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Yamaha Fz6 N Service Manual

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    Page
    of 538
    							
    CLUTCH
    5-50
    EAS25110
    CHECKING THE CLUTCH PLATES
    The following procedure applies to all of the 
    clutch plates.
    1. Check: Clutch plate Damage  → Replace the clutch plates as a 
    set.
    2. Measure:  Clutch plate warpage
    (with a surface plate and thickness gauge 
    “1”)
    Out of specification  → Replace the clutch 
    plates as a set.
    EAS25140
    CHECKING THE CLUTCH SPRINGS
    The following procedure applies to all of the 
    clutch springs.
    1. Check: Clutch spring
    Damage  → Replace the clutch springs as a 
    set.
    2. Measure:
     Clutch spring free length “a” Out of specification  → Replace the clutch 
    springs as a set.
    EAS25150
    CHECKING THE CLUTCH HOUSING
    1. Check:
     Clutch housing dogs “1” Damage/pitting/wear  → Deburr the clutch 
    housing dogs or replace the clutch hous-
    ing.
    NOTE:
    Pitting on the clutch housing dogs will cause 
    erratic clutch operation.
    2. Check:  Bearing
    Damage/wear  → Replace the bearing and 
    clutch housing.
    EAS25160
    CHECKING THE CLUTCH BOSS
    1. Check:  Clutch boss splines Damage/pitting/wear  → Replace the clutch 
    boss.
    Warpage limit 0.10 mm (0.0039 in)
    Clutch spring free length55.00 mm (2.17 in)
    Minimum length
    54.00 mm (2.13 in)
    Limit 52.3 mm (2.06 in) 
    						
    							
    CLUTCH
    5-51
    NOTE:
    Pitting on the clutch boss splines will cause 
    erratic clutch operation.
    EAS25170
    CHECKING THE PRESSURE PLATE
    1. Check:
     Pressure plate “1” Cracks/damage  → Replace.
     Bearing “2” Damage/wear  → Replace.
    EAS25220
    CHECKING THE PULL LEVER SHAFT AND 
    PULL ROD
    1. Check:
     Pull lever shaft pinion gear teeth “1”
     Pull rod teeth “2” Damage/wear  → Replace the pull rod and 
    pull lever shaft pinion gear as a set.
    2. Check:  Pull rod bearing Damage/wear  → Replace.
    EAS25270
    INSTALLING THE CLUTCH
    1. Install:
     Thrust plate “1”
     Clutch boss “2”
     Lock washer “3” 
     Clutch boss nut “4”
    2. Tighten:  Clutch boss nut
    NOTE:
    While holding the clutch boss with the univer-
    sal clutch holder “1”, tighten the clutch boss 
    nut.
    3. Bend the lock washer tab along a flat side  of the nut.
    4. Lubricate:  Friction plates
     Clutch plates
    (with the recommended lubricant)
    Clutch boss nut90 Nm (9.0 m·kg, 65 ft·lb)
    Universal clutch holder90890-04086
    YM-91042
    Recommended lubricantEngine oil
    New 
    						
    							
    CLUTCH
    5-52
    5. Install: Friction plates
     Clutch plates
    NOTE:
    First, install a friction plate and then alternate 
    between a clutch plate and a friction plate.
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Install the clutch plate and friction plate as 
    shown in the illustration.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    6. Install: Pressure plate “1”
    NOTE:
    Align the punch mark “a” in the pressure plate 
    with the punch mark “b” in the clutch boss.
    7. Install: Bearing “1”
     Pill rod “2”
     Pressure plate “3”
     Clutch springs
     Clutch spring bolts
    NOTE:
    Tighten the clutch spring bolts in stages and in 
    a crisscross pattern.
    8. Install:Pull lever
    9. Install: Clutch cover
    Gasket 
     Clutch cable holder
    NOTE:
     Install the pull rod so that the teeth a face 
    towards the rear of the vehicle. Then, install 
    the clutch cover.
     Apply oil onto the bearing.
     Apply molybdenum disulfide grease onto the 
    pull rod.
     When installing the clutch cover, push the  pull lever and check that the punch mark “a” 
    on the pull lever aligns with the mark “b” on 
    the clutch cover. Make sure that the pull rod 
    teeth and pull lever shaft pinion gear are 
    engaged.
     Tighten the clutch cover bolts in stages and 
    in a crisscross pattern.
    10. Adjust:  Clutch cable free play Refer to ADJUSTING THE CLUTCH 
    CABLE FREE PLAY on page 3-16.
    Clutch plate “1”: t=2.3 mm (0.09 in)
    Clutch plate “2”: t=2.0 mm (0.08 in)
    Friction plate “3”
    Friction plate “4”: Color/Brown
    Clutch spring bolt
    8 Nm (0.8 m·kg, 5.8 ft·lb)
    New 
    						
