Yamaha Fz1n Service Manual

							
CABLE ROUTING
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1. Clutch cable
2. Water pump breather hose
3. Oil level switch lead
4. Sidestand switch lead
5. O
2 sensor lead
6. Coolant reservoir tank drain hose
7. Wire harness
8. Battery negative lead
9. Seat lock cable
10.AC magneto lead
11.Rectifier/regulator lead
12.Water pump inlet pipe
13.Radiator fan motor lead (left)
14.Radiator stay
15.Main switch lead
16.Immobilizer lead
17.Left handlebar switch lead
18.Horn
19.Clutch cable swaging metal
20.Throttle cable
21.Stay assembly
22.Upper bracket
23.Right handlebar switch lead
24.Brake hose
25.Horn lead
26.Throttle body
27.Stay 1
28.Drive chain case cover
29.Starter motor lead
30.Fuel tank breather hose
31.EXUP cables
32.Rear brake light switch lead
33.Rear brake fluid reservoir hose
34.Speed sensor lead
A. Route in the concavity section of the radia- tor stay.
B. To the coolant reservoir tank
C. Clamp the wire harness, AC magneto lead,  rectifier/regulator lead , starter motor lead 
and battery negative lead. Point the clamp 
head to the inside of the vehicle and fit it so 
that the band tip is pointed downward.
D. Pass the O
2 sensor lead through the vehi-
cle inner side of the hose assembly 1 junc-
tion pipe of the water pump inlet pipe and 
route it by the outer down side of the hose 
assembly 1 and to the upper direction as 
shown in the illustration.
E. To the exhaust
F. Route the O
2 sensor lead to the vehicle 
rear side where the water pump inlet pipe 
is routed.
G. Physical relationship between the coolant  reservoir tank drain hose tip and sidestand 
switch lead can be in random order. H. Route the hose assembly 1 by the vehicle 
front side where the water pump inlet pipe 
is routed. For the hose tip position, route 
the hose so that 10 mm (0.39 in) or more 
can be assured as shown in the illustration.
I. More than 10 mm (0.39 in)
J. Route the sidestand switch lead by the  vehicle front side where the hose assembly 
1 and water pump inlet pipe are routed.
K. Pass the oil level switch lead to the vehicle  front side of the water pump breather hose 
and water pipe.
L. Route the AC magneto lead by the inside  of the frame.
M. There should be no exposure of bare con- ductors due to the misalignment of tubes.
N. Route the AC magneto lead by the inside  of vehicle away from the water hose.
O. Clamp the clutch cable, radiator fan motor  lead (left) and water pump breather hose. 
Point the clamp head to the upper side of 
the vehicle and fit it so that the band tip is 
positioned inside. For the band position, 
install the band using the engine position 
as a guide as shown in the illustration.
P. Insert the clamp to the frame and clamp  the clutch cable. For the clamping position, 
place the clamp so that the caulking 
attachment on the clutch  cable side is posi-
tioned at the vehicle front side where the 
clamp is located. Clamp opening should be 
positioned at the outside of the vehicle.
Q. The inserting direction of the onion-head of  the horn lead shall be  as shown in the illus-
tration.
R. The front side of the vehicle.
S. The outside of the vehicle.
T. The upper side of the vehicle.
U. The inside of the vehicle.
V. Route the clutch cable under the convexity  sections of the throttle bodies.
W. Route the radiator fan motor lead (left)  between the convexity sections of the throt-
tle bodies.
X. Route the wire harness between the con- vexity sections of the throttle bodies.
Y. Innermost section of the vehicle.
Z. Can be routed in any order.
AA.Route the water pump breather hose  finally in the guide after passing other 
hoses so that it can be positioned on the 
outside of the vehicle.
AB.Route the coolant reservoir tank drain  hose so that it is positioned at the inner-
most part in hoses and leads.
AC.The rear side of the vehicle.
AD.To the radiator
AE.Open to the air 
						

							
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AF.The coolant reservoir tank drain hose shall cross with the speed sensor lead under the 
rear arm bracket. The coolant reservoir 
tank drain hose shall be positioned above 
the vehicle. 
						

