Yamaha Fz6 N Service Manual
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TRANSMISSION 5-80 3. Install: Shift fork-R “1” Shift fork-L “2” Drive axle “3” Shift fork guide bar Shift drum retainer NOTE: Install shift fork-L into the groove in the 6th wheel gear and shift fork-R into the groove in the 5th wheel gear on the drive axle. Make sure that the drive axle bearing circlip “a” is inserted into the grooves in the upper crankcase. 4. Check: Transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. Shift drum retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE®
6 COOLING SYSTEM RADIATOR.................................................................................................... 6-1 CHECKING THE RADIATOR.................................................................. 6-3 INSTALLING THE RADIATOR ................................................................ 6-3 OIL COOLER ................................................................................................ 6-4 CHECKING THE OIL COOLER .............................................................. 6-5 INSTALLING THE OIL COOLER ............................................................ 6-5 THERMOSTAT .............................................................................................. 6-6 CHECKING THE THERMOSTAT ............................................................ 6-7 INSTALLING THE THERMOST AT ASSEMBLY ...................................... 6-7 WAT E R P U M P .............................................................................................. 6-9 DISASSEMBLING THE WATER PUMP................................................ 6-11 CHECKING THE WATER PUMP .......................................................... 6-11 ASSEMBLING THE WATER PU MP...................................................... 6-12 INSTALLING THE WATER PUMP ........................................................ 6-13
RADIATOR 6-1 EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1. Left front cowling inner panel (with cowling) Refer to GENERAL CHASSIS on page 4-1. Right front cowling inner panel (with cowlin g) Refer 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. Coolant Drain. Refer to CHANGING THE COOLANT on page 3-20. 1 Coolant reservoir hose 1 2 Thermo wax outlet hose 1 3 Water pump breather hose 1 4 Radiator outlet hose 1 5 Radiator inlet hose 1 6 Oil cooler outlet hose 1 7 Radiator 1 8 Radiator cap 1 9 Radiator fan 1 10 Coolant reservoir cover 1 11 Coolant reservoir 1 12 Coolant reservoir cap 1
RADIATOR 6-2 13 Coolant reservoir drain hose 1For installation, reverse the removal proce- dure. Removing the radiator Order Job/Parts to remove Q’ty Remarks
RADIATOR 6-3 EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: Radiator hoses Radiator pipes Cracks/damage → Replace. 3. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the radiator cap tester “1” and radia- tor cap tester adapter “2” to the radiator cap “3”. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check:Radiator fan Damage → Replace. Malfunction → Check and repair. Refer to ELECTRICAL COMPONENTS on page 8-105. EAS26400 INSTALLING THE RADIATOR 1. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to CHANGING THE COOLANT on page 3-20. 2. Check: Cooling system Leaks → Repair or replace any faulty part. 3. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to CHECKING THE RADIATOR on page 6-3. Radiator cap opening pressure 93–123 kPa (13.2–17.5 psi) (0.93–1.23 kgf/cm²) Radiator cap tester90890-01325 Radiator pressure tester YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984
OIL COOLER 6-4 EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty RemarksRadiator assembly Refer to RADIATOR on page 6-1. Coolant reservoir Refer to RADIATOR on page 6-1. Engine oil Drain. Refer to CHANGING THE ENGINE OIL on page 3-14. 1 Oil cooler outlet hose 1 2 Union bolt 1 3 Washer 1 4 Oil cooler 1 5O-ring 1 6 Oil cooler inlet hose 1 7 Oil cooler inlet pipe 1 8 Water jacket joint hose 1 9 Water jacket joint 1 10 O-ring 1 11 Water pump outlet hose 1 12 Radiator outlet hose 1 For installation, reverse the removal proce- dure.
OIL COOLER 6-5 EAS26420 CHECKING THE OIL COOLER 1. Check:Oil cooler Cracks/damage → Replace. 2. Check: Oil cooler inlet hose Oil cooler outlet hose Cracks/damage/wear → Replace. EAS26430 INSTALLING THE OIL COOLER 1. Clean: Mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thin- ner) 2. Install: O-ring Oil cooler “1” Washer “2” Union bolt “3” NOTE: Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of engine oil. Make sure the O-ring is positioned properly. 3. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to CHANGING THE COOLANT on page 3-20. Crankcase (with the specified amount of the recom- mended engine oil) Refer to CHANGING THE ENGINE OIL on page 3-14. 4. Check: Cooling system Leaks → Repair or replace any faulty part. 5. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to CHECKING THE RADIATOR on page 6-3. Oil cooler 63 Nm (6.3 m·kg, 46 ft·lb) New
THERMOSTAT 6-6 EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1. Left front cowling inner panel (with cowling)+ Refer to GENERAL CHASSIS on page 4-1. Right front cowling inner panel (with cowlin g) Refer 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. Coolant Drain. Refer to CHANGING THE ENGINE OIL on page 3-14. Throttle body assembly Refer to THROTTLE BODIES on page 7-4. 1 Radiator inlet hose 1 2 Thermostat cover 1 3 Thermostat 1 For installation, reverse the removal proce- dure.
THERMOSTAT 6-7 EAS26450 CHECKING THE THERMOSTAT 1. Check: Thermostat “1” Does not open at 71–85 °C (160–185 °F) → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat “3” in a container “4” filled with water. b. Slowly heat the water “2”. c. Place a thermometer “1” in the water. d. While stirring the water, observe the ther- mostat and thermometer’s indicated tem- perature. NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause seri- ous overheating or overcooling. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: Thermostat housing cover “1” Cracks/damage → Replace. EAS26490 INSTALLING THE THERMOSTAT ASSEM- BLY 1. Install: Thermostat NOTE: Install the thermostat with its breather hole “a” facing up. 2. Install: Thermostat cover NOTE: Before installing the thermostat cover to the cylinder head, lubricate the O-rings with a thin coat of lithium-soap-based grease. 3. Fill: Cooling system (with the specified amount of the recom- mended coolant) Refer to CHANGING THE COOLANT on page 3-20. 4. Check: Cooling system Leaks → Repair or replace any faulty part. 5. Measure: Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. A. Fully closed B. Fully open C. Opening (mm) D. Temperature Water jacket outlet joint bolt 12 Nm (1.2 m·kg, 8.7 ft·lb)