Yamaha Fz6n Manual
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3-14 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: NOTE: c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 20 55 810 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. The new valve pad number is only an approxi- mation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. e. Install the new valve pad 1 and the valve lift- er 2. Lubricate the valve pad with molybdenum dis- ulfide grease. Lubricate the valve lifter with molybdenum dis- ulfide oil. Install the valve lifter and the valve pad in the correct place. The valve lifter must turn smoothly when ro- tated by hand. f. Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 mkg, 7.2 ftlb)
3-15 ADJUSTING THE VALVE CLEARANCE CHK ADJ NOTE: Refer to “CAMSHAFTS” in chapter 5. Lubricate the camshaft bearings, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft marks with the camshaft cap marks. Turn the crankshaft counterclockwise several full turns to seat the parts. g. Measure the valve clearance again. h. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained.
3-16 ADJUSTING THE VALVE CLEARANCE CHK ADJ VALVE CLEARANCE (cold): 0.13 0.20 mm (0.0051 0.0079 in) Example: Installed is 175 Measured clearance is 0.27 mm (0.0106 in) Replace 175 pad with 185 pad Pad number: (example) Pad No.175 = 1.75 mm (0.0689 in) Pad No.185 = 1.85 mm (0.0728 in) MEASURED CLEARANCEINSTALLED PAD NUMBER VALVE CLEARANCE (cold): 0.23 0.30 mm (0.0091 0.0118 in) Example: Installed is 175 Measured clearance is 0.35 mm (0.0138 in) Replace 175 pad with 185 pad Pad number: (example) Pad No.175 = 1.75 mm (0.0689 in) Pad No.185 = 1.85 mm (0.0728 in) MEASURED CLEARANCEINSTALLED PAD NUMBER STANDARD CLEARANCE STANDARD CLEARANCE INTAKE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.13 0.20 0.21 0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.26 0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.31 0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.36 0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.41 0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.46 0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.51 0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.56 0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.61 0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.66 0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.71 0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.76 0.80 180 185 190 195 200 205 210 215 220 225 230 235 240 0.81 0.85 185 190 195 200 205 210 215 220 225 230 235 240 0.86 0.90 190 195 200 205 210 215 220 225 230 235 240 0.91 0.95 195 200 205 210 215 220 225 230 235 240 0.96 1.00 200 205 210 215 220 225 230 235 240 1.01 1.05 205 210 215 220 225 230 235 240 1.06 1.10 210 215 220 225 230 235 240 1.11 1.15 215 220 225 230 235 240 1.16 1.20 220 225 230 235 240 1.21 1.25 225 230 235 240 1.26 1.30 230 235 240 1.31 1.35 235 240 1.36 1.40 240 EXHAUST 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.13 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.18 0.22 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.23 0.30 0.31 0.35 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.36 0.40 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.41 0.45 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.46 0.50 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.51 0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.56 0.60 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.61 0.65 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.66 0.70 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.71 0.75 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.76 0.80 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.81 0.85 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.86 0.90 180 185 190 195 200 205 210 215 220 225 230 235 240 0.91 0.95 185 190 195 200 205 210 215 220 225 230 235 240 0.96 1.00 190 195 200 205 210 215 220 225 230 235 240 1.01 1.05 195 200 205 210 215 220 225 230 235 240 1.06 1.10 200 205 210 215 220 225 230 235 240 1.11 1.15 205 210 215 220 225 230 235 240 1.16 1.20 210 215 220 225 230 235 240 1.21 1.25 215 220 225 230 235 240 1.26 1.30 220 225 230 235 240 1.31 1.35 225 230 235 240 1.36 1.40 230 235 240 1.41 1.45 235 240 1.46 1.50 240
3-17 ADJUSTING THE VALVE CLEARANCE / SYNCHRONIZING THE THROTTLE BODIESCHK ADJ NOTE: NOTE: NOTE: 7. Install: all removed parts For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition tim- ing should be checked. 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. 2. Remove: seat Refer to “SEAT”. front cowling inner panel (left and right) Refer to “COWLINGS” fuel tank Refer to “FUEL TANK”. air filter case Refer to “AIR FILTER CASE”. 3. Install: vacuum gauge 1 (onto the synchronizing hose 2) Vacuum gauge 90890-03094, YU-08030 4. Install: air filter case Refer to “AIR FILTER CASE”. fuel tank Refer to “FUEL TANK”. changing the meter display. Refer to “FEATURES” in chapter 1. 5. Start the engine and let it warm up for several minutes.
