Yamaha Fz1n Service Manual

							
ENGINE REMOVAL
5-3
Removing the exhaust pipe
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
1 EXUP pulley cover 1
2 EXUP servo motor cover 1
3 EXUP cables 2
4 EXUP servo motor 1
5O
2 sensor 1
6 Exhaust pipe assembly 1
7 Exhaust pipe gasket 4
8 Muffler 1
9 Muffler gasket 1
10 Muffler cover 1
11 Muffler end cover 1 For installation, reverse the removal 
procedure. 
						

							
ENGINE REMOVAL
5-4
Disassembling the exhaust valve pipe
Order Job/Parts to remove Q’ty Remarks1Nut 1
2Pulley 1
3Spring 1
4 Spring seat 1 For assembly, reverse the disassem-
bly procedure. 
						

							
ENGINE REMOVAL
5-5
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty RemarksFuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on  page 4-1.
Throttle body assembly Refe r to THROTTLE BODIES on 
page 7-4.
Engine oil Drain. Refer to CHANGING THE ENGINE 
OIL on page 3-12.
Oil cooler Refer to OIL COOLER on page 6- 4.
Air cut-off valve Refer to AIR INDUCTION SYS- TEM on page 7-13.
Starter motor Refer to ELECTRIC STARTER on  page 5-40.
1 Battery negative lead 1
2 Battery positive lead 1
3Clutch cable 1
4 Ground lead 2
5 Stator coil assembly coupler 1 Disconnect. 
						

							
ENGINE REMOVAL
5-6
6 Crankshaft position sensor lead coupler 1 Disconnect.
7 Oil level switch connector 1 Disconnect.
8 Neutral switch connector 1 Disconnect.
9 Cylinder identification  sensor coupler 1 Disconnect.
10 Speed sensor coupler 1 Disconnect. For assembly, reverse the removal 
procedure.
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty Remarks 
						

							
ENGINE REMOVAL
5-7
Removing the engine
Order Job/Parts to remove Q’ty Remarks1 Right front engine mounting bolt 1 1
2 Left front engine mounting bolt 1
3 Upper self-locking nut 1
4 Upper engine mounting bolt 1
5 Lower self-locking nut 1
6 Lower engine mounting bolt 1
7 Engine mounting adjust bolt 2
8 Engine 1 For assembly, reverse the removal 
procedure. 
						

							
ENGINE REMOVAL
5-8
EAS23720
INSTALLING THE ENGINE
1. Install: Right front engine mounting bolt 2 “1”
Refer to CYLINDER HEAD on page 5-19.
2. Tighten:  Right front engine mounting bolt 2
3. Install:  Engine mounting adjust bolts(temporarily tighten)
4. Install:
 Engine
5. Install:  Lower engine mounting bolt “1”
 Upper engine mounting bolt “2”
 Self-locking nuts
NOTE:
Do not fully tighten the bolts and nuts.
6. Install: Left front engine mounting bolt “1”
(temporarily tighten)
 Right front engine mounting bolt 1 “2” (temporarily tighten) 7. Tighten:
 Engine mounting adjust bolts
NOTE:
Use the pivot shaft wrench “1” and pivot shaft 
wrench adapter “2” to tighten the engine 
mounting adjust bolts.
Right front engine mounting 
bolt 250 Nm (5.0 m·kg, 36 ft·lb)
Engine mounting adjust bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
Pivot shaft wrench90890-01518
Frame spanner socket
YM-01518
Pivot shaft wrench adapter 90890-01476 
						

							
ENGINE REMOVAL
5-9
8. Tighten: Lower self-locking nut “1”
 Upper self-locking nut “2”
NOTE:
First tighten the lower self-locking nut, and 
then tighten the upper self-locking nut.
9. Tighten: Left front engine mounting bolt ”1”
 Right front engine mounting bolt 1 ”2”
Upper self-locking nut51 Nm (5.1 m·kg, 37 ft·lb)
Lower self-locking nut 51 Nm (5.1 m·kg, 37 ft·lb)
Left front engine mounting bolt45 Nm (4.5 m·kg, 33 ft·lb)
Right front engine mounting 
bolt 1
45 Nm (4.5 m·kg, 33 ft·lb) 
						

							
CAMSHAFTS
5-10
EAS23760
CAMSHAFTS
Removing the cylinder head cover
Order Job/Parts to remove Q’ty RemarksFuel tank Refer to FUEL TANK on page 7-1.
Throttle body assembly Refer to THROTTLE BODIES on  page 7-4.
Radiator assembly Refer to RADIATOR on page 6-1.
Air cut-off valve Refer to AIR INDUCTION SYS- TEM on page 7-13.
1 Ignition coil 4
2 Spark plug 4
3 Cylinder head cover 1
4 Cylinder head cover gasket 1
5 Timing chain guide (top side) 1
6 Cylinder identification sensor 1
7O-ring 1 For assembly, reverse the removal 
procedure. 
						

							
CAMSHAFTS
5-11
Removing the camshafts
Order Job/Parts to remove Q’ty RemarksPickup rotor cover Refer to CRANKSHAFT POSITION  SENSOR on page 5-38.
1 Camshaft sprocket bolt 4 Loosen.
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Intake camshaft cap 3
5 Dowel pin 6 Refer to REMOVING THE CAM- SHAFTS on page 5-12.
6 Exhaust camshaft cap 3
7 Dowel pin 6 Refer to REMOVING THE CAM- SHAFTS on page 5-12.
8 Intake camshaft 1
9 Exhaust camshaft 1
10 Camshaft sprocket 2 For assembly, reverse the removal 
procedure. 
						

							
CAMSHAFTS
5-12
EAS23810
REMOVING THE CAMSHAFTS
1. Remove: Pickup rotor cover
Refer to CRANKSHAFT POSITION SEN-
SOR on page 5-38.
2. Align:
 “T” mark “a” on the pickup rotor(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark “a” on the 
pickup rotor with the crankcase mating sur-
face “b”.
NOTE:
TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Loosen: Camshaft sprocket bolts “1”
4. Remove:  Timing chain tensioner “1”
Gasket 5. Remove:
 Camshaft caps “1”
 Dowel pins
CAUTION:
ECA13720
To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
6. Remove: Intake camshaft “1”
 Exhaust camshaft “2”
NOTE:
To prevent the timing chain from falling into the 
crankcase, fasten it with a wire “3”.Camshaft wrench90890-04143