Yamaha Fz1n Service Manual

							
ENGINE
3-16
4. Install: Air filter case cover
CAUTION:
ECA14400
Never operate the engine without the air fil-
ter element installed. Unfiltered air will 
cause rapid wear of engine parts and may 
damage the engine. Operating the engine 
without the air filter element will also affect 
throttle bodies synchronization, leading to 
poor engine performance and possible 
overheating.
NOTE:
When installing the air filter element into the air 
filter case cover, make sure that the sealing 
surfaces are aligned to prevent any air leaks.
5. Install:
Fuel tankRefer to FUEL TANK on page 7-1.
 Rider and passenger seat
Refer to GENERAL CHASSIS on page 4-
1.
EAS21010
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the 
throttle body joints and intake manifolds.
1. Remove:  Throttle bodies
Refer to THROTTLE BODIES on page 7-
4.
2. Check:
 Throttle body joints “1”Cracks/damage  → Replace.
3. Install:  Throttle bodiesRefer to THROTTLE BODIES on page 7-
4.
EAS21030
CHECKING THE FUEL LINE
The following procedure applies to all of the 
fuel, vacuum and breather hoses. 1. Remove:
 Rider and passenger seat
Refer to GENERAL CHASSIS on page 4-
1.
 Fuel tank
Refer to FUEL TANK on page 7-1.
2. Check:  Fuel hose “1”
 Vacuum hose “2”
 Breather hose “3”Cracks/damage  → Replace.
Loose connection  → Connect properly.
NOTE:
Before removing the fuel hoses, place a few 
rags in the area under where it will be 
removed.
CAUTION:
ECA14940
Make sure the fuel tank breather hose is 
routed correctly.
3. Install:
 Fuel tankRefer to FUEL TANK on page 7-1.
 Rider and passenger seat Refer to GENERAL CHASSIS on page 4-
1.
CAUTION:
ECS2D002
To install the fuel tank, check that the 
breather hose is not folded or pinched by 
the fuel tank.
EAS21070
CHECKING THE CRANKCASE BREATHER 
HOSE
1. Remove: Rider and passenger seat
Refer to GENERAL CHASSIS on page 4-
1.
 Fuel tank 
						

							
ENGINE
3-17
Refer to FUEL TANK on page 7-1.
2. Check:
 Crankcase breather hose “1”Cracks/damage  → Replace.
Loose connection  → Connect properly.
CAUTION:
ECA13450
Make sure the crankcase breather hose is 
routed correctly.
3. Install:
 Fuel tankRefer to FUEL TANK on page 7-1.
 Rider and passenger seat
Refer to GENERAL CHASSIS on page 4-
1.
CAUTION:
ECS2D003
To install the fuel tank, check that the 
breather hose is not folded or pinched by 
the fuel tank.
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the 
exhaust pipes and gaskets.
1. Check: Exhaust pipe “1”
 Muffler “2”
Cracks/damage  → Replace.
 Gaskets “3” Exhaust gas leaks  → Replace.
2. Check: Tightening torque
 Exhaust pipe nut “4”
 Exhaust pipe and exhaust pipe bracket bolt 
“5”
 Exhaust pipe and muffler bolt “6”
 Muffler and rear footrest bracket bolt “7”
NOTE:
When installing the EXUP cables, make sure 
they are parallel and not twisted.
 Upper cable: White metal section “8”
 Lower cable: Black metal section “9”
ET2D1005
ADJUSTING THE EXUP CABLES
1. Remove:
 EXUP valve pulley cover “1”
Exhaust pipe nut20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe and exhaust pipe 
bracket bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe and muffler bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler and rear footrest 
bracket bolt 48 Nm (4.8 m·kg, 35 ft·lb) 
						

