Yamaha Fz6n Manual
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5-1 5 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7Removing the drive sprocket Drive chain Lock nut Shift rod Shift arm Drive sprocket cover Nut Lock washer Drive sprocket2 1 1 1 1 1 1Loosen. Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Loosen. For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) 90 Nm (9.0 mkg, 65 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) ENGINEENG EAS00188 ENGINE ENGINE DRIVE SPROCKET
5-2 Order Job / Part Q’ty Remarks 1 2 3 4 5Removing the exhaust pipe Exhaust pipe assembly Exhaust pipe gasket Catalyst pipe assembly Muffler protector assembly Muffler1 4 1 1 1Remove the parts in the order listed. For installation, reverse the removal procedure. 20 Nm (2.0 mkg, 15 ftlb) 16 Nm (1.6 mkg, 11.6 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 9 Nm (0.9 mkg, 6.5 ftlb) 34 Nm (3.4 mkg, 26 ftlb) ENGINEENG EAS00189 EXHAUST PIPE
5-3 Order Job / Part Q’ty Remarks Disconnecting the leads and hoses Seat Front cowling inner panel (left and right) Fuel tank Battery Air filter case Battery box and battery box bracket Throttle body assembly Engine oil Oil filter cartridge Oil cooler Air cut-off valveDisconnect the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “BATTERY BOX AND BATTERY BOX BRACKET” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Refer to “OIL COOLER” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in chapter 7. Drain Refer to “CHANGING THE ENGINE OIL” in chapter 3. ENGINEENG EAS00191 LEADS AND HOSES
5-4 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Radiator Starter motor Battery negative lead Battery positive lead Clutch cable Ground lead Stator coil assembly coupler Crankshaft position sensor coupler Oil level switch connector Neutral switch connector Speed sensor coupler1 1 1 1 1 1 1 1 1Refer to “COOLING SYSTEM” in chapter 6. Refer to “STARTER MOTOR” in chapter 8. Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure. ENGINEENG
5-5 Order Job / Part Q’ty Remarks 1 2 3 4 5Removing the engine Right front engine mounting bolt Left front engine mounting bolt Self locking nut Rear engine mounting bolt Engine1 2 2 2 1Remove the parts in the order listed. Place a suitable stand under the frame and engine. For installation, reverse the removal procedure. NOTE: Refer to “INSTALLING THE ENGINE”. 55 Nm (5.5 mkg, 40 ftlb) 55 Nm (5.5 mkg, 40 ftlb) 55 Nm (5.5 mkg, 40 ftlb) 55 Nm (5.5 mkg, 40 ftlb) ENGINEENG EAS00191 ENGINE
5-6 ENGINEENG NOTE: NOTE: 55 Nm (5.5 mkg, 40 ftlb) NOTE: 55 Nm (5.5 mkg, 40 ftlb) EAS00192 INSTALLING THE ENGINE 1. Install: rear engine mounting bolts 1 Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 2. Install: right front engine mounting bolt 2 left front engine mounting bolts 3 Do not fully tighten the bolts. 3. Tighten: self-locking nut 4 First tighten the lower self-locking nut. 4. Tighten left front engine mounting bolts 5
5-7 ENGINEENG 55 Nm (5.5 mkg, 40 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: 5. Tighten right front engine mounting bolts 6 6. Install: shift arm 7 Align the punch mark a in the shift shaft with the slot in the shift arm. Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket.
5-8 Order Job / Part Q’ty Remarks 1 2 3 4 5Removing the cylinder head cover Battery Air filter case Battery box and battery box bracket Throttle body assembly Radiator assembly Air cut-off valve Ignition coil Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)4 4 1 1 1Remove the parts in the order listed. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Refer to “BATTERY BOX AND BATTERY BOX BRACKET” in chapter 3. Refer to “THROTTLE BODIES” in chapter 7. Refer to “COOLING SYSTEM” in chapter 6. Refer to “AIR INDUCTION SYSTEM” in chapter 7. For installation, reverse the removal procedure. 18 Nm (1.8 mkg, 13 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CAMSHAFTSENG EAS00194 CAMSHAFTS CYLINDER HEAD COVER
5-9 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9Removing the camshafts Pickup rotor cover Camshaft sprocket bolt Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft4 1 1 1 3 6 3 6 1Remove the parts in the order listed. Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR” Loosen. During removal, the dowel pins may still be connected to the camshaft caps. NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CAMSHAFTSENG EAS00196 CAMSHAFTS
5-10 CAMSHAFTSENG Order Job / Part Q’ty Remarks 10 11 12 13Exhaust camshaft Pin Timing chain guide (intake side) Cam sprocket1 1 1 2 For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 20 Nm (2.0 mkg, 15 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)