Yamaha Fz6n Manual
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5-91 Order Job / Part Q’ty Remarks Bearing housing Bearing1 1 For installation, reverse the removal procedure. 15 16 TRANSMISSIONENG
5-92 Order Job / Part Q’ty Remarks Disassembling the drive axle assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip1 1 1 1 1 1 1 1 1 1 1 1 1 1Disassemble the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TRANSMISSIONENG
5-93 TRANSMISSIONENG Order Job / Part Q’ty Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure. 15 16 17 18 19 20 21 22 23 24
5-94 TRANSMISSIONENG WARNING EAS00420 REMOVING THE TRANSMISSION 1. Remove: main axle assembly 1 (with the Torx wrench T30) 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 crank- case surface. c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase. EAS00421 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 surface. Bends Replace. 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.
5-95 TRANSMISSIONENG EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: shift drum grooves Damage / scratches / wear Replace the shift drum assembly. shift drum segment 1 Damage / wear Replace the shift drum as- sembly. shift drum bearing 2 Damage / pitting Replace the shift drum assembly. EAS00425 CHECKING THE TRANSMISSION 1. Measure: main axle runout (with a centering device and dial gauge 1) Out of specification Replace the main axle. Main axle runout limit 0.02 mm (0.0008 in) 2. Measure: drive axle runout (with a centering device and dial gauge 1) Out of specification Replace the drive axle. Drive axle runout limit 0.02 mm (0.0008 in) 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).
5-96 TRANSMISSIONENG NOTE: NOTE: 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. EAS00430 INSTALLING THE TRANSMISSION 1. Install: oil pipe 1 main axle assembly 2 (with the Torx wrench T30) 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 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.
5-97 TRANSMISSIONENG 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: NOTE: 3. Install: shift fork “R” 1 and “L” 2 drive axle 3 shift fork guide bar shift drum retainer 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 crank- case. 4. Check: transmission Rough movement Repair. Oil each gear, shaft, and bearing thoroughly.
6-1 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the radiator Seat Front cowling inner panel (left and right) Fuel tank Air filter case Coolant Coolant reservoir hose Throttle body hose Water pump breather hose Radiator outlet hose Radiator inlet hose Oil cooler outlet hose Radiator Radiator cap1 1 1 1 1 1 1 1Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” Refer to “FUEL TANK” in chapter 3. Refer to “AIR FILTER CASE” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. Disconnect. Disconnect. 10 Nm (1.0 mkg, 7.2 ftlb)7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb) RADIATORCOOL EAS00454 COOLING SYSTEM RADIATOR
6-2 6 RADIATORCOOL Order Job / Part Q’ty Remarks 9 Radiator fan 1 For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb)7 Nm (0.7 mkg, 5.1 ftlb) 7 Nm (0.7 mkg, 5.1 ftlb)
6-3 RADIATORCOOL NOTE: EAS00455 CHECKING THE RADIATOR 1. Check: radiator fins Obstruction Clean. Apply compressed air to the rear of the radia- tor. Damage Repair or replace. 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. Radiator cap opening pressure 93 123 kPa (0.93 1.23 kg / cm 2, 13.2 17.5 psi) a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3. Radiator cap tester 90890-01325, YU-24460-01 Radiator cap tester adapter 90890-01352, YU-33984 b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. 4. Check: radiator fan Damage Replace. Malfunction Check and repair. Refer to “COOLING SYSTEM” in chapter 8.