Yamaha Fz1n Service Manual
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ELECTRIC STARTER 5-43 7. Check: Gear teethDamage/wear → Replace the gear. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: Brush seat “1” NOTE: Align the tab “a” on the brush seat with the tab “b” in the starter motor rear cover. 2. Install: Armature “1” 3. Install: Starter motor yoke “1” O-rings “2” Starter motor rear cover “3” Starter motor assembling bolts NOTE: Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers. EAS24810 INSTALLING THE STARTER MOTOR 1. Install: Starter motor “1” Starter motor bolts “2” 2. Connect: Starter motor lead “3” Starter motor assembling bolt5 Nm (0.5 m·kg, 3.6 ft·lb) Starter motor bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
CLUTCH 5-44 EAS25060 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE OIL on page 3-12. 1Clutch cable 1 2Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 For installation, reverse the removal procedure.
CLUTCH 5-45 Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks1 Circlip 2 2Pull lever 1 3Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation, reverse the removal procedure.
CLUTCH 5-46 Removing the clutch Order Job/Parts to remove Q’ty Remarks1 Compression spring 6 2 Pressure plate 1 3Pull rod 1 4 Bearing 1 5 Friction plate 1 1 6 Clutch plate 1 7 7 Friction plate 2 7 8 Wire circlip 1 9 Clutch plate 2 1 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Clutch boss nut 1 14 Washer 1 15 Clutch boss assembly 1 16 Thrust plate 1 17 Clutch housing 1 18 Bearing 1
CLUTCH 5-47 For assembly, reverse the removal procedure. Removing the clutch Order Job/Parts to remove Q’ty Remarks
CLUTCH 5-48 EAS25080 REMOVING THE CLUTCH 1. Remove: Clutch cover “1” Gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: Compression spring bolts “1” Compression springs Pressure plate “2” Pull rod “3” 3. Remove: Friction plate 1 “1” 4. Remove: Clutch plate 1 “1” Friction plate 2 5. Straighten the clutch boss nut rib “1”. 6. Loosen: Clutch boss nut “1” NOTE: While holding the clutch boss “2” with the uni- versal clutch holder “3”, loosen the clutch boss nut. 7. Remove: Clutch boss nut Washer Clutch boss assembly Universal clutch holder90890-04086 YM-91042
CLUTCH 5-49 Thrust plate 8. Remove: Wire circlip “1” NOTE: There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “1” and disassemble the built-in damper unless there is serious clutch chattering. 9. Remove: Clutch plate 2 “1” Friction plate 3 “2” 10. Remove: Clutch damper spring “1” Clutch damper spring seat “2” ET2D1010 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: Friction plate thicknessOut of specification → Replace the friction plates as a set. NOTE: Measure the friction plate at four places. EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: Clutch plateDamage → Replace the clutch plates as a set. 2. Measure: Clutch plate warpage(with a surface plate and thickness gauge “1”) Out of specification → Replace the clutch plates as a set. Friction plate thickness 2.9 - 3.1 mm (0.114 - 0.122 in) Limit 2.8 mm (0.110 in) Clutch plate warpage limit0.1 mm (0.0039 in)
CLUTCH 5-50 EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: Clutch springDamage → Replace the clutch springs as a set. 2. Measure: Clutch spring free length “a” Out of specification → Replace the clutch springs as a set. EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: Clutch housing dogsDamage/pitting/wear → Deburr the clutch housing dogs or replace the clutch hous- ing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: BearingDamage/wear → Replace the bearing and clutch housing. EAS25160 CHECKING THE CLUTCH BOSS 1. Check: Clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EAS25170 CHECKING THE PRESSURE PLATE 1. Check: Pressure plate “1” Cracks/damage → Replace. Bearing “2” Damage/wear → Replace. EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: Clutch spring free length 52.5 mm (2.07 in) Limit 49.9 mm (1.96 in)
CLUTCH 5-51 Pull lever shaft pinion gear teeth “1” Pull rod teeth “2”Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: Pull rod bearingDamage/wear → Replace. EAS25240 INSTALLING THE CLUTCH 1. Install: Clutch damper spring seat “1” Clutch damper spring “2” 2. Install: Friction plate 3 “1” Clutch plate 2 “2” NOTE: Lubricate the engine oil. 3. Install: Wire circlip “1” 4. Install: Clutch housing “1” NOTE: Align the projection of clutch housing “a” and hollow of the oil pump drive gear “b”. 5. Install: Thrust plate Clutch boss assembly “1” Washer Clutch boss nut “2” NOTE: Install the washer on the main axle with the “OUT” mark facing away from the vehicle. Clutch boss nut95 Nm (9.5 m·kg, 69 ft·lb)
CLUTCH 5-52 Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle. While holding the clutch boss assembly “1” with the clutch holding tool “3”, tighten the clutch boss nut. 6. Lubricate Friction plates Clutch plates(with the recommended lubricant) 7. Install: Friction plate 2 Clutch plate 1 “1” 8. Install: Friction plate 1 “1” NOTE: Install the last friction plate shifting half phase. 9. Install: Bearing Pull rod “1” Pressure plate “2” Clutch springs Clutch spring bolts “3” NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern. Universal clutch holder90890-04086 YM-91042 Recommended lubricant Engine oil Clutch spring bolt10 Nm (1.0 m·kg, 7.2 ft·lb)