Yamaha Fz1n Service Manual
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ENGINE REMOVAL 5-3 Removing the exhaust pipe Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on page 4-1. 1 EXUP pulley cover 1 2 EXUP servo motor cover 1 3 EXUP cables 2 4 EXUP servo motor 1 5O 2 sensor 1 6 Exhaust pipe assembly 1 7 Exhaust pipe gasket 4 8 Muffler 1 9 Muffler gasket 1 10 Muffler cover 1 11 Muffler end cover 1 For installation, reverse the removal procedure.
ENGINE REMOVAL 5-4 Disassembling the exhaust valve pipe Order Job/Parts to remove Q’ty Remarks1Nut 1 2Pulley 1 3Spring 1 4 Spring seat 1 For assembly, reverse the disassem- bly procedure.
ENGINE REMOVAL 5-5 Disconnecting the leads and hoses Order Job/Parts to remove Q’ty RemarksFuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4-1. Throttle body assembly Refe r to THROTTLE BODIES on page 7-4. Engine oil Drain. Refer to CHANGING THE ENGINE OIL on page 3-12. Oil cooler Refer to OIL COOLER on page 6- 4. Air cut-off valve Refer to AIR INDUCTION SYS- TEM on page 7-13. Starter motor Refer to ELECTRIC STARTER on page 5-40. 1 Battery negative lead 1 2 Battery positive lead 1 3Clutch cable 1 4 Ground lead 2 5 Stator coil assembly coupler 1 Disconnect.
ENGINE REMOVAL 5-6 6 Crankshaft position sensor lead coupler 1 Disconnect. 7 Oil level switch connector 1 Disconnect. 8 Neutral switch connector 1 Disconnect. 9 Cylinder identification sensor coupler 1 Disconnect. 10 Speed sensor coupler 1 Disconnect. For assembly, reverse the removal procedure. Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks
ENGINE REMOVAL 5-7 Removing the engine Order Job/Parts to remove Q’ty Remarks1 Right front engine mounting bolt 1 1 2 Left front engine mounting bolt 1 3 Upper self-locking nut 1 4 Upper engine mounting bolt 1 5 Lower self-locking nut 1 6 Lower engine mounting bolt 1 7 Engine mounting adjust bolt 2 8 Engine 1 For assembly, reverse the removal procedure.
ENGINE REMOVAL 5-8 EAS23720 INSTALLING THE ENGINE 1. Install: Right front engine mounting bolt 2 “1” Refer to CYLINDER HEAD on page 5-19. 2. Tighten: Right front engine mounting bolt 2 3. Install: Engine mounting adjust bolts(temporarily tighten) 4. Install: Engine 5. Install: Lower engine mounting bolt “1” Upper engine mounting bolt “2” Self-locking nuts NOTE: Do not fully tighten the bolts and nuts. 6. Install: Left front engine mounting bolt “1” (temporarily tighten) Right front engine mounting bolt 1 “2” (temporarily tighten) 7. Tighten: Engine mounting adjust bolts NOTE: Use the pivot shaft wrench “1” and pivot shaft wrench adapter “2” to tighten the engine mounting adjust bolts. Right front engine mounting bolt 250 Nm (5.0 m·kg, 36 ft·lb) Engine mounting adjust bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Pivot shaft wrench90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter 90890-01476
ENGINE REMOVAL 5-9 8. Tighten: Lower self-locking nut “1” Upper self-locking nut “2” NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut. 9. Tighten: Left front engine mounting bolt ”1” Right front engine mounting bolt 1 ”2” Upper self-locking nut51 Nm (5.1 m·kg, 37 ft·lb) Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb) Left front engine mounting bolt45 Nm (4.5 m·kg, 33 ft·lb) Right front engine mounting bolt 1 45 Nm (4.5 m·kg, 33 ft·lb)
CAMSHAFTS 5-10 EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty RemarksFuel tank Refer to FUEL TANK on page 7-1. Throttle body assembly Refer to THROTTLE BODIES on page 7-4. Radiator assembly Refer to RADIATOR on page 6-1. Air cut-off valve Refer to AIR INDUCTION SYS- TEM on page 7-13. 1 Ignition coil 4 2 Spark plug 4 3 Cylinder head cover 1 4 Cylinder head cover gasket 1 5 Timing chain guide (top side) 1 6 Cylinder identification sensor 1 7O-ring 1 For assembly, reverse the removal procedure.
CAMSHAFTS 5-11 Removing the camshafts Order Job/Parts to remove Q’ty RemarksPickup rotor cover Refer to CRANKSHAFT POSITION SENSOR on page 5-38. 1 Camshaft sprocket bolt 4 Loosen. 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 3 5 Dowel pin 6 Refer to REMOVING THE CAM- SHAFTS on page 5-12. 6 Exhaust camshaft cap 3 7 Dowel pin 6 Refer to REMOVING THE CAM- SHAFTS on page 5-12. 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Camshaft sprocket 2 For assembly, reverse the removal procedure.
CAMSHAFTS 5-12 EAS23810 REMOVING THE CAMSHAFTS 1. Remove: Pickup rotor cover Refer to CRANKSHAFT POSITION SEN- SOR on page 5-38. 2. Align: “T” mark “a” on the pickup rotor(with the crankcase mating surface “b”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark “a” on the pickup rotor with the crankcase mating sur- face “b”. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Loosen: Camshaft sprocket bolts “1” 4. Remove: Timing chain tensioner “1” Gasket 5. Remove: Camshaft caps “1” Dowel pins CAUTION: ECA13720 To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 6. Remove: Intake camshaft “1” Exhaust camshaft “2” NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire “3”.Camshaft wrench90890-04143