Yamaha Fz1n Service Manual

							
ENGINE SPECIFICATIONS
2-4
Limit 4.425 mm (0.1742 in)
Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in)
Limit 4.050 mm (0.1594 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.550 mm (0.1791 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
 
Valve springInner spring
Free length (intake) 40.47 mm (1.59 in)
Free length (exhaust) 40.53 mm (1.60 in)
Installed length (intake) 32.66 mm (1.29 in)
Installed length (exhaust) 33.88 mm (1.33 in)
Spring rate K1 (intake) 17.53 N/mm (100.10 lb/in) (1.79 kgf/mm)
Spring rate K2 (intake) 22.86 N/mm (130.53 lb/in) (2.33 kgf/mm)
Spring rate K1 (exhaust) 21.52 N/mm (122.88 lb/in) (2.19 kgf/mm)
Spring rate K2 (exhaust) 27.99 N/mm (159.82 lb/in) (2.85 kgf/mm)
Installed compression spring force (intake) 127.40–144.60 N (28.64–32.51 lb) (12.99– 14.74 kgf)
Installed compression spring force (exhaust) 133.00–153.00 N (29.90–34.39 lb) (13.56– 15.60 kgf)
Spring tilt (intake)* 2.5  °/1.8 mm
Spring tilt (exhaust)* 2.5  °/1.8 mm
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
 
Cylinder Bore 77.000–77.010 mm (3.0315–3.0319 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
 
PistonPiston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Limit 0.12 mm (0.0047 in)
Diameter D 76.975–76.990 mm (3.0305–3.0311 in)
Height H 5.0 mm (0.20 in) 
						

							
ENGINE SPECIFICATIONS
2-5
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in)
Piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in)
 
Piston ringTop ringRing type Barrel
Dimensions (B  × T) 0.90  × 2.75 mm (0.04  × 0.11 in)
End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
2nd ring
Ring type Taper
Dimensions (B  × T) 0.80  × 2.75 mm (0.03  × 0.11 in)
End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Oil ring
Dimensions (B  × T) 1.50  × 2.25 mm (0.06  × 0.09 in)
End gap (installed) 0.10–0.40 mm (0.0039–0.0157 in)
 
Connecting rod Oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green
 
CrankshaftWidth A 55.20–56.60 mm (2.173–2.228 in)
Width B 298.75–300.65 mm (11.76–11.84 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) 
						

							
ENGINE SPECIFICATIONS
2-6
Journal oil clearance (using plastigauge®) 0.014–0.037 mm (0.0006–0.0015 in)
Bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green
 
ClutchClutch type Wet, multiple-disc
Clutch release method Outer pull, rack and pinion pull
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 9 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 8 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 52.50 mm (2.07 in)
Spring quantity 6 pcs
 
Transmission
Transmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 65/43 (1.512)
Secondary reduction system Chain drive
Secondary reduction ratio 45/17 (2.647)
Operation Left foot operation
Gear ratio1st 38/15 (2.533)
2nd 33/16 (2.063)
3rd 37/21 (1.762)
4th 35/23 (1.522)
5th 27/20 (1.350)
6th 29/24 (1.208)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
 
Shifting mechanism
Shift mechanism type Guide bar
Shift fork guide bar bending limit 0.100 mm (0.0039 in)
Shift fork thickness 5.80–5.88 mm (0.2283–0.2315 in)
 
Air filterAir filter element Oil-coated paper element
 
Fuel pump
Pump type Electrical
Model/manufacturer 2D1/DENSO
Maximum consumption amperage 4.3 A
Output pressure 324.0 kPa (47.0 psi) (3.24 kgf/cm²)
 
Fuel injectionModel/quantity 297500-0300/4
Manufacturer DENSO
 
Throttle bodyType/quantity SE 45EIDW-B10/1
Manufacturer MIKUNI
ID mark 2D11 00
Throttle valve size #100
 
Throttle position sensorResistance 4.9–5.1 k Ω
Output voltage (at idle) 0.63–0.73 V
  
						

							
ENGINE SPECIFICATIONS
2-7
Idling conditionEngine idling speed 1100–1300 r/min
Intake vacuum 30.0 kPa (8.9 inHg) (225 mmHg)
Water temperature 95.0–105.0  °C (203.00–221.00  °F)
Oil temperature 80.0–90.0  °C (176.00–194.00  °F)
Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
  
						

							
CHASSIS SPECIFICATIONS
2-8
EAS20300
CHASSIS SPECIFICATIONS
ChassisFrame type Diamond
Caster angle 25.00  °
Trail 109.0 mm (4.29 in)
 
Front wheel
Wheel type Cast wheel
Rim size 17M/C x MT3.50
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
 
Rear wheelWheel type Cast wheel
Rim size 17M/C x MT6.00
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
 
Front tireSize 120/70 ZR17M/C (58W)
Manufacturer/model MICHELIN/Pilot Road S
Manufacturer/model DUNLOP/D221FA
Wear limit (front) 0.8 mm (0.03 in)
 
