grip end “3”
NOTE:
Align the projections “a” on the throttle cable 
housing with the hole “b” in the handlebar.
9. Install:
 Right handlebar switch
Lower handlebar holder nut32 Nm (3.2 m·kg, 23 ft·lb)
Grip end26 Nm (2.6 m·kg, 19 ft·lb) 
						

							
HANDLEBAR
4-47
NOTE:
 Align the projections a on the handlebar switch with the holes b in the handlebar.
 Threre should be 1–3 mm (0.04–0.12 in) of 
clearance “c” between the handlebar grip 
and the grip end.
10. Install:  Front brake master cylinder assembly
 Front brake master cylinder holder “1”
CAUTION:
ECS2D1010
 Install the brake master cylinder bracket with the “UP” mark facing up.
 First, tighten the upper bolt, then the 
lower bolt.
NOTE:
Align the end of the brake master cylinder 
holder with the punch mark “a” on the handle-
bar.
11. Adjust:  Throttle cable free play
Front brake master cylinder 
bracket bolt10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							
FRONT FORK
4-48
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty RemarksFront wheel
Front brake calipers Refer to CHECKING THE TIRES 
on page 3-32 and CHECKING THE 
WHEELS on page 3-34.
1 Front fender 1
2 Cap bolt 1 Loosen.
3 Upper bracket pinch bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1 For installation, reverse the removal 
procedure. 
						

							
FRONT FORK
4-49
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks1 Cap bolt 1
2O-ring 1
3 Damper adjusting rod 1
4Nut 1
5 Washer 1
6 Spacer 1
7Fork spring 1
8 Dust seal 1
9 Oil seal clip 1
10 Oil seal 1
11 Washer 1
12 Damper rod assembly bolt 1
13 Copper washer 1
14 Damper rod assembly 1
15 Inner tube 1
16 Outer tube 1 For assembly, reverse the disassem-
bly procedure. 
						

							
FRONT FORK
4-50
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
NOTE:
Each front fork leg is eqipped with a spring 
preload adjusting bolt, the right fork leg is 
equipped with a rebound damping force 
adjusting screan and left front fprk is equipped 
with a compression damping force adjusting 
screw. Pay attention not to mistake the right 
and left.
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 front wheel is elevated.
2. Loosen:  Upper bracket pinch bolts “1”
 Cap bolt “2”
 Lower bracket pinch bolts “3”
WARNING
EWA13640
Before loosening the upper and lower 
bracket pinch bolts, support the front fork 
leg.
3. Remove:Front fork leg
EAS22990
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Remove:
 Cap bolt “1”(from the damper adjusting rod)
 Spacers “2” Nut “3”
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a. Press down on the spacer with the fork 
spring compressor “4”.
b. Install the rod holder “5” between the nut 
“3” and the spacer “2”.
NOTE:
Use the side of the rod holder that is marked 
“B”.
c. Hold the spring preload adjusting bolt “6” and loosen the nut “3”.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring  compressor.
f. Remove the spacer and nut.
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2. Drain:  Fork oil
NOTE:
Stroke the damper rod “1” several times while 
draining the fork oil.
Fork spring compressor
90890-01441
YM-01441
Rod holder 90890-01434
Damper rod holder double 
ended
YM-01434 
						

							
FRONT FORK
4-51
3. Remove: Oil seal clip “1”(with a flat-head screwdriver)
CAUTION:
ECA14180
Do not scratch the inner tube.
4. Remove: Damper rod assembly bolt
 Damper rod assembly
CAUTION:
EC2D1080
For the damper rod assembly, the right side 
is used for the rebound operation and left 
side for the compression. Pay attention not 
to mistake the right and left.
NOTE:
The left side (for the compression) damper rod 
assembly has the four holes of oil path, unlike 
the right side.
NOTE:
While holding the damper rod with the damper 
rod holder “1”, loosen the damper rod assem-
bly bolt.
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Check: Inner tube “1”
 Outer tube “2”Bends/damage/scratches  → Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it.
2. Measure:
 Spring free length “a”Out of specification  → Replace.
A. Compression side
B. Rebound side
Damper rod holder
90890-01423
Damping rod holder YM-01423
Spring free length243.5 mm (9.59 in)
Limit 238.6 mm (9.39 in) 
						

