Yamaha Fz1n Service Manual
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TIGHTENING TORQUES 2-14 Cylinder head and exhaust pipe nutM8 8 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe and muffler bolt M 8 1 20 Nm (2.0 m·kg, 14 ft·lb) EXUP pulley and shaft arm nut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) EXUP valve pulley cover bolt M6 2 14 Nm (1.4 m·kg, 10 ft·lb) EXUP cable nut M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb) Exhaust pipe and exhaust pipe bracket bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) EXUP servo motor cover bolt M5 2 2 Nm (0.2 m·kg, 1.4 ft·lb) EXUP servo motor nut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Crankcase stud bolt M10 10 8 Nm (0.8 m·kg, 5.8 ft·lb) Crankcase bolt (main journal) M9 10 See NOTE Crankcase bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bolt M8 1 24 Nm (2.4 m·kg, 17 ft·lb) Crankcase bolt M8 5 24 Nm (2.4 m·kg, 17 ft·lb) Generator rotor cover bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb) Generator rotor cover bolt M8 3 22 Nm (2.2 m·kg, 16 ft·lb) Drive sprocket cover bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankcase cover screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Clutch cover bolt M6 7 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) Pickup rotor cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb) Breather cover bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb) Breather plate bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Plate bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Pickup rotor cover blind bolt M8 1 15 Nm (1.5 m·kg, 11 ft·lb) Generator rotor cover plug M20 1 8 Nm (0.8 m·kg, 5.8 ft·lb) Main gallery plug (oil return) M16 3 8 Nm (0.8 m·kg, 5.8 ft·lb) Main gallery plug M20 1 8 Nm (0.8 m·kg, 5.8 ft·lb) Oil return pipe bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil return plug M12 2 24 Nm (2.4 m·kg, 17 ft·lb) AC magneto lead bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Stator coil screw M6 3 14 Nm (1.4 m·kg, 10 ft·lb) Generator rotor cover screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Thermostat assembly stay bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Starter clutch idler gear bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Clutch boss nut M20 1 95 Nm (9.5 m·kg, 69 ft·lb) Stake Item Thread size Q’ty Tightening torque Remarks
TIGHTENING TORQUES 2-15 NOTE: Cylinder head nut 1 First, tighten the bolts to approximately 19 Nm (1.9 mkg, 14 ftlb) with a torque wrench following the tightening order. 2 Retighten the bolts 67 Nm (6.7 mkg, 48 ftlb) with a torque wrench. Connecting rod cap bolt 1 Tighten the connecting rod bolts to 20 Nm (2.0 mkg, 14 ftlb) and then tighten them further to reach the specified angle 150°. Crankcase bolt (main journal) 1 First, tighten the bolts to approximately 20 Nm (2.0 mkg, 14 ftlb) with a torque wrench following the tightening order. 2 Loosen all the bolts one by one following the tightening order and then tighten them to 20 Nm (2.0 mkg, 14 ftlb) again. 3 Retighten the bolts further to reach the specified angle (60°)Clutch spring bolt M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb) Use a lock washer Drive sprocket nut M22 1 85 Nm (8.5 m·kg, 61 ft·lb) Bearing plate bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Shift fork stopper plate bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Stopper screw M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Shift rod locknut (front) M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift rod locknut (rear) M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Left thread Shift rod joint bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Neutral switch M10 1 20 Nm (2.0 m·kg, 14 ft·lb) Sub-throttle servo motor cover bolt M4 3 2 Nm (0.2 m·kg, 1.4 ft·lb) Coolant temperature sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb) Cylinder identification sensor bol t M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb) Atmospheric pressure sensor bo lt M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Crankshaft position sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil level switch bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Item Thread size Q’ty Tightening torque Remarks
TIGHTENING TORQUES 2-17 EAS20350 CHASSIS TIGHTENING TORQUESItem Thread size Q’ty Tightening torque Remarks Upper bracket pinch bolt M8 2 26 Nm (2.6 m·kg, 19 ft·lb) Steering stem nut M28 1 113 Nm (11.3 m·kg, 82 ft·lb) Upper handlebar holder bolt M8 4 24 Nm (2.4 m·kg, 17 ft·lb) Lower handlebar holder nut M10 2 32 Nm (3.2 m·kg, 23 ft·lb) Lower bracket pinch bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb) Lower ring nut M30 1 SEE NOTE Cap bolt M46 2 23 Nm (2.3 m·kg, 17 ft·lb) Damper rod assembly bolt M10 1 23 Nm (2.3 m·kg, 17 ft·lb) Brake master cylinder bracket bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Brake master cylinder reservoir cap screw M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) Front brake hose union bolt M10 3 30 Nm (3.0 m·kg, 22 ft·lb) Front brake hose holder bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Cowling stay bolt (FZ1-S) M8 2 33 Nm (3.3 m·kg, 24 ft·lb) Cowling bracket bolt (FZ1-S) M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Front fender bolt M6 4 6 Nm (0.6 m·kg, 4.3 ft·lb) Clutch lever holder pinch bolt M6 1 11 Nm (1.1 m·kg, 8.0 ft·lb) Right front engine mounting bolt 1 M10 1 45 Nm (4.5 m·kg, 33 ft·lb) Right front engine mounting bolt 2 M10 1 50 