    							
    SHIFT SHAFT
    5-53
    EAS25410
    SHIFT SHAFT
    Removing the shift shaft and stopper lever
    Order Job/Parts to remove Q’ty RemarksDrive sprocket cover Refer to ENGINE REMOVAL on page 5-1.
    1 Shift shaft cover 1
    2 Shift shaft cover gasket 1
    3Dowel pin 2
    4 Oil seal 1
    5 Shift shaft 1
    6 Shift shaft spring 1
    7 Collar 1
    8 Stopper lever spring 1
    9 Circlip 1
    10 Washer 1
    11 Stopper lever 1
    12 Collar 1
    13 Washer 1
    14 Shift shaft spring stopper 1 For installation, reverse the removal proce-
    dure. 
    						
    							
    SHIFT SHAFT
    5-54
    EAS25420
    CHECKING THE SHIFT SHAFT
    1. Check: Shift shaft “1”
    Bends/damage/wear  → Replace.
     Shift shaft spring “2” Damage/wear  → Replace.
    EAS25430
    CHECKING THE STOPPER LEVER
    1. Check:
     Stopper lever “1” Bends/damage  → Replace.
    Roller turns roughly  → Replace the stopper 
    lever.
    EAS25450
    INSTALLING THE SHIFT SHAFT
    1. Install:  Shift shaft spring stopper “1”
     Washers
     Shift shaft “2”
    NOTE:
     Apply LOCTITE® to the threads of the shift shaft spring stopper.
     Hook the ends of the stopper lever spring “3”  onto the stopper lever “4” and the crankcase 
    boss.
     Mesh the stopper lever with the shift drum 
    segment assembly. 2. Install:
     Shift shaft cover
    NOTE:
    Lubricate the oil seal lips with lithium-soap-
    based grease. 
    						
    							
    CRANKCASE
    5-55
    EAS25540
    CRANKCASE
    Separating the crankcase
    Order Job/Parts to remove Q’ty RemarksEngine Refer to ENGINE REMOVAL on page 5-1.
    Cylinder head Refer to CYLINDER HEAD on page 5-16.
    Generator Refer to GENERATOR AND STARTER 
    CLUTCH on page 5-28.
    Starter clutch Refer to GENERATOR AND STARTER 
    CLUTCH on page 5-28.
    Shift shaft Refer to SHI FT SHAFT on page 5-53.
    Crankshaft position sensor Refer to PICKUP ROTOR on page 5-33.
    Pickup rotor Refer to PICKUP ROTOR on page 5-33.
    Clutch Refer to CLUTCH on page 5-46.
    Water pump Refer to WATER PUMP on page 6-9.
    Oil pan Refer to OIL PUMP on page 5-40.
    Oil pump Refer to OIL PUMP on page 5-40.
    1 Timing chain 1
    2 Oil pump drive chain 1
    3 Oil pump drive chain guide 1
    4 Lower crankcase 1
    5Dowel pin 3
    6 Thrust plate 1
    7 Washer 1 
    						
    							
    CRANKCASE
    5-56
    8Plate 1For installation, reverse the removal proce-
    dure.
    Separating the crankcase
    Order Job/Parts to remove Q’ty Remarks 
    						