							
FRONT FORK
4-52
3. Check: Damper rod “1”Damage/wear  → Replace.
Obstruction  → Blow out all of the oil pas-
sages with compressed air.
 Damper adjusting rod Bends/damage  → Replace.
CAUTION:
ECA14200
 The front fork leg has a built-in damper 
adjusting rod and a very sophisticated 
internal construction, which are particu-
larly sensitive to foreign material.
 When disassembling and assembling the 
front fork leg, do not allow any foreign 
material to enter the front fork.
EAS23030
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
 Make sure the oil levels in both front fork legs are equal.
 Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
 When assembling the front fork leg, be sure  to replace the following parts:
- Oil seal
-Dust seal
 Before assembling the front fork leg, make 
sure all of the components are clean.
1. Install:  Damper rod assembly “1”
 Inner tube “2”  Damper rod assembly bolt
 Copper washer 
CAUTION:
EC2D1080
For the damper rod assembly, the right side 
is used for the rebound operation and left 
side for the compression. Pay attention not 
to mistake the right and left.
NOTE:
The left side (for the compression) damper rod 
assembly has the four holes of oil path, unlike 
the right side.
CAUTION:
ECA14210
Allow the damper rod assembly to slide 
slowly down the inner tube “2” until it pro-
trudes from the bottom of the inner tube. 
Be careful not to damage the inner tube.
2. Lubricate:
 Inner tube’s outer surface
3. Tighten:  Damper rod assembly bolt “1”
NOTE:
While holding the damper rod assembly with 
the damper rod holder “2”, tighten the damper 
rod assembly bolt.
Recommended oilSuspension oil 01 or equiva-
lent
Damper rod assembly bolt23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
Damper rod holder90890-01423
Damping rod holder YM-01423 
						

							
FRONT FORK
4-53
4. Install: Dust seal “1”
 Oil seal clip “2”
 Oil seal “3”
 Washer “4”
CAUTION:
ECA14220
Make sure the numbered side of the oil seal 
faces up.
NOTE:
 Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
 Lubricate the outer surface of the inner tube  with fork oil.
 Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
5. Install:  Oil seal “1”
(with the fork seal driver “2”) 6. Install:
 Oil seal clip “1”
NOTE:
Adjust the oil seal clip so  that it fits into the 
outer tube’s groove.
7. Install:
 Dust seal “1”
(with the fork seal driver weight “2”)
8. Install:  Rod puller “1”
 Rod puller attachment (M 10) “2”(onto the damper rod “3”)
Fork seal driver
90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442
Fork seal driver90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442 
						

							
FRONT FORK
4-54
9. Fill:Front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA14230
 Be sure to use the recommended fork oil.  Other oils may have an adverse effect on 
front fork performance.
 When disassembling and assembling the 
front fork leg, do not allow any foreign 
material to enter the front fork.
NOTE:
Be sure to bleed the front fork.
10. After filling the front fork leg, slowly stroke  the damper rod “1” up and down (at least 
ten times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly 
because the fork oil may spurt out. 11. Before measuring the fork oil level, wait ten 
minutes until the oil has settled and the air 
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any resid-
ual air.
12. Measure: Front fork leg oil level “a”
(from the top of the outer tube, with the 
outer tube fully compressed and without 
the fork spring)
Out of specification  → Correct.
13. Install: Nut “1”
 Fork spring “2”
 Spacer “3”
 Damper adjusting rod “4”
 Cap bolt “5”
Rod puller
90890-01437
Rod puller attachment (M10)
90890-01436
Quantity
545.0 cm
3 (18.43 US oz) (19.18 
lmp.oz)
Recommended oil Suspension oil 01 or equiva-
lent
Front fork leg oil level91 mm (3.58 in) 
						

							
FRONT FORK
4-55
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a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring and spacer.
NOTE:
Install the spring with the smaller pitch “a” fac-
ing up “A”.
d. Press down in the spacer with the fork spring compressor “1”
e. Pull up the rod puller and install the rod 
holder “2” between the damper adjusting 
rod locknut “3” and the spacer “4”.
NOTE:
Use the side of the rod holder that is marked 
“B”. f. Remove the rod puller and the rod puller 
attachment.
g. Install the nut “1” and position it as speci- fied “b”.
h. Set the cap bolt distance “c” to specifica- tion.
i. Inatall the damper adjusting rod and cap  bolt, and then finger tighten the cap bolt.
j. Hold the cap bolt and tighten the damper  adjusting rod locknut to specification.
k. Remove the rod holder and fork spring  compressor.
Fork spring compressor90890-01441
YM-01441
Rod holder 90890-01434
Damper rod holder double 
ended YM-01434
Distance “b”
12 mm (0.47 in)
Distance “c”13 mm (0.51 in)
Damper adjusting rod locknut15 Nm (1.5 m·kg, 11 ft·lb)