							
ENGINE
3-18
2. Check: EXUP system operation
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a. Activate the diagnostic mode and select  the diagnostic code number “53”.
Refer to FUEL INJECTION SYSTEM on 
page 8-31.
b. Set the engine stop switch to “ ”.
c. Check that the EXUP valve operates prop- erly.
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3. Check:
 EXUP cable free play (at the EXUP valve pulley) “a” and “b”
4. Adjust:  EXUP cable free play
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a. Turn the main switch to “ON”
b. Check the EXUP pulley position.
c. Loosen the locknut “1”.
d. Loosen the locknut “3”
e. Turn the adjusting nut “2” in or out.
f. Tighten the locknut.
g. Turn the adjusting nut “4” in or out.
h. Tighten the locknut.
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5. Install: EXUP valve pulley cover
EAS28360
CHECKING THE EXUP SERVO MOTOR
1. Check: EXUP servo motor operationOut of specification  → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check whether or not the EXUP valve is 
seized.
 Disconnect the EXUP cable and check that 
the EXUP valve is moved smoothly by 
hand.
 When the valve is not moved smoothly, 
repair or replace it.
Refer to ADJUSTING THE EXUP 
CABLES on page 3-17.
b. When the EXUP valve is moved smoothly,  replace the EXUP servo motor.
c. Perform the self-diagnosis mode and check 
the operation of EXUP valve by visual 
inspection (Code No: 53).
The operation should be carried out as 3-
second drive in the full open direction, 2-
second stop and 3-second drive in the full 
close direction.
d. Check that the EXUP servo motor pulley  rotates several times.
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EAS21110
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
 Place the vehicle on a suitable stand.
 Make sure the vehicle is upright.
2. Check:
Maximum EXUP cable free play 
(at the EXUP valve pulley)a: Less than 3 mm (0.12 in)
b: Less than 3 mm (0.12 in)
EXUP cable locknut6 Nm (0.6 m·kg, 4.3 ft·lb)
EXUP valve pulley cover bolt
14 Nm (1.4 m·kg, 10 ft·lb) 
						

							
ENGINE
3-19
 Coolant levelThe coolant level should be between the 
maximum level mark “a” and minimum level 
mark “b”.
Below the minimum level mark  → Add the 
recommended coolant to the proper level.
CAUTION:
ECA13470
 Adding water instead of coolant lowers  the antifreeze content of the coolant. If 
water is used instead of coolant check, 
and if necessary, correct the antifreeze 
concentration of the coolant.
 Use only distilled water. However, if dis-
tilled water is not available, soft water 
may be used.
3. Start the engine, warm it up for several  minutes, and then turn it off.
4. Check:
 Coolant level
NOTE:
Before checking the coolant level, wait a few 
minutes until it settles.
EAS21120
CHECKING THE COOLING SYSTEM
1. Check: Radiator “1”
 Radiator inlet hose “2”
 Radiator outlet hose “3”
 Oil cooler “4”
 Oil cooler inlet hose “5”
 Oil cooler outlet hose “6”
 Water jacket joint “7”
 Water jacket joint inlet hose “8”
 Water pump inlet pipe “9”
 Water pump outlet pipe “10”
Cracks/damage  → Replace.
Refer to RADIATOR on page 6-1.
EAS21130
CHANGING THE COOLANT
1. Remove:  Rider and passenger seatRefer to GENERAL CHASSIS on page 4-
1.
2. Remove:  Coolant reservoir tank
 Coolant reservoir hose
3. Disconnect:  Coolant reservoir cap “1” 
						

