Yamaha Fz1n Service Manual
Have a look at the manual Yamaha Fz1n Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
SPECIAL TOOLS 1-12 Oil filter wrench 90890-01426 YU-384113-13 Rod holder 90890-01434 Damper rod holder double ended YM-01434 4-50, 4-55 Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A8703 4-54 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A8703 4-54 Fork spring compressor 90890-01441 YM-01441 4-50, 4-55 Fork seal driver 90890-01442 Adjust table fork seal driver (36-46 mm) YM-01442 4-53 Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456 3-7 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-13 Compression gauge 90890-03081 Engine compression tester YU-332233-11 Valve spring compressor 90890-04019 YM-04019 5-23, 5-29 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter (22 mm) YM-04108 5-23, 5-29 Valve spring compressor attachment 90890-04114 Valve spring compressor adapter YM-04114 5-23, 5-29 Middle driven shaft bearing driver 90890-04058 Bearing driver (40 mm) YM-04058 6-12 Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A 6-12 Universal clutch holder 90890-04086 YM-91042 5-47, 5-51 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-14 Valve guide remover (ø4) 90890-04111 Valve guide remover (4.0 mm) YM-041115-25 Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 5-25 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 5-25 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) YM-04117 5-25 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 5-25 Valve guide reamer (ø4.5) 90890-04118 Valve guide reamer (4.5 mm) YM-04118 5-25 Ignition checker 90890-06754 Opama pet-4000 spark checker YU-34487 8-104 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-15 Yamaha bond No.1215 (Three Bond No.1215®) 90890-855055-67, 6-12 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 7-9, 7-10 Pivot shaft wrench 90890-01518 Frame spanner socket YM-01518 5-7 Pivot shaft wrench adapter 90890-01476 5-7 Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1-10, 5-41, 8- 95, 8-96, 8-97, 8-100, 8-102, 8- 103, 8-104, 8- 105, 8-106, 8- 107, 8-108, 8- 109, 8-110, 8- 111, 8-112 Oil pressure gauge 90890-03153 Pressure gauge YU-03153 3-14 Oil pressure gauge adapter 90890-03139 3-14 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-16 Vacuum/pressure pump gauge set 90890-067567-8 Valve lapper 90890-04101 Valve lapping tool YM-A8998 3-5 Fuel pressure adapter 90890-03176 YM-03176 7-8 Pressure gauge 90890-03153 YU-03153 3-14, 7-8 Camshaft wrench 90890-04143 YM-04143 5-11, 5-16 Tool name/Tool No. Illustration Reference pages
2 SPECIFICATIONS GENERAL SPECIFICATIONS...................................................................... 2-1 ENGINE SPECIFICATIONS .......................................................................... 2-1 CHASSIS SPECIFICATIONS ....................................................................... 2-8 ELECTRICAL SPECIFICATIONS ............................................................... 2-10 TIGHTENING TORQUES ............................................................................ 2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS....................... 2-12 ENGINE TIGHTENING TORQUES ...................................................... 2-13 CHASSIS TIGHTENING TORQUES .................................................... 2-17 LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-20 ENGINE ................................................................................................ 2-20 CHASSIS .............................................................................................. 2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS ................................. 2-23 ENGINE OIL LUBRICATION CHART ................................................... 2-23 LUBRICATION DIAGRAMS .................................................................. 2-25 COOLING SYSTEM DIAGRAMS ............................................................... 2-35 CABLE ROUTING ...................................................................................... 2-39
