Yamaha Fz1n Service Manual
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TRANSMISSION 5-93 4. Check: TransmissionRough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
6 COOLING SYSTEM RADIATOR.................................................................................................... 6-1 CHECKING THE RADIATOR.................................................................. 6-3 INSTALLING THE RADIATOR ................................................................ 6-3 OIL COOLER ................................................................................................ 6-4 CHECKING THE OIL COOLER.............................................................. 6-5 INSTALLING THE OIL COOLER ............................................................ 6-5 THERMOSTAT .............................................................................................. 6-6 CHECKING THE THERMOSTAT ............................................................ 6-8 ASSEMBLING THE THERMOSTAT ASSEMBLY ................................... 6-8 INSTALLING THE THERMOST AT ASSEMBLY ...................................... 6-8 WAT E R P U M P ............................................................................................ 6-10 DISASSEMBLING THE WATER PUMP ............................................... 6-11 CHECKING THE WATER PUMP .......................................................... 6-11 ASSEMBLING THE WATER PUMP ..................................................... 6-11
RADIATOR 6-1 EAS26380 RADIATOR Removing the radiator 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. Air filter case Refer to GENERAL CHASSIS on page 4-1. Coolant Drain. Refer to CHANGING THE COOL- ANT on page 3-19. 1 Radiator side covers 2 2 Coolant reservoir hose 1 3 Radiator front cover 1 4 Radiator 1 5 Radiator fan motor 2 6 Radiator inlet hose 1 7 Oil cooler outlet hose 1 8 Water pump breather hose 1 9 Radiator outlet hose 1
RADIATOR 6-2 10 Water pump inlet pipe 1 11 O-ring 1For installation, reverse the removal procedure. Removing the radiator Order Job/Parts to remove Q’ty Remarks
RADIATOR 6-3 EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: Radiator hoses Radiator pipes Cracks/damage → Replace. 3. Measure: Radiator cap opening pressureBelow the specified pressure → Replace the radiator cap. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the radiator cap tester “1” and radia- tor cap tester adapter “2” to the radiator cap “3”. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check:Radiator fanDamage → Replace. Malfunction → Check and repair. Refer to RADIATOR on page 6-1. EAS26400 INSTALLING THE RADIATOR 1. Fill: Cooling system(with the specified amount of the recom- mended coolant) Refer to CHANGING THE COOLANT on page 3-19. 2. Check: Cooling system Leaks → Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to CHECKING THE RADIATOR on page 6-3. Radiator cap opening pressure 93.3 - 122.7 kPa (0.93 - 1.23 kg/cm 2, 0.9 - 1.2 bar, 13.5 - 17.8 psi) Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984
OIL COOLER 6-4 EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE OIL on page 3-12. 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 3 Washer 1 4 Oil cooler 1 5O-ring 1 6 Water pump outlet pipe 1 7O-ring 1 8 Water jacket joint inlet hose 1 9O-ring 1 10 Water jacket joint 1 11 Stay 1 12 O-ring 1 For assembly, reverse the removal procedure.
OIL COOLER 6-5 EAS26420 CHECKING THE OIL COOLER 1. Check: Oil cooler Cracks/damage → Replace. 2. Check: Oil cooler inlet hose Oil cooler outlet hoseCracks/damage/wear → Replace. EAS26430 INSTALLING THE OIL COOLER 1. Clean: Mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thin- ner) 2. Install: O-ring Oil cooler “1” Washer “2” Oil cooler bolt “3” NOTE: Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil. Make sure the O-ring is positioned properly. Align the projection “a” on the oil cooler with the slot “b” in the crankcase. 3. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to CHANGING THE COOLANT on page 3-19. Crankcase (with the specified amount of the recom- mended engine oil) Refer to CHANGING THE ENGINE OIL on page 3-12. 4. Check: Cooling systemLeaks → Repair or replace any faulty part. 5. Measure: Radiator cap opening pressureBelow the specified pressure → Replace the radiator cap. Refer to CHECKING THE RADIATOR on page 6-3. Oil cooler bolt 63 Nm (6.3 m·kg, 46 ft·lb)
THERMOSTAT 6-6 EAS26440 THERMOSTAT Removing the thermostat assembly 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. Air filter case Refer to GENERAL CHASSIS on page 4-1. Coolant Drain. Refer to CHANGING THE COOL- ANT on page 3-19. 1 Thermostat assembly outlet hose 1 2 Thermostat assembly 1 3 Thermostat assembly inlet hose 1 4 Band 2 For installation, reverse the removal procedure.
THERMOSTAT 6-7 Disassembling the thermostat assembly Order Job/Parts to remove Q’ty Remarks1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 4O-ring 1 For assembly, reverse the disassem- bly procedure.
THERMOSTAT 6-8 EAS26450 CHECKING THE THERMOSTAT 1. Check: Thermostat Does not open at 71 – 85 °C (160 – 185 °F) → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container “4” filled with water. b. Slowly heat the water “2”. c. Place a thermometer “1” in the water. d. While stirring the water, observe the ther- mostat and thermometer’s indicated tem- perature. NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause seri- ous overheating or overcooling. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: Thermostat housing cover “1” Thermostat housing “2” Cracks/damage → Replace. EAS26460 ASSEMBLING THE THERMOSTAT ASSEM- BLY 1. Install: Thermostat housing “1” Thermostat “2” O-ring “3” Thermostat housing cover “4” NOTE: Install the thermostat with its breather hole “a” facing up. EAS26480 INSTALLING THE THERMOSTAT ASSEM- BLY 1. Fill: Cooling system(with the specified amount of the recom- mended coolant) Refer to CHANGING THE COOLANT on page 3-19. 2. Check: Cooling systemLeaks → Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure A. Fully closed B. Fully open Thermostat housing cover nut10 Nm (1.0 m·kg, 7.2 ft·lb)