							
ENGINE
3-20
4. Drain: Coolant(from the coolant reservoir)
5. Remove:
 Radiator cap “1”
WARNING
EWA13030
A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the 
engine is hot. Scalding hot fluid and steam 
may be blown out, which could cause seri-
ous injury. When the engine has cooled, 
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap 
counterclockwise toward the detent to 
allow any residual pressure to escape. 
When the hissing sound has stopped, 
press down on the radiator cap and turn it 
counterclockwise to remove.
The following procedure applies to all of the 
coolant drain bolts and copper washers.
6. Remove:  Coolant drain bolts “1”(along with the copper washers) 7. Drain:
 Coolant(from the water pump inlet pipe and outlet 
pipe)
8. Check:
 Copper washers “1” 
9. Install:  Coolant drain bolts “2”
10. Install:  Coolant reservoir tank
11. Connect:  Coolant reservoir hose
12. Fill:
 Cooling system(with the specified amount of the recom-
mended coolant)
Handling notes for coolant
Coolant drain bolt10 Nm (1.0 m·Kg, 7.2 ft·lb)
Recommended antifreeze
High-quality ethylene glycol 
antifreeze containing corrosion 
inhibitors for aluminum engines
Mixing ratio 1:1 (antifreeze: water)
Quantity
Total amount 2.25 L
(1.98 lmp qt, 2.38 US qt)
Coolant reservoir capacity 0.25 L
(0.22 lmp qt, 0.26 US qt) 
						

							
ENGINE
3-21
Coolant is potentially harmful and should 
be handled with special care.
WARNING
EWA13040
 If coolant splashes in your eyes, thor-oughly wash them with water and consult 
a doctor.
 If coolant splashes on your clothes, 
quickly wash it away with water and then 
with soap and water.
 If coolant is swallowed, induce vomiting 
and get immediate medical attention.
CAUTION:
ECA13480
 Adding water instead of coolant lowers 
the antifreeze content of the coolant. If 
water is used instead of coolant check, 
and if necessary, correct the antifreeze 
concentration of the coolant.
 Use only distilled water. However, if dis-
tilled water is not available, soft water 
may be used.
 If coolant comes into contact with painted  surfaces, immediately wash them with 
water.
 Do not mix different types of antifreeze.
13. Install:
 Radiator cap
14. Fill:
 Coolant reservoir tank(with the recommended coolant to the max-
imum level mark “a”)
15. Install:  Coolant reservoir cap
16. Start the engine, warm it up for several 
minutes, and then stop it.
17. Check:  Coolant level
Refer to CHECKING THE COOLANT 
LEVEL on page 3-18.
NOTE:
Before checking the coolant level, wait a few 
minutes until the coolant has settled.
18. Install: Rider and passenger seat
Refer to GENERAL CHASSIS on page 4-
1. 
						

							
CHASSIS
3-22
EAS21140
CHASSIS
EAS21160
ADJUSTING THE FRONT DISC BRAKE
1. Adjust: Brake lever position(distance “a” from the throttle grip to the 
brake lever)
NOTE:
 While pushing the brake lever forward, turn 
the adjusting dial “1” until the brake lever is in 
the desired position.
 Be sure to align the setting on the adjusting  dial with the arrow mark “2” on the brake 
lever holder.
WARNING
EWA13060
 After adjusting the brake lever position, make sure the pin on the brake lever 
holder is firmly inserted in the hole in the 
adjusting dial.
 A soft or spongy feeling in the brake lever  can indicate the presence of air in the 
brake system. Before the vehicle is oper-
ated, the air must be removed by bleeding 
the brake system. Air in the brake system 
will considerably reduce in loss of control 
and possibly an accident. Therefore, 
check and if necessary, bleed the brake 
system.
CAUTION:
ECA13490
After adjusting the brake lever position, 
make sure there is no brake drag.
EAS21190
ADJUSTING THE REAR DISC BRAKE
1. Adjust: Brake pedal position
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a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or 
“b” until the specified brake pedal position 
is obtained.
WARNING
EWA13070
After adjusting the brake pedal position, 
check that the end of the adjusting bolt “c” 
is visible through the hole “d”.
c. Tighten the locknut “1” to specification.
WARNING
EWA13050
A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance.
CAUTION:
ECA13510
After adjusting the brake pedal position, 
make sure there is no brake drag.
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2. Adjust: Rear brake light switch
Refer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-24.
Direction “b”
Distance “a” is the largest.
Direction “c”
Distance “a” is the smallest.
Direction “a” Brake pedal is raised.
Direction “b” Brake pedal is lowered.
Locknut18 Nm (1.8 m·kg, 13 ft·lb) 
						

							
CHASSIS
3-23
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
 Place the vehicle on a suitable stand.
 Make sure the vehicle is upright.
2. Check: Brake fluid levelBelow the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
WARNING
EWA13090
 Use only the designated brake fluid. 
Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid  that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of  the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the 
brake fluid level, make sure the top of the 
brake fluid reservoir is horizontal.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
 Front brake pad
Wear indicators “a” almost touch the brake 
disc  → Replace the brake pads as a set.
Refer to FRONT BRAKE on page 4-20.
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
 Rear brake padWear indicators “b” almost touch the brake 
disc  → Replace the brake pads as a set.
Refer to REAR BRAKE on page 4-32.
Recommended brake fluid DOT4
A. Front brake
B. Rear brake 
						

							
CHASSIS
3-24
EAS21280
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the 
brake hoses and brake hose clamps.
1. Check:Brake hose “1”Cracks/damage/wear  → Replace.
2. Check:  Brake hose clamp “2”
Loose  → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the front  brake several times.
4. Check: Brake hoseBrake fluid leakage  → Replace the dam-
aged hose.
Refer to FRONT BRAKE on page 4-20.
EAS21290
CHECKING THE REAR BRAKE HOSE
1. Check: Brake hose “1”Cracks/damage/wear  → Replace. 2. Check:
 Brake hose clamp “2”Loose Connection  → Tighten the clamp 
bolt.
3. Hold the vehicle upright and apply the rear  brake several times.
4. Check:
Brake hoseBrake fluid leakage  → Replace the dam-
aged hose.
Refer to REAR BRAKE on page 4-32.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT 
SWITCH
NOTE:
The rear brake light switch is operated by 
movement of the brake pedal. The rear brake 
light switch is properly adjusted when the 
brake light comes on just before the braking 
effect starts.
1. Check:
 Rear brake light operation timingIncorrect  → Adjust.
2. Adjust:  Rear brake light operation timing
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a. Lifting the brake light switch, hold the main  body “1” of the rear brake light switch so 
that it does not rotate and turn the adjusting  
						

							
CHASSIS
3-25
nut “2” in direction “a” or “b” until the rear 
brake light comes on at the proper time.
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EAS21350
BLEEDING THE HYDRAULIC BRAKE SYS-
TEM
WARNING
EWA13100
Bleed the hydraulic brake system when-
ever:
 The system is disassembled.
 A brake hose is loosened, disconnected or replaced.
 The brake fluid level is very low.
 Brake operation is faulty.
NOTE:
 Be careful not to spill any brake fluid or allow  the brake master cylinder reservoir or brake 
fluid reservoir to overflow.
 When bleeding the hydraulic brake system, 
make sure there is always enough brake fluid 
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic 
brake system, considerably lengthening the 
bleeding procedure.
 If bleeding is difficult, it may be necessary to  let the brake fluid settle for a few hours. 
Repeat the bleeding procedure when the tiny 
bubbles in the hose have disappeared.
1. Bleed:  Hydraulic brake system
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a. Fill the brake fluid reservoir to the proper  level with the recommended brake fluid.
b. Install the diaphragm (brake master cylin- der reservoir or brake fluid reservoir). c. Connect a clear plastic hose “1” tightly to 
the bleed screw “2”.
d. Place the other end of the hose into a con- tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press  down the brake pedal and hold it in posi-
tion.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the 
pressure and cause the brake lever to contact 
the throttle grip or the brake pedal to fully 
extend.
h. Tighten the bleed screw and then release  the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air  bubbles have disappeared from the brake 
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the brake fluid reservoir to the proper  level with the recommended brake fluid.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
Direction “a”
Brake light comes on sooner.
Direction “b” Brake light comes on later.
A. Front brake caliper
B. Rear brake caliper
Bleed screw5 Nm (0.5 m·kg, 3.6 ft·lb)