Home > Yamaha > Motorcycle > Yamaha Fz6 N Service Manual

Yamaha Fz6 N Service Manual

    Download as PDF Print this page Share this page

    Have a look at the manual Yamaha Fz6 N Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.

    Page
    of 538
    							
    CRANKSHAFT
    5-70
    9. Tighten: Connecting rod bolts
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    CAUTION:
    ECA14980
    Tighten the connecting rod bolts using the 
    plastic-region tightening angle method.
    a. Clean the connecting rod bolts.
    b. Tighten the connecting rod bolts.
    c. Put a mark “1” on the corner of the con-
    necting rod bolt “2” and the connecting rod 
    cap “3”.
    d. Tighten the bolt further to reach the speci- fied angle (120 °).
    e. After the installation, check that the section  shown “a” is flush with each other by touch-
    ing the surface.
    WARNING
    EWA13990
     When the bolt is tightened more than the specified angle, do not loosen the bolt 
    and then retighten it. Replace the bolt 
    with a new one and perform the proce-
    dure again.
     If they are not flush with each other,  remove the connecting rod bolt and big 
    end bearing and restart from step “7”. In 
    this case, make sure to replace the con-
    necting rod bolt.
    CAUTION:
    ECA4S81029
     Do not use a torque wrench to tighten the 
    bolt to the specified angle.
     Tighten the bolt until it is at the specified 
    angles.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    EAS4S81038
    CHECKING THE CRANKSHAFT
    1. Measure:  Crankshaft runout
    Out of specification  → Replace the crank-
    shaft.
    2. Check:  Crankshaft journal surfaces
     Crankshaft pin surfaces
     Bearing surfaces Scratches/wear  → Replace the crankshaft.
    EAS4S81039
    CHECKING THE CRANKSHAFT JOURNAL 
    BEARINGS
    1. Measure:
     Crankshaft-journal-to-crankshaft-journal  bearing clearance
    Connecting rod bolt15 Nm (1.5 m·kg, 11 ft·lb) + 
    120 °
    a. Side machined face
    Crankshaft runout
    Less than 0.03 mm (0.0012 in) 
    						
    							
    CRANKSHAFT
    5-71
    Out of specification → Replace the crank-
    shaft journal bearings.
    CAUTION:
    ECA4S81028
    Do not interchange the crankshaft journal 
    bearings. To obtain the correct crankshaft 
    journal- to-crankshaft-journal-bearing 
    clearance and prevent engine damage, the 
    crankshaft journal bearings must be 
    installed in their original positions.
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Clean the crankshaft journal bearings, 
    crankshaft journals, and bearing portions of 
    the crankcase.
    b. Place the upper crankcase upside down on 
    a bench.
    c. Install the crankshaft journal upper bear- ings “1” and the crankshaft into the upper 
    crankcase.
    NOTE:
    Align the projections “a” on the crankshaft jour-
    nal upper bearings with the notches “b” in the 
    upper crankcase.
    d. Put a piece of Plastigauge
    ® “2” on each 
    crankshaft journal.
    NOTE:
    Do not put the Plastigauge® over the oil hole in 
    the crankshaft journal. e. Install the crankshaft journal lower bear-
    ings “1” into the lower crankcase and 
    assemble the crankcase halves.
    NOTE:
     Align the projections “a” of the crankshaft journal lower bearings with the notches “b” in 
    the lower crankcase.
     Do not move the crankshaft until the clear-
    ance measurement has been completed.
    f. Tighten the bolts to specification in the  tightening sequence cast on the crankcase.
    *Loosen the bolts following the tightening 
    order and then tighten to specification 
    torque.
    NOTE:
    Lubricate the crankcase bolt threads with 
    engine oil.
    Crankshaft-journal-to-crank-
    shaft journal bearing clearance0.028–0.052 mm 
    (0.0011–0.0020 in)
    Crankcase boltBolt “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) 
    						
    							
    CRANKSHAFT
    5-72
    Refer to CRANKCASE on page 5-55.
    g. Remove the lower crankcase and the crankshaft journal lower bearings.
    h. Measure the compressed Plastigauge®  width “c” on each crankshaft journal.
    If the crankshaft-journal-to-crankshaft-jour-
    nal-bearing clearance is out of specifica-
    tion, select replacement crankshaft journal 
    bearings.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    2. Select: Crankshaft journal bearings (J1–J5)
    NOTE:
     The numbers “A” stamped into the crank-shaft web and the numbers “1” stamped into 
    the lower crankcase are used to determine 
    the replacement crankshaft journal bearing 
    sizes.
     “J1–J5” refer to the bearings shown in the 
    crankshaft illustration.
     If “J1–J5” are the same, use the same size  for all of the bearings.
     If the size is the same for all “J
    1 to J5” one 
    digit for that size is indicated. (Crankcase 
    side only) For example, if the crankcase “J
    1” and 
    crankshaft web “J
    1” numbers are “6” and 
    “2” respectively, than the bearing size for 
    “J
    1” is:
    EAS4S81040
    INSTALLING THE CRANKSHAFT
    1. Install:  Crankshaft journal upper bearings “1” (into the upper crankcase)
    “J1” (crankcase) – “J1”
    (crankshaft web) – 1 =
    6 – 2 – 1 = 3 (brown)
    CRANKSHAFT JOURNAL BEARING  COLOR CODE
    0 White
    1Blue
    2Black
    3Brown
    4 Green 
    						
    							
    CRANKSHAFT
    5-73
    NOTE:
     Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in 
    the upper crankcase.
     Be sure to install each crankshaft journal 
    upper bearing in its original place.
    2. Install:  Crankshaft
    3. Install:  Lower crankcase Refer to CRANKCASE on page 5-55. 
    						
