Yamaha Fz1n Service Manual

							
OIL PUMP
5-63
EAS24970
CHECKING THE RELIEF VALVE
1. Check: Relief valve body “1”
Relief valve “2”
 Spring “3”
 O-ring “4”
Damage/wear  → Replace the defective 
part(s).
EAS24980
CHECKING THE OIL DELIVERY PIPES
1. Check:  Oil delivery pipe “1”
 Oil pipe “2”
Damage  → Replace.
Obstruction  → Wash and blow out with 
compressed air.
EAS24990
CHECKING THE OIL STRAINER
1. Check:  Oil strainer “1”
Damage  → Replace.
Contaminants  → Clean with solvent.
ET2D1013
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil 
nozzles.
1. Check:
 Oil nozzle “1”Damage/wear  → Replace the oil nozzles.
 O-ring “2” Damage/wear  → Replace.
 Oil nozzle passage
Obstruction  → Blow out with compressed 
air.
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:  Inner rotor
 Outer rotor
 Oil pump shaft(with the recommended lubricant)
2. Install: Pin “1”
 Inner rotor “2”
 Outer rotor “3”
 Oil pump housing “4”
Recommended lubricantEngine oil 
						

							
OIL PUMP
5-64
NOTE:
When installing the inner rotor, align the pin “1” 
in the oil pump shaft with the groove in the 
inner rotor “2”.
3. Install: Oil/water pump driven sprocket “1”
NOTE:
5VY mark of the oil/water pump driven gear is 
installed at oil pump side.
4. Check: Oil pump operation
Refer to CHECKING THE OIL PUMP on 
page 5-62.
EAS25030
INSTALLING THE OIL/WATER PUMP 
ASSEMBLY
1. Install:
 Oil ring 
 Oil/water pump assembly “1”
Dowel pin
 Bolts “2” 2. Install:
 Washer
 Oil/water pump assembly drive chain “1”
 Oil/water pump assembly drive sprocket “2”
Collar
NOTE:
Install the oil/water pump assembly drive chain 
“1” onto the oil/water pump assembly drive 
sprocket “2”.
CAUTION:
EC2D1008
After installing the oil/water pump assem-
bly drive chain and drive sprocket, make 
sure the oil/water pump turns smoothly.
3. Install: Oil/water pump assembly drive chain guide 
“1”
NOTE:
“UP” mark of the oil/water pump assembly 
drive chain guide is upward.
Oil/water pump driven sprocket 
bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil/water pump assembly bolt 12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE®
Oil/water pump assembly drive 
chain guide bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE® 
						

							
OIL PUMP
5-65
4. Install: Oil delivery pipe “1”
5. Install: Relief valve “1”
 O-ring 
 Oil strainer “2”
 O-ring 
 Oil pipe “3”
 O-ring 
 Drain pipe “4”
 O-ring 
EAS25050
INSTALLING THE OIL PAN
1. Install: Dowel pins
Gasket 
 Oil pan “1”
 Oil level switch “2”
 Engine oil drain bolt “3”
WARNING
EWA12820
Always use new copper washers.
NOTE:
 Tighten the oil pan bolts in stages and in a 
crisscross pattern.
 Lubricate the oil level switch O-ring with 
engine oil.
Oil delivery pipe bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil strainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE®
Oil pan bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
Oil level switch bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
Engine oil drain bolt43 Nm (4.3 m·kg, 31 ft·lb) 
						

							
CRANKCASE
5-66
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty RemarksAir filter case Refer to GENERAL CHASSIS on  page 4-1.
Throttle body assembly Refer to THROTTLE BODIES on  page 7-4.
Engine Refer to ENGINE REMOVAL on  page 5-2.
Cylinder head Refer to CYLINDER HEAD on  page 5-19.
Generator Refer to GENERATOR on page 5- 31.
Starter clutch Refer to STARTER CLUTCH on  page 5-35.
Shift shaft Refer to SHIFT SHAFT on page 5- 54.
Crankshaft position sensor Refer to CRANKSHAFT POSITION  SENSOR on page 5-38.
Clutch Refer to CLUTCH on page 5-44. 
						

							
CRANKCASE
5-67
Oil pump Refer to OIL PUMP on page 5-58.
Starter motor Refer to ELECTRIC STARTER on page 5-40.
1 Timing chain 1
2 Timing chain guide (intake side) 1
3Pin 2
4 Timing chain guide (exhaust side) 1
5 Left side cover 1
6O-ring 1
7 Lower crankcase 1
8 Dowel pin 3
9Damper 1 For assembly, reverse the removal 
procedure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks 
						