Rear tireSize 190/50 ZR17M/C (73W)
Manufacturer/model MICHELIN/Pilot Road D
Manufacturer/model DUNLOP/D221G
Wear limit (rear) 0.8 mm (0.03 in)
 
Tire air pressure (measured on cold tires)Loading condition 0–90 kg (0–198 lb)
Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
Loading condition 90–196 kg (198–432 lb) (FZ1-N)  90–190 kg (198–419 lb) (FZ1-S)
Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
High-speed riding
Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
 
Front brake Type Dual disc brake
Operation Right hand operation
Front brake lever free play 2.3–11.5 mm (0.09–0.45 in)
Front disc brakeDisc outside diameter  × thickness 320.0  × 4.5 mm (12.60  × 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness (inner) 4.5 mm (0.18 in)
Limit 0.5 mm (0.02 in)
Brake pad lining thickness (outer) 4.5 mm (0.18 in)
Limit 0.5 mm (0.02 in) 
						

							
CHASSIS SPECIFICATIONS
2-9
Master cylinder inside diameter 16.00 mm (0.63 in)
Caliper cylinder inside diameter 30.20 mm (1.19 in)
Caliper cylinder inside diam eter 27.00 mm (1.06 in)
Recommended fluid DOT 4
 
Rear brake
Type Single disc brake
Operation Right foot operation
Brake pedal free play 4.3–9.3 mm (0.17–0.37 in)
Rear disc brakeDisc outside diameter  × thickness 245.0  × 5.0 mm (9.65  × 0.20 in)
Brake disc thickness li mit 4.5 mm (0.18 in)
Brake disc deflection li mit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.0 mm (0.24 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 6.0 mm (0.24 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diam eter 38.20 mm (1.50 in)
Recommended fluid DOT 4
 
Steering
Steering bearing type Angular bearing
Lock to lock angle (left) 33.0  °
Lock to lock angle (right) 33.0  °
 
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm (5.12 in)
Fork spring free length 243.5 mm (9.59 in)
Collar length 100.0 mm (3.94 in)
Installed length 239.0 mm (9.41 in)
Spring rate K1 9.32 N/mm  (53.22 lb/in) (0.95 kgf/mm)
Spring stroke K1 0.0–130.0 mm (0.00–5.12 in)
Inner tube outer diameter 43.0 mm (1.69 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Suspension oil 01 or equivalent
Quantity 545.0 cm³ (18.43 US oz) (19.18 Imp.oz)
Level 91.0 mm (3.58 in)
 
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 60.0 mm (2.36 in)
Spring free length 191.3 mm (7.53 in)
Installed length 181.8 mm (7.16 in)
Spring rate K1 120.00 N/mm (685.20 lb/in) (12.24 kgf/mm)
Spring stroke K1 0.0–60.0 mm (0.00–2.36 in)
Optional spring available No
Enclosed gas/air pressure (STD) 1000 kPa (142.2 psi) (10.0 kgf/cm²)
 
Drive chain
Type/manufacturer 50VA8/DAIDO
Link quantity 122
Drive chain slack 25.0–35.0 mm (0.98–1.38 in)
15-link length limit 239.3 mm (9.42 in)
  
						

							
ELECTRICAL SPECIFICATIONS
2-10
EAS20310
ELECTRICAL SPECIFICATIONS
Vo l t a g eSystem voltage 12 V
 
Ignition system
Ignition system Transistorized coil ignition (digital)
Ignition timing (B.T.D.C.) 5.0  °/1200 r/min
 
Engine control unit
Model/manufacturer TBDF20/DENSO
 
Transistorized coil ignitionCrankshaft position sensor resistance 336–504  Ω at 20 °C (68 °F)
 
Ignition coil
Model/manufacturer F6T558/MITSUBISHI
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 1.19–1.61  Ω at 20 °C (68 °F)
Secondary coil resistance 8.5–11.5 k Ω at 20 °C (68 °F)
 
AC magneto
Model/manufacturer STATOR:F074T85073/MITSUBISHI
Standard output 14.0 V40.0 A6500 r/min
Stator coil resistance 0.14–0.18  Ω at 20 °C (68 °F)
 
Voltage regulator
Rectifier/regulatorRegulator type Semi conductor-short circuit
Model/manufacturer FH012AA/SHINDENGEN
Regulated voltage (DC) 14.2–14.8 V
Rectifier capacity 50.0 A
Withstand voltage 40.0 V
 
Battery Model YTZ14S
Voltage, capacity 12 V, 11.2 Ah
Specific gravity 1.310
Manufacturer GYM
Ten hour rate amperage 1.12 A
 
HeadlightBulb type Halogen bulb
 
Bulb voltage, wattage  × quantity
Headlight 12 V, 60 W/55.0 W  × 1 (FZ1-N) 
12 V, 60 W/55.0 W  × 2 (FZ1-S)
Auxiliary light 12 V, 5.0 W  × 2
Tail/brake light 12 V, 5.0 W/21.0 W  × 1
Front turn signal light 12 V, 10.0 W  × 2
Rear turn signal light 12 V, 10.0 W  × 2
License plate light 12 V, 5.0 W  × 1
Meter lighting LED
 