3-18 SYNCHRONIZING THE THROTTLE BODIES CHK ADJ NOTE: CAUTION: NOTE: 6. Measure: engine idling speed Out of specification Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 1,250 1,350 r / min 7. Adjust: throttle body synchronization a. With throttle body #1 as standard, adjust throttle bodies #2, #3, and #4 using the air screws 1. #1 2, #2 3, #3 4, #4 5 After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. If the air screw is removed, turn the screw 3 / 4 turn in and be sure to synchronize the throttle body. Do not use the throttle valve adjusting screws to adjust the throttle body synchro- nization. Vacuum pressure at engine idling speed 29 kPa (218 mmHg, 8.5827 inHg) The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg, 0.39 inHg).
3-19 ADJUSTING THE ENGINE IDLING SPEED CHK ADJ NOTE: a b EAS00052 ADJUSTING THE ENGINE IDLING SPEED Prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Check: engine idling speed Out of specification Adjust. Engine idling speed 1250 1350 r / min 3. Adjust: engine idling speed a. Turn the idle adjusting screw 1 in direction a or b until the specified engine idling speed is obtained. Direction Engine idling speed is increased. DirectionEngine idling speed is decreased. 4. Adjust: throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 5 mm (0.12 0.20 in)
3-20 ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ NOTE: NOTE: a b NOTE: EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 3 5 mm (0.12 0.20 in) 2. Remove: seat Refer to “SEAT”. front cowling inner panel (left and right) Refer to “COWLINGS”. fuel tank Refer to “FUEL TANK”. air filter case Refer to “AIR FILTER CASE”. battery Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. 3. Adjust: throttle cable free play When the throttle is opened, the accelerator cable 1 is pulled. Throttle body a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. Direction Throttle cable free play is increased. DirectionThrottle cable free play is decreased. c. Tighten the locknuts. If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.
3-21 ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ a b WARNING NOTE: NOTE: Handlebar side a. Loosen the locknut 1. b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction Throttle cable free play is increased. DirectionThrottle cable free play is decreased. c. Tighten the locknut. 4. Install: battery assembly Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. air filter case Refer to “AIR FILTER CASE”. fuel tank Refer to “FUEL TANK”. front cowling inner panel (left and right) Refer to “COWLINGS”. seat Refer to “SEAT”. After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. ADJUSTING THE EXHAUST GAS VOLUME Be sure to set the carbon monoxide density to standard, and then adjust the exhaust gas. 1. Turn the main switch to “OFF” and engine stop switch “ON”. 2. While keeping the “SELECT” and “RESET” buttons pressed simultaneously, turn “ON” the main switch (keep them pressed for 8 se- conds or more). All indications on the meter disappear except the clock and trip indications. Letters “dIAG” appear on the odo meter LCD.
3-22 ADJUSTING THE EXHAUST GAS VOLUME CHK ADJ NOTE: NOTE: 3. Using the “SELECT” button, select either the Co adjustment mode (which appears as “Co”) or the diagnosis mode (which appears as “dIAG”) 4. After “Co” appears as a result of pressing the “SELECT” button, simultaneously press the “SELECT” and “RESET” buttons for 2 se- conds or more to excute the selection. 5. Press the “SELECT” or “RESET” buttons to select the “C1” or “C2”. C1=“#1” and “#4” C2=“#2” and “#3” The adjustment cylinder appears on the odo- meter LCD. “RESET” button = decrement “SELECT” button = increment 6. Execute the selection of the cylinder by si- multaneously pressing the “SELECT” and “RESET” buttons for approximately 2 se- conds. 7. After selecting the adjustment cylinder, change the “Co” adjustment volume by pressing the “SELECT” and “RESET” but- tons. The Co adjustment volume appears on the odo meter LCD. “RESET” button = decrement “SELECT” button = increment 8. The selection is executed upon releasing the finger from the switch. 9. Simultaneously press the “SELECT” and “RESET” buttons to return to the cylinder selection. (step 5) 10. Cancel the mode by turning “OFF” the main switch.
3-23 A B CHECKING THE SPARK PLUGS CHK ADJ CAUTION: EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: radiator lower bolt 1 radiator lower hose bracket bolt 2 2. Remove: spark plug caps spark plugs ARight side #1 and #2 and #3 BLeft side #4 Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal- ling into the cylinders. 3. Check: spark plug type Incorrect Change. Spark plug type (manufacturer) CR9EK (NGK) 4. Check: electrode 1 Damage / wear Replace the spark plug. insulator 2 Abnormal color Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: spark plug (with a spark plug cleaner or wire brush) 6. Measure: spark plug gap a (with a wire Thickness gauge) Out of specification Regap. Spark plug gap 0.6 0.7 mm (0.0236 0.0276 in)