Yamaha Fz1n Service Manual
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CLUTCH 5-53 10. Install:Pull lever NOTE: Install the pull lever with the “O“ mark facing toward lower side. 11. Install:Clutch cover Clutch cover gasket NOTE: Install the pull rod so that the teeth a face towards the rear of the vehicle. Then, install the clutch cover. Apply oil onto the bearing. Apply molybdenum disulfide grease onto the pull rod. When installing the clutch cover, push the pull lever and check that the punch mark “a” on the pull lever aligns with the mark “b” on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. Tighten the clutch cover bolts in stages and in a crisscross pattern. 12. Tighten Clutch cover bolts “1” Clutch cover bolt “2” NOTE: Tighten the clutch cover bolts in a stages and in a crisscross pattern. 13. Adjust: Clutch cable free playRefer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3-14. Clutch cover bolt12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE®
SHIFT SHAFT 5-54 EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty RemarksClutch assembly Refer to CLUTCH on page 5-44. Shift arm and shift rod Refer to ENGINE REMOVAL on page 5-2. 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4Collar 1 5 Shift shaft spring 1 6 Washer 1 7 Stopper screw 1 8 Stopper lever 1 9 Washer 1 10 Oil seal 1 11 Bearing 1 12 Bearing 1 13 Stopper lever spring 1
SHIFT SHAFT 5-55 For installation, reverse the removal procedure. Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks
SHIFT SHAFT 5-56 ET2D1011 REMOVING THE SHIFT SHAFT 1. Remove: Clutch assembly Refetr to CLUTCH on page 5-44 2. Remove: Shift arm Shift rod Refetr to ENGINE REMOVAL on page 5- 2 3. Remove: Circlip “1” Washer “2”(left side of the engine) 4. Remove Shift shaft “1” Shift shaft spring “2” Collar Washer 5. Remove: Stopper lever spring “1” Stopper screw “2” Stopper lever “3” Washer EAS25420 CHECKING THE SHIFT SHAFT 1. Check: Shift shaft “1” Bends/damage/wear → Replace. Shift shaft spring “2” Collar “3” Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: Stopper lever “1”Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. EAS25450 INSTALLING THE SHIFT SHAFT 1. Install: Washer Stopper lever “1” Stopper screw “2” Stopper screw22 Nm (2.2 m·kg, 16 ft·lb) LOCTITE®
SHIFT SHAFT 5-57 Stopper lever spring “3” 2. Install: Washer Collar Shift shaft spring “1” Shift shaft “2” NOTE: Mesh the stopper lever with the shift drum segment assembly. Lubricate the oil seal lips with lithium soap base grease. Install the end of the shift shaft spring onto the shift shaft spring stopper. 3. Install: Washer “1” Circlip “2” 4. Install: Shift rod Shift arm Refer to ENGINE REMOVAL on page 5- 2. 5. Install: Clutch assemblyRefer to CLUTCH on page 5-44.
OIL PUMP 5-58 EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE OIL on page 3-12. EXUP cables Refer to ENGINE REMOVAL on page 5-2. O 2 sensor Refer to ENGINE REMOVAL on page 5-2. Muffler Refer to ENGINE REMOVAL on page 5-2. Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5-2. Clutch assembly Refer to CLUTCH on page 5-44. Water pump inlet pipe Refer to OIL COOLER on page 6- 4. Water pump outlet pipe Refer to OIL COOLER on page 6- 4. 1 Oil level switch lead coupler 1 Disconnect.
OIL PUMP 5-59 2 Oil level switch 1 3 Oil level switch lead holder 1 4Oil pan 1 5 Oil pan gasket 1 6 Dowel pin 2 7Drain pipe 1 8Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Relief valve assembly 1 12 Oil/water pump assembly drive chain guide 1 13 Collar 1 14 Oil/water pump assembly drive sprocket 1 15 Washer 1 16 Oil/water pump assembly drive chain 1 17 Dowel pin 1 Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks
OIL PUMP 5-60 18 Oil/water pump assembly 1For assembly, reverse the removal procedure. Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks
OIL PUMP 5-61 Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks1 Oil/water pump driven sprocket 1 2Collar 1 3 Oil pump housing 1 4 Bearing 1 5Pin 2 6 Oil pump outer roter 1 7 Oil pump inner roter 1 8Pin 1 For assembly, reverse the disassem- bly procedure.
OIL PUMP 5-62 EAS24930 REMOVING THE OIL PAN 1. Remove: Oil level switch “1” Oil pan “2” Oil pan gasket Dowel pins 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. ET2D1012 CHECKING THE SPROCKET AND CHAIN 1. Check: Oil/water pump assembly drive sprocket “1”Cracks/damage/wear → Replace the defective part(-s). 2. Check: Oil/water pump assembly drive chain “1”Damag/stiffness → Replace the oil/water pump assembly drive chain and oil/water pump assembly drive sprocket as a set. EAS24960 CHECKING THE OIL PUMP 1. Check: Oil pump driven gear “1” Oil pump rotor housing “2” Oil pump coverCracks/damage/wear → Replace the defective part(s). 2. Measure: Inner-rotor-to-outer-rotor-tip clearance “a” Outer-rotor-to-oil-pump-housing clearance “b” 3. Check: Oil pump operationRough movement → Repeat steps (1) and (2) or replace the defective part(s). Inner-rotor-to-outer-roter-tip- clearance 0.01–0.10 mm (0.0004–0.0039 in) Limit 0.18 mm (0.0071 in) Outer-rotor-to-oil-pump-hous- ingclearance 0.09–0.15 mm (0.0035–0.0059 in) Limit 0.22 mm (0.0087 in) 1. Oil pump inner rotor 2. Oil pump outer rotor 3. Oil pump housing