    							
    CRANKCASE
    5-57
    EAS25550
    DISASSEMBLING THE CRANKCASE
    1. Place the engine upside down.
    2. Remove: Crankcase bolts
    NOTE:
     Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of 
    the bolts are fully loosened, remove them.
     Loosen the bolts in decreasing numerical  order (refer to the numbers in the illustration).
     The numbers embossed on the crankcase 
    indicate the crankcase tightening sequence.
    M8  × 85 mm (3.3 in) bolts: “1”–“7”, “10”
    M8  × 115 mm (4.5 in) bolts: “8”, “9”
    M8  × 65 mm (2.6 in) bolts: “11”, “12”
    M6  × 65 mm (2.6 in) bolts: “13”, “14”
    M6  × 55 mm (2.2 in) bolts: “15”, “22”–“26”
    M6  × 45 mm (1.8 in) bolts: “16”, “19”, “20”
    M6  × 65 mm (2.6 in) bolts: “17”, “27”
    M6  × 75 mm (3.0 in) bolt: “18”
    M6  × 100 mm (3.9 in) bolt: “21”
    3. Remove:  Lower crankcase
    CAUTION:
    ECA13900
    Tap on one side of the crankcase with a 
    soft-face hammer. Tap only on reinforced 
    portions of the crankcase, not on the 
    crankcase mating surfaces. Work slowly 
    and carefully and make sure the crankcase 
    halves separate evenly.
    4. Remove: Dowel pins
    5. Remove:  Crankshaft journal lower bearing (from the lower crankcase)
    NOTE:
    Identify the position of each crankshaft journal 
    lower bearing so that it can be reinstalled in its 
    original place.
    EAS25580
    CHECKING THE CRANKCASE
    1. Thoroughly wash the crankcase halves in a 
    mild solvent.
    2. Thoroughly clean all the gasket surfaces 
    and crankcase mating surfaces.
    3. Check:  Crankcase
    Cracks/damage  → Replace.
     Oil delivery passages Obstruction  → Blow out with compressed 
    air.
    EAS4S81034
    CHECKING THE BEARINGS AND OIL 
    SEALS
    1. Check:
     Bearings Clean and lubricate the bearings, then 
    rotate the inner race with your finger.
    Rough movement  → Replace.
    2. Check:  Oil seals
    Damage/wear  → Replace.
    EAS25620
    CHECKING THE OIL PUMP DRIVE CHAIN
    1. Check:
     Oil pump drive chain “1” Damage/stiffness  → Replace the oil pump 
    drive chain, oil pump drive sprocket and oil 
    pump shaft as a set.
    2. Check:  Oil pump drive sprocket Cracks/damage/wear  → Replace the oil 
    pump drive sprocket and the oil pump drive 
    chain as a set. 
    						
    							
    CRANKCASE
    5-58
    EAS25660
    ASSEMBLING THE CRANKCASE
    1. Lubricate: Crankshaft journal bearings
    (with the recommended lubricant)
    2. Apply:  Sealant (onto the crankcase mating surfaces)
    NOTE:
    Do not allow any sealant to come into contact 
    with the oil gallery or crankshaft journal bear-
    ings. Do not apply sealant to within 2–3 mm of 
    the crankshaft journal bearings.
    3. Install:
    Dowel pin
    4. Set the shift drum assembly and transmis-
    sion gears in the neutral position.
    5. Install:  Lower crankcase “1”
    (onto the upper crankcase “2”)
    CAUTION:
    ECA13980
    Before tightening the crankcase bolts, 
    make sure the transmission gears shift cor-
    rectly when the shift drum assembly is 
    turned by hand. 6. Install:
     Crankcase bolts
    NOTE:
     Lubricate the bolt threads with engine oil.
     Install a washer on bolts “1”–”10” 
     Seal bolt “18”
     Tighten the bolts in the tightening sequence 
    cast on the crankcase.
    M8  × 85 mm (3.3 in) bolts: “1”–“7”, “10”
    M8  × 115 mm (4.5 in) bolts: “8”, “9”
    M8  × 65 mm (2.6 in) bolts: “11”, “12”
    M6  × 65 mm (2.6 in) bolts: “13”, “14”
    M6  × 55 mm (2.2 in) bolts: “15”, “22”–“26”
    M6  × 45 mm (1.8 in) bolts: “16”, “19”, “20”
    M6  × 65 mm (2.6 in) bolts: “17”, “27”
    M6  × 75 mm (3.0 in) bolt: “18” LOCTITE®
    M6  × 100 mm (3.9 in) bolt: “21”
    *Loosen the bolts following the tightening 
    order and then tighten to specification 
    torque.
    Recommended lubricant Engine oil
    Yamaha bond No. 1215
    (Three bond No.1215
    ®)
    90890-85505
    Crankcase bolt Bolt “1”–“10”
    1st: 12 Nm (1.2 m·kg, 8.7 ft·lb)
    2nd: 25 Nm (2.5 m·kg, 18 ft·lb)
    3rd*: 27 Nm (2.7 m·kg, 20 ft·lb)
    Bolt “11”, “12”
    24 Nm (2.4 m·kg, 17 ft·lb)
    Bolt “13”, “14”
    14 Nm (1.4 m·kg, 1.0 ft·lb)
    Bolt “15”–“27”
    12 Nm (1.2 m·kg, 8.7 ft·lb) 
    						
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