							
CRANKCASE
5-68
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove: Crankcase bolts
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.
 Loosen the bolts in decreasing numerical  order (refer to the numbers in the illustration).
 The numbers embossed on the crankcase 
indicate the crankcase tightening sequence.
M9 x 105 mm (4.1 in) bolts: “1” – “10”
M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®
M8 x 60 mm (2.4 in) bolts: “12”, “16”
M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”
M6 x 65 mm (2.5 in) bolts: “17”, “18”
M6 x 60 mm (2.4 in) bolt and washer: “22”
M6 x 60 mm (2.4 in) bolts: “24”, “25”
M6 x 50 mm (2.0 in) bolts: “20”, “26”
M8 x 50 mm (2.0 in) bolts: “13” – “15”
3. Remove:  Lower crankcase
CAUTION:
ECA13900
Tap on one side of the crankcase with a 
soft-face hammer. Tap only on reinforced 
portions of the crankcase, not on the 
crankcase mating surfaces. Work slowly 
and carefully and make sure the crankcase 
halves separate evenly.
4. Remove: Dowel pins
5. Remove:  Crankshaft journal lower bearing(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal 
lower bearing so that it can be reinstalled in its 
original place.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a 
mild solvent.
2. Thoroughly clean all the gasket surfaces 
and crankcase mating surfaces.
3. Check:  Crankcase
Cracks/damage  → Replace.
 Oil delivery passages Obstruction  → Blow out with compressed 
air.
ET2D1014
CHECKING THE BEARING AND OIL SEALS
1. Check:  Bearings
Clean and lubricate the bearings, then 
rotate the inner race with your finger.
Rough movement  → Replace.
2. Check:  Oil sealsDamage/wear  → Replace.
EAS25650
ASSEMBLING THE CRANKCASE
1. Lubricate:
 Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:  Sealant
NOTE:
Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm 
(0.08–0.12 in) of the crankshaft journal bear-
ings.
Recommended lubricantEngine oil
Yamaha bond No. 1215(Three Bond No.1215®)
90890-85505 
						

							
CRANKCASE
5-69
3. Install: Dowel pin
4. Set the shift drum assembly and transmis- sion gears in the neutral position.
5. Install:  Lower crankcase “1”(onto the upper crankcase “2”)
CAUTION:
ECA13980
Before tightening the crankcase bolts, 
make sure the transmission gears shift cor-
rectly when the shift drum assembly is 
turned by hand.
6. Install:
 Crankcase bolts
NOTE:
 Lubricate the bolt threads with engine oil.
 Install a washer on bolts “1” – “10” and “22”.
 Seal bolt “18”
 Tighten the bolts in the tightening sequence 
cast on the crankcase.
M9 x 105 mm (4.1 in) bolts: “1” – “10”
M8 x 60 mm (2.4 in) bolt: “11” LOCTITE®
M8 x 60 mm (2.4 in) bolts: “12”, “16”
M6 x 70 mm (2.8 in) bolts: “19”, “21”, “23”
M6 x 65 mm (2.5 in) bolts: “17”, “18”
M6 x 60 mm (2.4 in) bolt and washer: “22”
M6 x 60 mm (2.4 in) bolts: “24”, “25”
M6 x 50 mm (2.0 in) bolts: “20”, “26”
M8 x 50 mm (2.0 in) bolts: “13” – “15” *Following the tightening order, loosen the 
bolt one by one and then retighten it to the 
specific torque.
Crankcase bolt
Bolt “1”–“10”
1st: 20 Nm (2.0 m·kg, 14 ft·lb)
2nd*: 20 Nm (2.0 m·kg, 14 ft·lb)
3rd: +60 °
Bolt “11”–“16”
24 Nm (2.4 m·kg, 17 ft·lb)
Bolt “17”–“26” 12 Nm (1.2 m·kg, 8.7 ft·lb) 
						

							
CRANKSHAFT
5-70
EAS25950
CRANKSHAFT
Removing the connecting rods and pistons
Order Job/Parts to remove Q’ty RemarksLower crankcase Refer to CRANKCASE on page 5- 66.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4
4 Piston pin clip 8
5 Piston pin 4
6Piston 4
7 Connecting rod 4
8Top ring 4
9 2nd ring 4
10 Oil ring 4
11 Cylinder 1
12 Cylinder gasket 1 For installation, reverse the removal 
procedure. 
						

							
CRANKSHAFT
5-71
Removing the crankshaft
Order Job/Parts to remove Q’ty RemarksCrankcase Separate. Refer to CRANKCASE on page 5-
66.
Connecting rod and connecting rod 
caps Refer to REMOVING THE CON-
NECTING RODS AND PISTONS 
on page 5-72.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
4 Washer 1
5 Crankshaft drive gear 1
6Pin 1
7Pickup rotor 1 For assembly, reverse the disassem-
bly procedure. 
						

							
CRANKSHAFT
5-72
EAS26030
REMOVING THE CONNECTING RODS AND 
PISTONS
The following procedure applies to all of the 
connecting rods and pistons.
1. Remove: Connecting rod cap “1”
 Big end bearings
NOTE:
 Idetify the position of each big end bearing 
so that it can be reinstalled in its original 
place.
 After removing the connecting rods and con- necting rod caps, care should be taken not to 
damage the mating surfaces of the connect-
ing rods and connecting rod caps.
2. Remove:  Cylinder
 Cylinder gasket
 Cylinder stud bolts
3. Remove:  Piston pin clips “1”
 Piston pin “2”
 Piston “3”
CAUTION:
EC2D1006
Do not use a hammer to drive the piston 
pin out.
NOTE:
 For reference during installation, put identifi-
cation marks on the piston crown.
 Before removing the piston pin, deburr the  piston pin clip groove and the piston pin bore 
area. If both areas are debarred and the pis-
ton pin is still difficult to remove, remove it 
with the piston pin puller set “4”. 4. Remove:
 Top ring
 2nd ring
 Oil ring
NOTE:
When removing a piston ring, open the end 
gap with your fingers and lift the other side of 
the ring over the piston crown.
EAS25980
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove: Crankshaft assembly
 Crankshaft journal upper bearings(from the upper crankcase)
Refer to CRANKSHAFT on page 5-70.
Piston pin puller set90890-01304
Piston pin puller
YU-01304