    							
    TRANSMISSION
    5-74
    EAS26240
    TRANSMISSION
    Removing the transmission, shift drum assembly, and shift forks
    Order Job/Parts to remove Q’ty RemarksLower crankcase 1 Refer to CRANKCASE on page 5-55.
    1 Drive axle assembly 1
    2 Circlip 1
    3 Oil seal 1
    4 Bearing 1
    5 Shift drum retainer 1
    6 Shift fork guide bar 2
    7Spring 4
    8 Shift fork-L 1
    9 Shift fork-R 1
    10 Shift drum assembly 1
    11 Shift fork-C 1
    12 Main axle assembly 1
    13 Oil pipe 1
    14 Oil baffle plate 1
    15 Thrust plate 1
    16 Washer 1 For installation, reverse the removal proce-
    dure. 
    						
    							
    TRANSMISSION
    5-75
    Disassembling the main axle assembly
    Order Job/Parts to remove Q’ty Remarks1 Bearing 1
    2 2nd pinion gear 1
    3 Toothed lock washer 1
    4 Toothed lock washer retainer 1
    5 6th pinion gear 1
    6 Collar 1
    7 Washer 1
    8 Circlip 1
    9 3rd pinion gear 1
    10 Circlip 1
    11 Washer 1
    12 5th pinion gear 1
    13 Collar 1
    14 Main axle 1
    15 Bearing housing 1
    16 Bearing 1 For installation, reverse the removal proce-
    dure. 
    						
    							
    TRANSMISSION
    5-76
    Disassembling the drive axle assembly
    Order Job/Parts to remove Q’ty Remarks1 Washer 1
    2 1st wheel gear 1
    3 Collar 1
    4 5th wheel gear 1
    5 Circlip 1
    6 Washer 1
    7 Collar 1
    8 3rd wheel gear 1
    9 Toothed lock washer 1
    10 Toothed lock washer retainer 1
    11 4th wheel gear 1
    12 Collar 1
    13 Washer 1
    14 Circlip 1
    15 6th wheel gear 1
    16 Circlip 1
    17 Washer 1
    18 2nd wheel gear 1
    19 Collar 1
    20 Collar 1
    21 Oil seal 1
    22 Bearing 1
    23 Circlip 1
    24 Drive axle 1 
    						
    							
    TRANSMISSION
    5-77
    For installation, reverse the removal proce-
    dure.
    Disassembling the drive axle assembly
    Order Job/Parts to remove Q’ty Remarks 
    						
    							
    TRANSMISSION
    5-78
    EAS26250
    REMOVING THE TRANSMISSION
    1. Remove: Main axle assembly “1”
    (with the Torx® wrench)
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Insert two bolts “2” of the proper size, as  shown in the illustration, into the main axle 
    assembly bearing housing.
    b. Tighten the bolts until they contact the  crankcase surface.
    c. Continue tightening the bolts until the main 
    axle assembly comes free from the upper 
    crankcase.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    EAS26260
    CHECKING THE SHIFT FORKS
    The following procedure applies to all of the 
    shift forks.
    1. Check: Shift fork cam follower “1”
     Shift fork pawl “2” Bends/damage/scoring/wear  → Replace 
    the shift fork. 2. Check:
     Shift fork guide bar Roll the shift fork guide bar on a flat sur-
    face.
    Bends  → Replace.
    WARNING
    EWA12840
    Do not attempt to straighten a bent shift 
    fork guide bar.
    3. Check:
     Shift fork movement (along the shift fork guide bar)
    Rough movement  → Replace the shift 
    forks and shift fork guide bar as a set.
    EAS26270
    CHECKING THE SHIFT DRUM ASSEMBLY
    1. Check:  Shift drum groove
    Damage/scratches/wear  → Replace the 
    shift drum assembly.
     Shift drum segment “1”
    Damage/wear  → Replace the shift drum 
    assembly.
     Shift drum bearing “2”
    Damage/pitting  → Replace the shift drum 
    assembly. 
    						
    							
    TRANSMISSION
    5-79
    EAS26300
    CHECKING THE TRANSMISSION
    1. Measure: Main axle runout
    (with a centering device and dial gauge “1”)
    Out of specification  → Replace the main 
    axle.
    2. Measure:  Drive axle runout (with a centering device and dial gauge “1”)
    Out of specification  → Replace the drive 
    axle.
    3. Check:  Transmission gears Blue discoloration/pitting/wear  → Replace 
    the defective gear(s).  Transmission gear dogs
    Cracks/damage/rounded edges  → Replace 
    the defective gear(s).
    4. Check:  Transmission gear engagement (each pinion gear to its respective wheel 
    gear)
    Incorrect  → Reassemble the transmission 
    axle assemblies.
    5. Check:
     Transmission gear movement Rough movement  → Replace the defective 
    part(s).
    6. Check: Circlips Bends/damage/looseness  → Replace.
    EAS26350
    INSTALLING THE TRANSMISSION
    1. Install:
     Oil pipe “1”
     Main axle assembly “2” (with the Torx® wrench)
    NOTE:
    Make sure to caulk the bolts at three positions 
    after installing the bearing housing.
    2. Install: Shift fork-C “3”
     Shift drum assembly “4”
     Shift fork guide bar
    NOTE:
     The embossed marks on the shift forks should face towards the right side of the 
    engine and be in the following sequence: “R”, 
    “C”, “L”.
     Carefully position the shift forks so that they 
    are installed correctly into the transmission 
    gears.
     Install shift fork-C into the groove in the 3rd 
    and 4th pinion gear on the main axle.
    Main axle runout limit
    0.02 mm (0.0008 in)
    Drive axle runout limit0.02 mm (0.0008 in) 
    						
    All Yamaha manuals Comments (0)

    Related Manuals for Yamaha Fz6 N Service Manual