Yamaha Fz1n Service Manual
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SWINGARM 4-66 8Drive chain 1 9Dust cover 2 10 Drive chain guide 1 11 Spacer 1 12 Bearing 2 For installation, reverse the removal procedure. Removing the swingarm Order Job/Parts to remove Q’ty Remarks
SWINGARM 4-67 EAS23350 REMOVING THE SWINGARM 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: Relay arm-to-swingarm bolt “1” Connecting arm bolt “2” Rear shock absorber assembly lower bolt “3” NOTE: When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 3. Measure: Swingarm side play Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the tightening torque of the pivot shaft nut. b. Measure the swingarm side play “A” by moving the swingarm from side to side. c. If the swingarm side play is out of specifica- tion, check the spacers, bearings, washers, and dust covers. d. Check the swingarm vertical movement “B” by moving the swingarm up and down. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust cov- ers. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23360 CHECKING THE SWINGARM 1. Check: SwingarmBends/cracks/damage → Replace. 2. Check: Pivot shaftRoll the pivot shaft on a flat surface. Bends → Replace. WARNING EWA13770 Do not attempt to straighten a bent pivot shaft. 3. Wash: Pivot shaft Dust covers Spacer Washers Bearings 4. Check: Dust covers “1” Spacer “2” Bearings “3”Damage/pitting → Replace. Pivot shaft nut 105 Nm (10.5 m·kg, 76 ft·lb) Swingarm side play (at the end of the swingarm)1.0 mm (0.04 in) Recommended cleaning solventKerosene
SWINGARM 4-68 5. Check: Connecting arms “1” Relay arm “2”Damage/wear → Replace. 6. Check: Bearings “3” Oil seals “4”Damage/pitting → Replace. 7. Check: Collars “5” Damage/scratches → Replace. EAS23380 INSTALLING THE SWINGARM 1. Lubricate: Bearings Spacers Dust covers Pivot shaft 2. Install: Swingarm Pivot shaft “1” Pivot shaft nut “2” 3. Install: Rear shock absorber assembly Rear wheelRefer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY on page 4-64 and INSTALLING THE REAR WHEEL (DISC) on page 4-18. 4. Adjust: Drive chain slackRefer to ADJUSTING THE DRIVE CHAIN SLACK on page 3-26. Recommended lubricant Lithium-soap-based grease Drive chain slack25–35 mm (0.98–1.38 in)
CHAIN DRIVE 4-69 EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty RemarksDrive sprocket Refer to ENGINE REMOVAL on page 5-2. 1 Drive chain guard 1 2 Drive chain 1 For installation, reverse the removal procedure.
CHAIN DRIVE 4-70 EAS23410 REMOVING THE DRIVE CHAIN 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:Drive chain(with the drive chain cutter) NOTE: Only cut the drive chain if it or the swingarm is to be replaced. EAS23440 CHECKING THE DRIVE CHAIN 1. Measure: Measure the dimension between 15-links on the inner side “a” and outer side “b” of the roller and calculate the dimension between pin centers. Dimension “c” between pin centers = (Inner dimension “a” + Outer dimension “b”)/2 15-link section “c” of the drive chain Out of specification → Replace the drive chain, front drive sprocket and rear drive sprocket as a set. NOTE: While measuring the 15-link section, push down on the drive chain to increase its ten- sion. Perform this measurement at two or three dif- ferent places. 2. Check: Drive chainStiffness → Clean and lubricate or replace. 3. Clean: Drive chain ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. CAUTION: ECA14290 This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pres- sure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain. Do not soak the drive chain in kerosene for more than ten minutes, otherwise the O-rings can be damaged. 15-link drive chain section limit (maximum)239.3 mm (9.42 in)
CHAIN DRIVE 4-71 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: O-rings “1” Damage → Replace the drive chain. Drive chain rollers “2” Damage/wear → Replace the drive chain. Drive chain side plates “3” Damage/wear → Replace the drive chain. Cracks → Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lubricate: Drive chain EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4-18. ET2D1031 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4-17. EAS28800 INSTALLING THE DRIVE CHAIN 1. Lubricate: Drive chain 2. Install: Drive sprocket Lock washer Drive sprocket nutRefer to ENGINE REMOVAL on page 5- 2. Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains b. Correct 1. Drive chain roller 2. Drive chain sprocket Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains Drive sprocket nut85 Nm (8.5 m·kg, 61 ft·lb)
5 ENGINE ENGINE REMOVAL...................................................................................... 5-2 INSTALLING THE ENGINE .................................................................... 5-8 CAMSHAFTS .............................................................................................. 5-10 REMOVING THE CAMSHAFTS ........................................................... 5-12 CHECKING THE CAMSHAFTS ........................................................... 5-13 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ....... 5-14 CHECKING THE TIMING CHAIN GUIDES .......................................... 5-14 CHECKING THE TIMING CHAIN TENSIONER ................................... 5-14 INSTALLING THE CAMSHAFTS .......................................................... 5-16 CYLINDER HEAD ....................................................................................... 5-19 REMOVING THE CYLINDER HEAD .................................................... 5-20 CHECKING THE CYLINDER HEAD .................................................... 5-20 INSTALLING THE CYLINDER HEAD ................................................... 5-20 VALVES AND VALVE SPRINGS ................................................................ 5-22 REMOVING THE VALVES .................................................................... 5-24 CHECKING THE VALVES AND VALVE GUIDES ................................. 5-25 CHECKING THE VALVE SEATS .......................................................... 