Yamaha Fz1n Service Manual
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FRONT FORK 4-56 WARNING EW2D1003 The fork spring is compressed. Always use a new cap bolt O-ring. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23050 INSTALLING 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 screw and left front fork is equipped with a compression damping force adjusting screw. Pay attension not to mistake the right and left. 1. Install: Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: Lower bracket pinch bolt “1” Cap bolt “2” Upper bracket pinch bolt “3” WARNING EWA13680 Make sure the brake hoses are routed prop- erly. 3. Adjust: Spring preload Rebound damping Compression dampingRefer to ADJUSTING THE FRONT FORK LEGS on page 3-29. Lower bracket pinch bolt23 Nm (2.3 m·kg, 17 ft·lb) Cap bolt23 Nm (2.3 m·kg, 17 ft·lb) Upper bracket pinch bolt26 Nm (2.6 m·kg, 19 ft·lb)
STEERING HEAD 4-57 EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page 4-8. Front brake calipers Refer to FRONT BRAKE on page 4-20. Front cowling (FZ1-S) Refer to GENERAL CHASSIS on page 4-1. Headlight and meter assembly (FZ1 -N) Refer to GENERAL CHASSIS on page 4-1. Handlebar Refer to HANDLEBAR on page 4- 43. Front fork legs Refer to FRONT FORK on page 4- 48. 1 Main switch connector 2 Disconnect. 2 Steering stem nut 1 3 Upper bracket 1 4 Front brake hose joint 1
STEERING HEAD 4-58 5 Front brake hose joint bracket 1 6Horn 1 7 Horn bracket 1 8 Lock washer 1 9 Upper ring nut 1 10 Rubber washer 1 11 Lower ring nut 1 12 Lower bracket 1 13 Lower bearing 1 14 Lower bearing dust seal 1 15 Lower bearing inner race 1 16 Bearing cover 1 17 Upper bearing inner race 1 18 Upper bearing 1 19 Bearing outer race 2 For installation, reverse the removal procedure. Removing the lower bracket Order Job/Parts to remove Q’ty Remarks
STEERING HEAD 4-59 EAS23110 REMOVING THE LOWER BRACKET 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: Upper ring nut “1” Rubber washer Lower ring nut “2” Lower bracket NOTE: Hold the lower ring nut with the ring nut wrench “3”, and then remove the upper ring nut with the steering nut wrench “4”. WARNING EWA13730 Securely support the lower bracket so that there is no danger of it falling. EAS23120 CHECKING THE STEERING HEAD 1. Wash: Bearings Bearing races 2. Check: Bearings “1” Bearing races “2” Damage/pitting → Replace. 3. Replace: Bearings Bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races from the steer- ing head pipe with a long rod “1” and ham- mer. b. Remove the bearing race from the lower bracket with a floor chisel “2” and hammer. c. Install a new rubber seal and new bearing races. CAUTION: ECA14270 If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the bearings and bearing races as a set. Whenever the steering head is disassem- bled, replace the rubber seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Ring nut wrench 90890-01268 Spanner wrench YU-01268 Steering nut wrench 90890-01403 Spanner wrench YU-33975 Recommended cleaning solvent Kerosene
STEERING HEAD 4-60 4. Check: Upper bracket Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: Upper bearing Lower bearing Bearing races 2. Install: Lower ring nut “1” Rubber washer “2” Upper ring nut “3” Lock washer “4”Refer to INSTALLING THE STEERING HEAD on page 4-60. 3. Install: Front brake hose joint bracket Front brake hose joint 4. Install: Upper bracket Steering stem nut NOTE: Temporarily tighten the steering stem nut. 5. Install: Front fork legs Refer to FRONT FORK on page 4-48. NOTE: Temporarily tighten the upper and lower bracket pinch bolts. 6. Tighten: Steering stem nut Recommended lubricantLithium-soap-based grease Steering stem nut113 Nm (11.3 m·kg, 82 ft·lb)
REAR SHOCK ABSORBER ASSEMBLY 4-61 EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on page 4-1. Side cover (left and right) Refer to GENERAL CHASSIS on page 4-1. Brake fluid reservoir tank bolt Refer to REAR BRAKE on page 4- 32. 1 Self-locking nut/bolt 1/1 2 Self-locking nut/bolt 1/1 3 Self-locking nut/bolt 1/1 4 Self-locking nut/bolt/collar 1/1/1 5 Rear shock absorber assembly 1 6 Oil seal/bearing/collar 6/3/3 7 Collar/self-locking nut/bolt 1/1/1 8 Connecting arm 2 9 Oil seal/bearing/collar 2/1/1 10 Relay arm 1
REAR SHOCK ABSORBER ASSEMBLY 4-62 For installation, reverse the removal procedure. Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks
REAR SHOCK ABSORBER ASSEMBLY 4-63 EAS23180 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. Rear shock absorber damage will result in poor damping per- formance. EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release the gas pressure, drill a 2–3mm (0.079– 0.118 in) hole through the rear shock absorber at a point 15–20 mm (0.59–0.79 in) from its end as shown. WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips. EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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: Rear shock absorber assembly lower bolt “1” Relay arm-to-swingarm bolt “2” Connecting arm-to-relay arm bolt “3” NOTE: While removing the rear shock absorber assembly lower bolt, hold the swigarm so that it does not drop down. 3. Remove: Rear shock absorber assembly upper bolt “1” Rear shock absorber assembly NOTE: Raise the swigarm and then remove the rear shock absorber assembly from between the swingar m. EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: Rear shock absorber rodBends/damage → Replace the rear shock absorber assembly. Rear shock absorber
REAR SHOCK ABSORBER ASSEMBLY 4-64 Gas leaks/oil leaks → Replace the rear shock absorber assembly. Spring Damage/wear → Replace the rear shock absorber assembly. Bushings Damage/wear → Replace. Dust seals Damage/wear → Replace. Bolts Bends/damage/wear → Replace. EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: Connecting arms “1” Relay arm “2”Damage/wear → Replace. 2. Check: Bearings Oil sealsDamage/pitting → Replace. 3. Check: Coller Damage/scratches → Replace. EAS23300 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: Spacers Bearings 2. Install: Rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lift up the swingarm. 3. Tighten: Rear shock absorber assembly upper nut Rear shock absorber assembly lower nut Relay-arm-to-swingarm nut Recommended lubricant Lithium-soap-based grease Rear shock absorber assembly upper nut44 Nm (4.4 m·kg, 32 ft·lb) Rear shock absorber assembly lower nut44 Nm (4.4 m·kg, 32 ft·lb) Relay-arm-to-swingarm nut44 Nm (4.4 m·kg, 32 ft·lb)
SWINGARM 4-65 EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty RemarksRear wheel Refer to REAR WHEEL on page 4- 14. Rear brake caliper Refer to REAR BRAKE on page 4- 32. Rear shock absorber Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4-61. Drive sprocket Refer to ENGINE REMOVAL on page 5-2. 1 Rear fender cover 1 2 Drive chain guard 1 3 Brake hose holder 1 4 Drive chain adjusting bolt/locknut 2/2 5 Pivot shaft nut/washer 1/1 6 Pivot shaft 1 7 Swingarm 1