GENERAL SPECIFICATIONS 2-1 EAS20280 GENERAL SPECIFICATIONS ModelModel 2D11 (EUR) 2D13 (AUS) 3C31 (EUR) 3C33 (AUS) 3C37 (EUR) 3C39 (AUS) Dimensions Overall length 2140 mm (84.3 in) Overall width 770 mm (30.3 in) Overall height 1060 mm (41.7 in) (FZ1-N) 1205 mm (47.4 in) (FZ1-S) Seat height 815 mm (32.1 in) Wheelbase 1460 mm (57.5 in) Ground clearance 135 mm (5.31 in) Minimum turning radius 3000 mm (118.1 in) Weight With oil and fuel 214.0 kg (472 lb) (FZ1-N) 220.0 kg (485 lb) (FZ1-S) Maximum load 196 kg (432 lb) (FZ1-N) 190 kg (419 lb) (FZ1-S) EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998.0 cm³ (60.90 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 11.50 : 1 Standard compression pressure (at sea level) 1480 kPa/350 r/min (210.5 psi/350 r/min) (14.8 kgf/cm²/350 r/min) Starting system Electric starter Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 18.0 L (4.76 US gal) (3.96 Imp.gal) Fuel reserve amount 3.4 L (0.90 US gal) (0.75 Imp.gal) Engine oilLubrication system Wet sump Type SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade API service SE, SF, SG type or higher Engine oil quantity Total amount 3.80 L (4.02 US qt) (3.34 Imp.qt) Without oil filter cartridge replacement 2.90 L (3.07 US qt) (2.55 Imp.qt) With oil filter cartridge replacement 3.10 L (3.28 US qt) (2.73 Imp.qt) Oil filterOil filter type Paper Oil pumpOil pump type Trochoid
ENGINE SPECIFICATIONS 2-2 Inner-rotor-to-outer-rotor-tip clearance 0.010–0.100 mm (0.0004–0.0039 in) Limit 0.18 mm (0.0071 in) Outer-rotor-to-oil-pump-housing clear ance 0.090–0.150 mm (0.0035–0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.06–0.13 mm (0.0024–0.0051 in) Limit 0.20 mm (0.0079 in) Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) Relief valve operating pressure 600.0–680.0 kPa (87.0–98.6 psi) (6.00–6.80 kgf/cm²) Cooling system Radiator capacity (including all routes) 2.25 L (2.38 US qt) (1.98 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23 kgf/cm²) Radiator core Width 222.6 mm (8.76 in) Height 360.0 mm (14.17 in) Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 65/43 × 25/32 (1.181) Max impeller shaft tilt limit 0.15 mm (0.0059 in) Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder headVolume 12.20–13.00 cm³ (0.74–0.79 cu.in) Warpage limit* 0.10 mm (0.0039 in) CamshaftDrive system Chain drive (right) Camshaft cap inside diameter 22.500–22.521 mm (0.8858–0.8867 in) Camshaft journal diameter 22.459–22.472 mm (0.8842–0.8847 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Camshaft lobe dimensionsIntake A 32.500–32.600 mm (1.2795–1.2835 in) Limit 32.400 mm (1.2756 in) Intake B 24.950–25.050 mm (0.9823–0.9862 in) Limit 24.850 mm (0.9783 in) Exhaust A 30.699–30.799 mm (1.2086–1.2126 in) Limit 30.599 mm (1.2047 in) Exhaust B 22.950–23.050 mm (0.9035–0.9075 in) Limit 22.850 mm (0.8996 in)
ENGINE SPECIFICATIONS 2-3 Camshaft runout limit 0.030 mm (0.0012 in) Timing chainModel/number of links RH2020/122 Tensioning system Automatic Valve, valve seat, valve guideValve clearance (cold)Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.21–0.25 mm (0.0083–0.0098 in) Valve dimensions Valve head diameter A (intake) 23.40–23.60 mm (0.9213–0.9291 in) Valve head diameter A (exhaust) 24.90–25.10 mm (0.9803–0.9882 in) Valve face width B (intake) 1.760–2.900 mm (0.0693–0.1142 in) Valve face width B (exhaust) 1.760–2.900 mm (0.0693–0.1142 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in) Valve margin thickness D (exhaust) 0.50–0.90 mm (0.0197–0.0354 in) Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in) Limit 3.945 mm (0.1553 in) Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)