5-26 CHECKING THE VALVE SPRINGS...................................................... 5-28 CHECKING THE VALVE LIFTERS ....................................................... 5-29 INSTALLING THE VALVES ................................................................... 5-29 GENERATOR .............................................................................................. 5-31 REMOVING THE GENERATOR ........................................................... 5-33 INSTALLING THE GENERATOR .......................................................... 5-33 STARTER CLUTCH .................................................................................... 5-35 REMOVING THE STARTER CLUTCH ................................................. 5-36 CHECKING THE DAMPER .................................................................. 5-36 CHECKING THE STARTER CLUTCH .................................................. 5-36 INSTALLING THE STARTER CLUTCH ................................................ 5-37 CRANKSHAFT POSITION SENSOR ......................................................... 5-38 REMOVING THE CRANKSHAFT POSITION SENSOR ...................... 5-39 INSTALLING THE CRANKSHAFT POSITION SENSOR ..................... 5-39 ELECTRIC STARTER ................................................................................. 5-40 CHECKING THE STARTER MOTOR ................................................... 5-42 ASSEMBLING THE STARTER MOTOR ............................................... 5-43 INSTALLING THE STARTER MOTOR .................................................. 5-43 CLUTCH ...................................................................................................... 5-44 REMOVING THE CLUTCH................................................................... 5-48
CHECKING THE FRICTION PLATES .................................................. 5-49 CHECKING THE CLUTCH PLATES..................................................... 5-49 CHECKING THE CLUTCH SPRINGS .................................................. 5-50 CHECKING THE CLUTCH HOUSING ................................................. 5-50 CHECKING THE CLUTCH BOSS ........................................................ 5-50 CHECKING THE PRESSURE PLATE .................................................. 5-50 CHECKING THE PULL LEVER SHAFT AND PULL ROD.................... 5-50 INSTALLING THE CLUTCH ................................................................. 5-51 SHIFT SHAFT ............................................................................................. 5-54 REMOVING THE SHIFT SHAFT .......................................................... 5-56 CHECKING THE SHIFT SHAFT .......................................................... 5-56 CHECKING THE STOPPER LEVER .................................................... 5-56 INSTALLING THE SHIFT SHAFT ......................................................... 5-56 OIL PUMP ................................................................................................... 5-58 REMOVING THE OIL PAN ................................................................... 5-62 CHECKING THE SPROCKET AND CHAIN ......................................... 5-62 CHECKING THE OIL PUMP ................................................................ 5-62 CHECKING THE RELIEF VALVE ......................................................... 5-63 CHECKING THE OIL DELIVERY PIPES.............................................. 5-63 CHECKING THE OIL STRAINER......................................................... 5-63 CHECKING THE OIL NOZZLES .......................................................... 5-63 ASSEMBLING THE OIL PU MP ............................................................ 5-63 INSTALLING THE OIL/WATER PUMP ASSEMBLY.............................. 5-64 INSTALLING THE OIL PAN .................................................................. 5-65 CRANKCASE ............................................................................................. 5-66 DISASSEMBLING THE CRANKCASE ................................................. 5-68 CHECKING THE CRANKCASE ........................................................... 5-68 CHECKING THE BEARING AND OIL SEALS ..................................... 5-68 ASSEMBLING THE CRANKC ASE ........................................... ............ 5-68 CRANKSHAFT ........................................................................................... 5-70 REMOVING THE CONNECTING RODS AND PISTONS .................... 5-72 REMOVING THE CRANKSHA FT ASSEMBLY ..................................... 5-72 CHECKING THE CYLINDER AND PISTON......................................... 5-73 CHECKING THE PISTON RINGS ........................................................ 5-73 CHECKING THE PISTON PINS ........................................................... 5-74 CHECKING THE BIG END BEARINGS ............................................... 5-75 INSTALLING THE CONNECTING ROD AND PISTON ........................ 5-78 CHECKING THE CRANKSHAFT ......................................................... 5-81 CHECKING THE CRANKSHAFT DRIVE SPROCKET......................... 5-81 CHECKING THE CRANKSHAFT JOURNAL BEARINGS .................... 5-81 INSTALLING THE CRANKSHAFT........................................................ 5-83 TRANSMISSION ......................................................................................... 5-85 REMOVING THE TRANSMISSION ...................................................... 5-90 CHECKING THE SHIFT FORKS .......................................................... 5-90 CHECKING THE SHIFT DRUM ASSEMBLY ........................................ 5-91
CHECKING THE TRANSMISSION ...................................................... 5-91 INSTALLING THE TRANSMISSION..................................................... 5-92
ENGINE REMOVAL 5-2 EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty Remarks1Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 8Plate 1 For installation, reverse the removal procedure.