Yamaha Fz6 N Service Manual
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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)