Yamaha Fz1n Service Manual
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CABLE ROUTING 2-54 1. Fuel tank 2. Fuel tank drain hose 3. Fuel tank breather hose 4. Clip 5. Air filter bracket 6. 3 way connector 7. Hose 8. Fuel hose 9. Damper 10.Collar 11.Fuel tank bracket 12.O-ring 13.Fuel pump A. Hook the cover pawl to the fuel tank bracket. B. The knob of the clip can be positioned in any direction. C. Assemble the two fold ing sections of the collar flange as shown in the illustration. D. Fit the knob of the clip as shown in the illustration. E. Fit the white paint section of the hose pointed downward. F. Pass the hose through the fuel tank bracket clamp. There should be no bend of the hose between the fuel tank nipple and clamp. G. Align the projection part with the pump seat nut. H. Fit the orange double lock side to the pump side. I. Fit the black double lock side to the engine side. J. The fuel tank bracket shall not run on the tank flange as shown in the illustration. K. Fit the O-ring with its lip pointed upward. L. Tightening sequence M. Fuel piping connector attachment direc- tions. (fuel pump side) Always perform the connection/disconnection works by hand. Do not use tools. N. 1. Insert the connector until the click sound is heard and check that the connector does not come off. Make sure that no foreign matter is caught in the sealing section. (It is prohibited to wear the cotton work gloves or equivalent coverings.) O. This part works as a dropout stopper. P. 2.After Step [N] as above is finished, check that the connector is completely attached by sliding the double lock (orange part) on the connector as shown in the illustration and seeing if it touches firmly or not.
3 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE......................................................................... 3-1 INTRODUCTION .................................................................................... 3-1 ENGINE ......................................................................................................... 3-4 ADJUSTING THE VALVE CLEARANCE ................................................ 3-4 SYNCHRONIZING THE THROTTLE BODIES ....................................... 3-6 ADJUSTING THE EXHAUST GAS VOLUME ......................................... 3-8 ADJUSTING THE ENGINE IDLING SPEED .......................................... 3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-9 CHECKING THE SPARK PLUGS......................................................... 3-10 MEASURING THE COMPRESSI ON PRESSURE ............................... 3-10 CHECKING THE ENGINE OIL LEVEL ................................................. 3-11 CHANGING THE ENGINE OIL............................................................. 3-12 MEASURING THE ENGINE OIL PRESSURE ..................................... 3-13 ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-14 REPLACING THE AIR FILTER ELEMENT ........................................... 3-15 CHECKING THE THROTTLE BODY JOINTS ...................................... 3-16 CHECKING THE FUEL LINE ............................................................... 3-16 CHECKING THE CRANKCASE BREA THER HOSE ............................ 3-16 CHECKING THE EXHAUST SYSTEM ................................................. 3-17 ADJUSTING THE EXUP CABLES ....................................................... 3-17 CHECKING THE EXUP SERVO MOTOR ............................................ 3-18 CHECKING THE COOLANT LEVEL .................................................... 3-18 CHECKING THE COOLING SYSTEM ................................................. 3-19 CHANGING THE COOLANT ................................................................ 3-19 CHASSIS .................................................................................................... 3-22 ADJUSTING THE FRONT DISC BRAKE ............................................. 3-22 ADJUSTING THE REAR DISC BRAKE ............................................... 3-22 CHECKING THE BRAKE FLUID LEVEL .............................................. 3-23 CHECKING THE FRONT BRAKE PADS .............................................. 3-23 CHECKING THE REAR BRAKE PADS ................................................ 3-23 CHECKING THE FRONT BR AKE HOSES........................................... 3-24 CHECKING THE REAR BRAKE HOSE ............................................... 3-24 ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................. 3-24 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................. 3-25 ADJUSTING THE SHIFT PEDAL ......................................................... 3-26 ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-26 LUBRICATING THE DRIVE CHAIN...................................................... 3-27 CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-27 CHECKING THE FRONT FORK .......................................................... 3-28 ADJUSTING THE FRONT FORK LEGS .............................................. 3-29 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................ 3-31 CHECKING THE TIRES ....................................................................... 3-32 CHECKING THE WHEELS .................................................................. 3-34 CHECKING AND LUBRICATING THE CABLES .................................. 3-34 LUBRICATING THE LEVER S............................................................... 3-34 LUBRICATING THE PEDAL ................................................................. 3-34 LUBRICATING THE SIDESTAND ......................................................... 3-34