Nm (5.0 m·kg, 36 ft·lb) Left front engine mounting bolt M10 1 45 Nm (4.5 m·kg, 33 ft·lb) Upper self-locking nut M10 1 51 Nm (5.1 m·kg, 37 ft·lb) Lower self-locking nut M10 1 51 Nm (5.1 m·kg, 37 ft·lb) Engine mounting adjust bolt (upper) M11 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Engine mounting adjust bolt (lower) M11 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Pivot shaft nut M18 1 105 Nm (11 m·kg, 76 ft·lb) Connecting arm nut (connecting arm and frame) M10 1 44 Nm (4.4 m·kg, 32 ft·lb) Relay arm nut (relay arm and swingarm) M10 1 44 Nm (4.4 m·kg, 32 ft·lb) Relay arm nut (relay arm and connecting arm) M10 1 44 Nm (4.4 m·kg, 32 ft·lb) Main frame and rear frame nut M10 4 41 Nm (4.1 m·kg, 30 ft·lb) Clutch cable locknut M8 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Throttle cable locknut M6 2 5 Nm (0.5 m·kg, 3.6 ft·lb) Rear shock absorber assembly upper nut M10 1 44 Nm (4.4 m·kg, 32 ft·lb) Rear shock absorber assembly lower nut M10 1 44 Nm (4.4 m·kg, 32 ft·lb) Drive chain guard bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb) Drive chain guide bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear fender screw M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
TIGHTENING TORQUES 2-18 Rear brake hose holder screw M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt (front) M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bolt (rear) M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank bracket screw M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank cap bolt M5 5 6 Nm (0.6 m·kg, 4.3 ft·lb) Fuel pump bolt M5 6 4 Nm (0.4 m·kg, 2.9 ft·lb) Seat lock assembly nut M6 27 Nm (0.7 m·kg, 5.1 ft·lb) Mud guard assembly bolt M8 4 16 Nm (1.6 m·kg, 12 ft·lb) License plate light screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Rear reflector nut M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Mud guard assembly bracket screw M5 6 2 Nm (0.2 m·kg, 1.4 ft·lb) Tail/brake light bracket bolt M8 3 16 Nm (1.6 m·kg, 12 ft·lb) Rear fender bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) Seat bracket bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) Exhaust pipe assembly bracket bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) Side cover screw M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Lean angle sensor bolt M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) Coolant reserver tank bolt M6 1 5 Nm (0.5 m·kg, 3.6 ft·lb) Front wheel axle shaft M18 1 72 Nm (7.2 m·kg, 52 ft·lb) Front wheel axle pinch bolt M 8 1 23 Nm (2.3 m·kg, 17 ft·lb) Front brake caliper bolt M10 4 40 Nm (4.0 m·kg, 29 ft·lb) Front brake disc screw M6 10 18 Nm (1.8 m·kg, 13 ft·lb) Brake caliper bleed screw M8 3 5 Nm (0.5 m·kg, 3.6 ft·lb) Rear wheel axle nut M24 1 150 Nm (15.0 m·kg, 108 ft·lb) Rear brake disc screw M8 5 30 Nm (3.0 m·kg, 22 ft·lb) Rear brake caliper bolt (front) M12 1 27 Nm (2.7 m·kg, 20 ft·lb) Rear brake caliper bolt (rear) M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Rear wheel sprocket nut M10 6 100 Nm (10.0 m·kg, 72 ft·lb) Drive chain adjusting locknut M8 2 16 Nm (1.6 m·kg, 12 ft·lb) Rear brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb) Sidestand nut M10 1 48 Nm (4.8 m·kg, 35 ft·lb) Sidestand bracket bolt M10 2 63 Nm (6.3 m·kg, 46 ft·lb) Sidestand switch bolt M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Footrest bracket bolt M8 4 30 Nm (3.0 m·kg, 22 ft·lb) Rear brake fluid reserver tank bolt M5 1 4 Nm (0.4 m·kg, 2.9 ft·lb) Rear brake master cylinder bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb) Centerstand nut (FZ1-S) M10 2 56 Nm (5.6 m·kg, 41 ft·lb) Centerstand bracket nut (FZ1-S) M10 4 55 Nm (5.5 m·kg, 40 ft·lb) Centerstand bracket adapter bolt (FZ1-S) M10 2 73 Nm (7.3 m·kg, 53 ft·lb) Footrest bolt M10 4 55 Nm (5.5 m·kg, 40 ft·lb) Throttle cable adjust nut M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Item Thread size Q’ty Tightening torque Remarks
TIGHTENING TORQUES 2-19 NOTE: 1 First, tighten the ring nut to approximately 52 Nm (5.2 mkg, 38 ftlb) with a torque wrench, then loosen the lower ring nut completely. 2 Retighten the lower ring nut 18 Nm (1.8 mkg, 13 ftlb).Clutch cable adjust nut M8 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Item Thread size Q’ty Tightening torque Remarks
LUBRICATION POINTS AND LUBRICANT TYPES 2-20 EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Oil/water pump drive sprocket and washer Clutch (thrust plate) Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No. 1215 Crankcase mating surface Yamaha bond No. 1215 Clutch cover (crankcase mating surface) Yamaha bond No. 1215 Generator rotor cover (crankcase mating surface) Yamaha bond No. 1215
LUBRICATION POINTS AND LUBRICANT TYPES 2-21 Pickup rotor cover Yamaha bond No. 1215 Lubrication point Lubricant
LUBRICATION POINTS AND LUBRICANT TYPES 2-22 EAS20380 CHASSISLubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Engine mount bolts (front left and right) Relay arm, connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end, oil seal and bush Oil seal (relay arm, connecting arm and rear shock absorber) Seat lock assembly moving parts Sidestand pivoting point and me tal-to-metal moving parts Sidestand switch contact point Sidestand hook and spring contact point Shift shaft joint rod moving parts Shift pedal pivoting parts Rear footrest ball and metal-to-metal moving parts Centerstand metal-to-metal moving parts (FZ1-S) Front wheel oil seal (left and right) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART