Yamaha Fz1n Service Manual

							
GENERAL CHASSIS
4-6
Removing the air filter case
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
1 Intake air temperature sensor lead cou- pler 1 Disconnect.
2 Intake air temperature sensor 1
3 Air filter case cover 1
4 Air filter 1
5 Funnel 2
6 Air filter case 1
7 Air induction system hose 1
8 Crankcase breather hose 1 For installation, reverse the removal 
procedure. 
						

							
GENERAL CHASSIS
4-7
EAS21840
REMOVING THE COVER
1. Remove:Tail cover
 Rear fender
NOTE:
To remove the quick fastener, push its center 
with a screwdriver, then pull the fastener out.
EAS21850
INSTALLING THE COVER
1. Install: Rear fender
Tail cover
NOTE:
To install the quick fastener, push its pin so that 
it protrudes from the fastener head, then insert 
the fastener into the cover and push the pin “a” 
in with screwdriver. Make sure that the pin is 
flush with the fastener’s head. 
						

							
FRONT WHEEL
4-8
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs
Order Job/Parts to remove Q’ty Remarks1 Brake hose holder (left and right) 2
2 Front brake caliper (left and right) 2
3 Front wheel axle pinch bolt 1
4 Front wheel axle 1
5 Collar (left and right) 2
6Dust cover 2
7 Front wheel 1
8 Front brake disc (left and right) 2 For installation, reverse the removal 
procedure. 
						

							
FRONT WHEEL
4-9
Disassembling the front wheel
Order Job/Parts to remove Q’ty Remarks1 Oil seal (left and right) 2
2 Wheel bearing (left and right) 2
3 Spacer 1 For assembly, reverse the disassem-
bly procedure. 
						

							
FRONT WHEEL
4-10
EAS21900
REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that 
the front wheel is elevated.
2. Remove: Left brake caliper
 Right brake caliperRefer to FRONT BRAKE on page 4-20.
NOTE:
Do not apply the brake lever when removing 
the brake calipers.
3. Elevate:  Front wheel
NOTE:
Place the vehicle on a suitable stand so that 
the front wheel is elevated.
4. Loosen: Front wheel axle pinch bolt
5. Remove:  Front wheel axle
 Front wheel
EAS21920
CHECKING THE FRONT WHEEL
1. Check:
 Wheel axleRoll the wheel axle on a flat surface.
Bends  → Replace.
WARNING
EWA13460
Do not attempt to straighten a bent wheel 
axle.
2. Check:
Tire
 Front wheel
Damage/wear  → Replace. Refer to CHECKING THE TIRES on page 
3-32 and CHECKING THE WHEELS on 
page 3-34.
3. Measure:  Radial wheel runout “1”
 Lateral wheel runout “2”
Over the specified limits  → Replace.
4. Check:  Wheel bearingsFront wheel turns roughly or is loose  → 
Replace the wheel bearings.
 Oil seals
Damage/wear  → Replace.
5. Replace:  Wheel bearings 
 Oil seals 
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a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head  screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2” 
between the screwdriver and the wheel sur-
face.
Radial wheel runout limit1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in) 
						

							
FRONT WHEEL
4-11
c. Remove the wheel bearings “3” with a gen-eral bearing puller.
d. Install the new wheel bearings and oil seals  in the reverse order of disassembly.
CAUTION:
ECA14130
Do not contact the wheel bearing inner race 
“1” or balls “2”. Contact should be made 
only with the outer race “3”.
NOTE:
Use a socket “4” that matches the diameter of 
the wheel bearing outer race and oil seal.
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EAS21970
ADJUSTING THE FRONT WHEEL STATIC 
BALANCE
NOTE:
 After replacing the tire, wheel or both, the front wheel static balance should be 
adjusted.  Adjust the front wheel static balance with the 
brake disc installed.
1. Remove:  Balancing weight(s)
2. Find:  Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing 
stand.
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a. Spin the front wheel.
b. When the front wheel stops, put an “X
1” 
mark at the bottom of the wheel.
c. Turn the front wheel 90 ° so that the “X
1” 
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X
2” mark at 
the bottom of the wheel.
f. Repeat steps (c) through (e) several times  until all the marks come to rest at the same 
spot.
g. The spot where all the marks come to rest  is the front wheel’s heavy spot “X”.
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3. Adjust:
 Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 
						

							
FRONT WHEEL
4-12
a. Install a balancing weight “1” onto the rim exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90 ° so that the heavy 
spot is positioned as shown.
c. If the heavy spot does not stay in that posi- tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front  wheel is balanced.
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4. Check:
 Front wheel static balance
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a. Turn the front wheel and make sure it stays  at each position shown.
b. If the front wheel does not remain station- ary at all of the positions, rebalance it.
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EAS22000
INSTALLING THE FRONT WHEEL (DISC)
The following procedure applies to both of the 
brake discs.
1. Lubricate: Wheel axle
 Oil seal lips
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
NOTE:
Install the tire and wheel with the mark “1” 
pointing in the direction of wheel rotation.
4. Lower the front wheel so that it is on the  ground.
5. Tighten:  Wheel axle
 Wheel axle pinch bolt
CAUTION:
ECA14140
Before tightening the front wheel axle, push 
down hard on the handlebar several times 
and check if the front fork rebounds 
smoothly.
6. Install: Brake caliper
Recommended lubricantLithium-soap-based grease
Wheel axle nut72 Nm (7.2 m·kg, 52 ft·lb)
Wheel axle pinch bolt23 Nm (2.3 m·kg, 17 ft·lb)
Brake caliper bolt
40 Nm (4.0 m·kg, 29 ft·lb) 
						

							
FRONT WHEEL
4-13
WARNING
EWA13490
Make sure the brake cable is routed prop-
erly.
NOTE:
Make sure that there is enough space between 
the brake pads before installing the brake cali-
pers onto the brake discs. 
						

							
REAR WHEEL
4-14
EAS22020
REAR WHEEL
Removing the rear wheel
Order Job/Parts to remove Q’ty Remarks1 Rear brake caliper 1
2 Locknut (left and right) 2 Loosen.
3 Adjusting bolt (left and right) 2 Loosen.
4 Wheel axle nut 1
5 Washer 1
6 Rear wheel axle 1
7 Adjusting block (left) 1
8 Adjusting block (right) 1
9 Rear wheel 1
10 Brake caliper bracket 1 For installation, reverse the removal 
procedure. 
						

							
REAR WHEEL
4-15
Removing the brake disc and rear wheel sprocket
Order Job/Parts to remove Q’ty Remarks1 Rear brake disc 1
2 Rear wheel sprocket 1
3 Coller (left and right) 2
4Dust cover 2
5 Oil seal 1
6 Bearing 1
7 Rear wheel drive hub 1
8 Rear wheel drive hub damper 6
9 Rear wheel 1 For installation, reverse the removal 
procedure.