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
Oil level warning light LED
High beam indicator light LED 
						

							
ELECTRICAL SPECIFICATIONS
2-11
Coolant temperature warning light LED
Engine trouble warning light LED
Immobilizer system indicator light LED
 
Electric starting systemSystem type Constant mesh
 
Starter motorModel/manufacturer SM13/MITSUBA
Power output 0.80 kW
Armature coil resistance 0.0250–0.0350  Ω
Brush overall length 12.5 mm (0.49 in)
Limit 5.00 mm (0.20 in)
Brush spring force 7.65–10.01 N (27.54–36.03 oz) (780–1021 gf)
Commutator diameter 28.0 mm (1.10 in)
Limit 27.0 mm (1.06 in)
Mica undercut (depth) 0.70 mm (0.03 in)
 
Starter relay
Model/manufacturer 2768109-A/JIDECO
Amperage 180.0 A
Coil resistance 4.18–4.62  Ω at 20 °C (68 °F)
 
Horn
Horn type Plane
Quantity 1 pcs
Model/manufacturer YF-12/NIKKO
Maximum amperage 3.0 A
Coil resistance 1.15–1.25  Ω at 20 °C (68 °F)
Performance 105–113 dB/2m
 
Turn signal/hazard relay
Relay type Full transistor
Model/manufacturer FE218BH/DENSO
Built-in, self-canceling device No
Turn signal blinking frequency 75.0–95.0 cycles/min
Wattage 10 W  × 2.0 +3.4 W
 
Oil level gauge
Model/manufacturer 5VY/SOMIC ISHIKAWA
 
Servo motorModel/manufacturer 2D1/YAMAHA
 
FusesMain fuse 50.0 A
Headlight fuse 15.0 A (FZ1-N) 25.0 A (FZ1-S)
Taillight fuse 10.0 A
Signaling system fuse 10.0 A
Ignition fuse 15.0 A
Radiator fan fuse 10.0 A  × 2
Fuel injection system fuse 15.0 A
Backup fuse 10.0 A
Reserve fuse 25.0 A (FZ1-S)
Reserve fuse 15.0 A
Reserve fuse 10.0 A
  
						

							
TIGHTENING TORQUES
2-12
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE SPECIFI-
CATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread 
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided 
for each chapter of this manual. To avoid 
warpage, tighten multi-fastener assemblies in 
a crisscross pattern and progressive stages 
until the specified tightening torque is reached. 
Unless otherwise specified, tightening torque 
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut) B (bolt) General tightening  torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94 
						

							
TIGHTENING TORQUES
2-13
EAS20340
ENGINE TIGHTENING TORQUESItem Thread 
size Q’ty Tightening torque Remarks
Spark plug M10 4 13 Nm (1.3 m·kg, 9.4 ft·lb)
Cylinder head nut M10 10 See NOTE
Cylinder head bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb)
Camshaft caps bolt M6 28 10 Nm (1.0 m·kg, 7.2 ft·lb)
Cylinder head cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb)
Cylinder head stud bolt (exhaust 
pipe) M8 8 15 Nm (1.5 m·kg, 11 ft·lb)
Air indication system cap bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft sprocket bolt M7 4 24 Nm (2.4 m·kg, 17 ft·lb)
Cylinder head and throttle body 
clamp M5 4 3 Nm (0.3 m·kg, 2.2 ft·lb)
Connecting rod cap bolt (1st) M8 8 20 Nm (2.0 m·kg, 14 ft·lb)
Connecting rod cap bolt (final) M8 8 Specified angle 150 °
Generator rotor bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump outlet pipe bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump inlet pipe bolt (water 
pump side) M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump inlet pipe bolt (front 
side) M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil/water pump drive sprocket 
bolt M6 1 15 Nm (1.5 m·kg, 11 ft·lb)
Water pump bolt M6 5 12 Nm (1.2 m·kg, 8.7 ft·lb)
Thermostat cover nut M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Thermostat inlet pipe bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil cooler bolt M20 1 63 Nm (6.3 m·kg, 46 ft·lb)
Engine oil drain bolt M14 1 43 Nm (4.3 m·kg, 31 ft·lb)
Oil pipe bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil strainer bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil delivery pipe bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil filter union bolt M20 1 70 Nm (7.0 m·kg, 51 ft·lb)
Oil filter M20 1 17 Nm (1.7 m·kg, 12 ft·lb)
Oil pan bolt M6 14 12 Nm (1.2 m·kg, 8.7 ft·lb)
Oil pan bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Air filter case cover screw M5 11 1.2 Nm (0.12 m·kg, 0.9 ft·lb)
Throttle body and throttle body 
joint clamp M5 4 3 Nm (0.3 m·kg, 2.2 ft·lb)
Throttle body and funnel bolt M5 6 4.2 Nm (0.42 m·kg, 3.0 ft·lb)
Throttle cable adjusting bolt M6 1 4.5 Nm (0.45 m·kg, 3.3 ft·lb)