LUBRICATING THE CENTERSTAND (FZ1-S) ..................................... 3-34 LUBRICATING THE REAR SUSPENSION .......................................... 3-34 ELECTRICAL SYSTEM .............................................................................. 3-35 CHECKING AND CHARGING THE BATTERY..................................... 3-35 CHECKING THE FUSES...................................................................... 3-35 REPLACING THE HEADLIGHT BULBS............................................... 3-35 ADJUSTING THE HEADLIGH T BEAM ................................................ 3-36
PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. Periodic maintenance and lubrication chart NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READ- ING (X 1000 km) Annual check 1 10203040 1 * Fuel line Check fuel hoses for cracks or dam- age. ✓✓✓✓ ✓ 2 * Spark plugs Check condition. Clean and regap. ✓✓ Replace. ✓✓ 3 * Valves Check valve clearance. Adjust. Every 40000 km 4* Air filter ele- ment Replace. ✓ 5Clutch Check operation. Adjust. ✓✓✓✓✓ 6 * Front brake Check operation, fluid level and vehi- cle for fluid leakage. ✓✓✓✓✓ ✓ Replace brake pads. Whenever worn to the limit 7 * Rear brake Check operation, fluid level and vehi- cle for fluid leakage. ✓✓✓✓✓ ✓ Replace brake pads. Whenever worn to the limit 8 * Brake hoses Check for cracks or damage. ✓✓✓✓ ✓ Replace. Every 4 years 9 * Wheels Check runout and for damage. ✓✓✓✓ 10 * Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. ✓✓✓✓ ✓ 11 * Wheel bearings Check bearing for looseness or dam- age. ✓✓✓✓ 12 * Swingarm Check operation and for excessive play. ✓✓✓✓
PERIODIC MAINTENANCE 3-2 13 Drive chain Check chain slack, alignment and condition. Adjust and lubricate chain with a special O-ring chain lubricant thor- oughly. Every 1000 km and after wash- ing the motorcycle or riding in the rain 14 * Steering bear- ings Check bearing play and steering for roughness. ✓✓✓✓✓ Lubricate with lithium-soap-based grease. Every 20000 km 15 * Chassis fasten- ers Make sure that all nuts, bolts and screws are properly tightened. ✓✓✓✓ ✓ 16 Sidestand Check operation. Lubricate. ✓✓✓✓ ✓ 17 * Sidestand switch Check operation. ✓✓✓✓✓ ✓ 18 * Front fork Check operation and for oil leakage. ✓✓✓✓ 19 * Shock absorber assembly Check operation and shock absorber for oil leakage. ✓✓✓✓ 20 * Rear suspen- sion relay arm and connect- ing arm pivot- ing points Check operation. ✓✓✓✓ 21 * Fuel injection Adjust engine idling speed and syn- chronization. ✓✓✓✓✓ ✓ 22 Engine oil Change. Check oil level and vehicle for oil leakage. ✓✓✓✓✓ ✓ 23 Engine oil filter cartridge Replace. ✓✓✓ 24 * Cooling system Check coolant level and vehicle for coolant leakage. ✓✓✓✓ ✓ Change. Every 3 years 25 * Front and rear brake switches Check operation. ✓✓✓✓✓ ✓ 26 Moving parts and cables Lubricate. ✓✓✓✓ ✓ 27 * Throttle grip housing and cable Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. ✓✓✓✓ ✓ NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READ- ING (X 1000 km) Annual check 1 10203040
PERIODIC MAINTENANCE 3-3 NOTE: Air filter This model’s air filter is equipped with a dispos able oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. 28 * Air induction system Check the air cut-off valve, reed valve, and hose for damage. Replace the entire air induction sys- tem if necessary. ✓✓✓✓ ✓ 29 * Muffler and exhaust pipe Check the screw clamp for loose- ness. ✓✓✓✓✓ 30 * Lights, signals and switches Check operation. Adjust headlight beam. ✓✓✓✓✓ ✓ NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READ- ING (X 1000 km) Annual check 1 10203040
ENGINE 3-4 EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: Rider and passenger seatRefer 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. Throttle body assembly Refer to THROTTLE BODIES on page 7- 4. Air cut-off valve Refer to AIR INDUCTION SYSTEM on page 7-13. Radiator Radiator fan motor Refer to RADIATOR on page 6-1. 2. Remove: Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5-10. 3. Remove: Pickup rotor cover 1 4. Measure: Valve clearance Out of specification → Adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC 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. c. Measure the valve clearance with a thick- ness gauge “1”. NOTE: If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance (cold) Intake valve 0.11–0.20 mm (0.0043–0.0079 in) Exhaust valve 0.21–0.25 mm (0.0083–0.0098 in) Valve clearance measuring sequence Cylinder #1 → #2 → #4 → #3
ENGINE 3-5 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: Camshaft NOTE: Refer to CAMSHAFTS on page 5-10. When removing the timing chain and cam-shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. b. Calculate the difference between the speci- fied valve clearance and the measured valve clearance. Example: Specified valve clearance = 0.11–0.20 mm (0.004–0.008 in) Measure valve clearance = 0.25 mm (0.010 in) 0.25 mm (0.010 in)–0.20 mm (0.008 in) = 0.05 mm (0.002 in) c. Check the thickness of the current valve pad. NOTE: The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Example: A. Front Cylinder #2 180 ° Cylinder #4 360 ° Cylinder #3 540 ° A. Degrees that the crankshaft is turned counterclockwise B. Cylinder C. Combustion cycle Valve lapper 90890-04101