Yamaha Fz6n Manual
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5-51 CLUTCHENG NOTE: NOTE: 2. Measure: clutch spring free length a Out of specification Replace the clutch springs as a set. Clutch spring free length 55 mm (2.17 in) : 52.3 mm (2.06 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: clutch housing dogs Damage / pitting / wear Deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: bearing Damage / wear Replace the bearing and clutch housing. EAS00285 CHECKING THE CLUTCH BOSS 1. Check: clutch boss splines Damage / pitting / wear Replace the clutch boss. Pitting on the clutch boss splines will cause er- ratic clutch operation. EAS00286 CHECKING THE PRESSURE PLATE 1. Check: pressure plate 1 Cracks / damage Replace. bearing 2 Damage / wear Replace.
5-52 CLUTCHENG 90 Nm (9.0 mkg, 65 ftlb) NOTE: EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: pull lever shaft pinion gear teeth a pull rod teeth b Damage / wear Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: pull rod bearing Damage / wear Replace. EAS00299 INSTALLING THE CLUTCH 1. Install: thrust plate 1 clutch boss 2 lock washer 3 New clutch boss nut 4 While holding the clutch boss 2 with the clutch holding tool 5, tighten the clutch boss nut. Universal clutch holder 90890-04089, YM-91042 2. Bend the lock washer tab along a flat side of the nut. 3. Lubricate: friction plates clutch plates (with the recommended lubricant) Recommended lubricant Engine oil
5-53 CLUTCHENG NOTE: NOTE: 8 Nm (0.8 mkg, 5.8 ftlb) NOTE: 4. Install: friction plates clutch plates First, install a clutch plate and then alternate be- tween a friction plate and a friction plate. a. Install the clutch plate and friction plate as shown in the illustration. 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 5. Install: pressure plate 1 Align the punch mark b in the pressure plate with the punch mark a in the clutch boss. 6. Install: bearing 1 pull rod 2 pressure plate 3 clutch springs clutch pressure plate screw Tighten the clutch spring bolts in stages and in a crisscross pattern. 7. Install: pull lever
5-54 CLUTCHENG NOTE: 8. Install: clutch cover gasket New clutch cable holder Install the pull rod so that the teeth a face to- wards the rear of the motorcycle. 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. 9. Adjust: clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3.
5-55 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the oil pan and oil pump Engine oil Coolant Exhaust pipe assembly Water pump Oil level switch coupler Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin Oil strainer Oil strainer gasket1 1 1 1 1 2 1 1Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “CHANGING THE COOLANT” in chapter 3. Refer to “ENGINE”. Refer to “WATER PUMP” in chapter 6. Disconnect. 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)43 Nm (4.3 mkg, 31 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) OIL PAN AND OIL PUMPENG EAS00356 OIL PAN AND OIL PUMP
5-56 Order Job / Part Q’ty Remarks 9 10 11 12 13Oil pipe Oil delivery pipe Oil pump assembly Dowel pin Relief valve assembly1 1 1 2 1 For installation, reverse the removal procedure. 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)43 Nm (4.3 mkg, 31 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) OIL PAN AND OIL PUMPENG
5-57 OIL PAN AND OIL PUMPENG Order Job / Part Q’ty Remarks Disassembling the oil pump assembly Oil pump cover Pin Oil pump inner rotor Oil pump outer rotor Pin Washer Oil pump rotor housing Oil pump driver sprocket1 2 1 1 1 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 12 Nm (1.2 mkg, 8.7 ftlb)
5-58 OIL PAN AND OIL PUMPENG NOTE: EAS00362 REMOVING THE OIL PAN 1. Remove: oil level switch 1 oil pan 2 oil pan gasket dowel pins 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. EAS00364 CHECKING THE OIL PUMP 1. Check: oil pump driven gear 1 oil pump rotor housing 2 oil pump cover Cracks / damage / wear Replace the de- fective part(s). 2. Measure: inner-rotor-to-outer-rotor-tip clearance a outer-rotor-to-oil-pump-housing clearance b 1Inner rotor 2Outer rotor 3Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.03 0.09 mm (0.0012 0.0035 in) : 0.15 mm (0.0059 in) Outer-rotor-to-oil-pump-housing clearance 0.03 0.08 mm (0.0012 0.0032 in) : 0.15 mm (0.0059 in)
5-59 OIL PAN AND OIL PUMPENG 3. Check: oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: relief valve body 1 relief valve 2 spring 3 O-ring 4 Damage / wear Replace the defective part(s). EAS00367 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1. Check: oil delivery pipe 1 oil pipe 2 Damage Replace. Obstruction Wash and blow out with com- pressed air. EAS00368 CHECKING THE OIL STRAINER 1. Check: oil strainer 1 Damage Replace. Contaminants Clean with solvent. EAS00373 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles. 1. Check: oil nozzle 1 Damage / wear Replace the oil nozzle. O-ring 2 Damage / wear Replace. oil nozzle passage Obstruction Blow out with compressed air.
5-60 OIL PAN AND OIL PUMPENG 12 Nm (1.2 mkg, 8.7 ftlb) NOTE: 12 Nm (1.2 mkg, 8.7 ftlb) CAUTION: EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: inner rotor outer rotor oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: oil pump housing 1 oil pump shaft 2 washer 3 pin 4 inner rotor 5 outer rotor 6 dowel pins 7 oil pump cover 8 When installing the inner rotor, align the pin 4 in the oil pump shaft with the groove in the inner ro- tor 5. 3. Check: oil pump operation Refer to “CHECKING THE OIL PUMP”. EAS00376 INSTALLING THE OIL PUMP 1. Install: oil pump drive chain gear cover oil pump After tightening the bolts, make sure the oil pump turns smoothly.