							
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1. Throttle cables
2. Right handlebar switch lead
3. Wire harness
4. Throttle cable (pull side)
5. Throttle cable (return side)
6. Radiator fan motor lead (Right)
7. Coolant reservoir tank hose
8. Radiator inlet hose
9. Air filter drain hose
10.Crankshaft position sensor lead
11.Direct ignition coil lead coupler
12.Immobilizer anti safety alarm coupler
13.Engine ground lead
14.Neutral switch lead
15.Rear brake light switch lead
16.EXUP cable
17.EXUP servo motor
18.Main fuse
19.Atmospheric pressure sensor
20.Battery positive lead
21.Radiator fan motor relay
22.Starting circuit cut-off relay
23.Fuse box
24.Lean angle sensor
25.Turn signal light lead (right)
26.License plate light lead
27.Turn signal relay
28.Turn signal light lead (left)
29.Seat lock cable
30.Tail/brake light lead
31.Tail/brake light lead coupler
32.Headlight relay
33.Turn signal light lead coupler (left)
34.Starter relay
35.Fuel tank breather hose
36.Battery negative lead
37.AC magneto lead
38.Starter motor lead
39.Coolant reservoir tank drain hose
40.Fuel hose bend R section
41.Idle adjust screw wire
42.Throttle body lead
43.Air cut-off valve hose
44.ECU (engine control unit)
45.Water pump breather hose
46.Radiator fan motor lead (left)
47.Clutch cable
48.Left handlebar switch lead
49.Main switch lead
50.Immobilizer lead
51.Frame
52.Cover53.Direct ignition coil lead
54.Speed sensor lead
55.Lean angle sensor lead
56.Battery box
57.Turn signal light relay lead
58.Rear frame
59.Battery
60.Sidestand switch lead
61.Oil level switch lead
62.O
2 sensor lead
63.Velcro
64.Protector
65.Mad guard
66.Fender
67.Fuel hose
A. Check that it is secured with the guide of  the radiator stay.
B. To the direct ignition coil lead
C. Make sure to install the air filter after  checking that the leads are positioned out-
side of the vehicle from the throttle body 
side cover.
D. To the engine
E. Direct ignition coil lead protector edge
F. Bind the left handle bar switch leads, main  switch leads, right handle bar switch leads, 
immobilizer leads, radiator fan motor leads 
(right), wire harness and direct ignition 
leads (in random order). Make sure to set 
the clamping position to be ahead of the 
immobilizer anti-safety alarm coupler and 
rear brake switch leadÅfs branch position, 
and to be within a range of 0 to 30 mm (0 
to 1.18 inches) away from the protector 
end of the direct ignition coil lead. Install 
the band pointing its tip end downward 
inside the vehicle.
G. Route the pickup coil lead below the fuel  hose, throttle body hoses and air filter drain 
hose.
H. Route the wire harness below the clutch  cable and route the coupler branched from 
the wire harness below the clutch cable 
and then connect it.
I. Insert the wire harness wrapping clamp to  the hole of the frame.
J. To the rear brake light switch
K. Open to the air
L. Insert the main fuse to the battery band.  Soapy water can be spread.
M. Route the battery positive lead under the  relays.
N. Route the fuse box lead under the radiator  fan motor relay.
O. Route the battery positive lead above the  fuse box lead.
P. Pass the license plate light lead and turn  signal light lead under the turn signal relay. 
						

