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Yamaha Fz1n Service Manual

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    Page
    of 451
    							
    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 
    						
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