							
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Q. Pass the turn signal light lead (right) and license plate light lead under the rear 
fender bracket and route between the ribs 
of the battery box.
R. Pass the turn signal light lead (left) and tail/ brake light lead under the rear fender 
bracket and route between the ribs of the 
battery box.
S. Route the tail/brake light lead by the inner  side of the rear fender bracket and the out-
side of the battery box ribs. When installing 
the tail cover assembly, pay attention so 
that it does not catch anything between 
rear frame and rear fender bracket surface.
T. After wiring the coupler, make sure to  cover the connector with the squid-shaped 
protective cover on the wire harness side 
and then insert it to the space made by the 
external side of rear frame and tail cover 
assembly. At this time, the lead should be 
pushed in so that the lead does not hook 
on the seat loading accepter.
U. Route the tail/brake light lead in the space  made by the top surface of the rear frame 
and the bottom face of the seat bracket. 
When installing the se at bracket, pay atten-
tion so that the lead is not caught by the 
rear frame surface.
V. Route the battery positive lead from the  inner side of the vehicle to the down side of 
the wire harness. It is not allowed to route 
the lead over the wire harness.
W. Route it so that the branch connection of  the main fuse lead is placed in the upper 
side.
X. To the rectifier/regulator. Route the AC.  magneto lead and rectifier/regulator lead 
inside the battery box.
Y. To the speed sensor
Z. Route the AC. magneto lead under the   clutch cable.
AA.To the fuel pump
AB.Fit so that the engine ground lead is posi- tioned below and the battery negative lead 
above. Fit the leads so that each projection 
of lead is positioned on the upper side of 
the vehicle.
AC.To the starter motor
AD.Route the leads under the throttle bodies.
AE.Route the intake air temperature sensor by  the upper side of the air filter drain hose.
AF.To the air filter case
AG.Check that the radiator fan motor lead  (left) is secured with the guide of the radia-
tor stay.
AH.Positioning tape (shaded area)
AI. Fit the protector by aligning the positioning  tape end and protector end for the main 
switch lead, immobilizer lead and left han-
dlebar switch lead. The misalignment toler-
ance of ends is ±5 mm (0.20 in). AJ.Clamp each lead at the positioning taping 
section (white) and then insert it to the 
cover. (In random order)
AK.Clamp each lead at the positioning taping  section (blue) and then insert it to the 
cover. For routing leads, the wire harness 
shall be downside but others can be in ran-
dom order. Positioning tape is only used for 
the wire harness and right handlebar 
switch.
AL.The upper side of the vehicle.
AM.The inside of the vehicle.
AN.Secure the leads with a clamp. The cut  position of the tip of the clamp shall be on 
the upper side of the vehicle. (Cut it leaving 
2 to 4mm (0.08 to 0.16in) of the tip). Route 
the leads over the frame plate and insert 
them through the hole into the inside of the 
vehicle.
AO.Route the lean angle sensor lead at the  uppermost side of the vehicle. Also, it must 
not be protruded from the battery box ribs 
toward the upper side.
AP.Routing can be in random order.
AQ.Push the wire harness securely in as far  as it will go.
AR.Secure the leads with a clamp. The cut  position of the tip of the clamp shall be on 
the upper side of the vehicle. (Cut it leaving 
2 to 4mm (0.08 to 0.16in) of the tip). Route 
the leads over the frame plate and insert 
them through the hole into the inside of the 
vehicle. Route the wire harness at the posi-
tion shown in the  illustration and other 
leads can be in random order. Inserting the 
band can be in any direction. 
AS.15 X 20 mm (0.59 X 0.79 in) (shaded area)
AT. Installation procedure  1. Secure the main  switch lead and immob ilizer lead with Vel-
cro strap.  2. Secure the left handlebar 
switch lead with Velcro strap.  The main 
switch lead and immobilizer lead shall not 
be twisted in the protector. The installation 
position is where the protector end and 
lead positioning tape end align.
AU.20 X 58 mm (0.79 X 2.28 in) (shaded area)
AV.Route it between the battery box ribs in the  order indicated in the figure.
AW.Clamp the fuel hose and direct ignition coil  lead. Point the opening section of the 
clamp to the front side of the vehicle and 
install it at the position as shown in the 
illustration. 
						

							
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FZ1-S1. Clutch cable
2. Left handlebar switch lead
3. Immobilizer lead
4. Main switch lead
5. Protector
6. Throttle cables
7. Right handlebar switch lead
8. Throttle cable (pull side)
9. Throttle cable (return side)
10.Bracket
11.Wire harness
12.Turn signal light lead
13.Seat lock cable
14.Tail/brake light lead
15.Battery box
16.Mud guard
17.Fender
18.Frame
19.Cover
A. Positioning tape (shaded area)
B. Secure the wire harness to the bracket.  Position the clamp head on the upper side 
of the vehicle and point the tip to the front 
side of the vehicle.
C. Attach the clamp to the front upper cowl- ing. Clamp the turn signal light lead (left) 
and headlight lead.
D. Pass the turn signal light lead (left) and tail/ brake light lead under the rear fender 
bracket.
E. Pass the turn signal light lead (left) the  route between the ribs of the battery box 
and tail/brake light lead.
F. Clamp each lead at the positioning taping  section and then insert it to the cover. (In 
random order) Positioning tape is only 
used for the right handlebar switch. Fit 
other leads so that they are not slack.
G. Clamp each lead at the positioning taping  section and then insert it to the cover. (In 
random order) Route the rear side of the 
vehicle to the wire harness. 
						

							
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