Yamaha Fz6n Manual
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2-14 ELECTRICAL SPECIFICATIONSSPEC ELECTRICAL SPECIFICATIONS ItemStandardLimit System voltage12 V Ignition system Ignition system type Ignition timing Advancer type Crankshaft position sensor resistance / color T.C.I. unit model (manufacturer) DC. T.C.I. 5 BTDC at 1,300 r / min Digital 248 372 Ω at 20C (68F) / Gy-B F8T811 (MITSUBISHI) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance JO383 (DENSO) 6 mm (0.24 in) 1.53 2.07 Ω at 20C (68F) 12.0 18.0 kΩ at 20C (68F) Spark plug cap Material Resistance Resin 10.0 kΩ at 20C (68F) Charging system System type Model (manufacturer) Normal output Stator coil resistance / color A.C. magneto F5VX (MORIC) 14 V / 310 W at 5,000 r / min 0.22 0.34 Ω at 20C (68F) / W-W Rectifier / regulator Regulator type Model (manufacture) Semi conductor short circuit SH719AA (SHINDENGEN) () No-load regulated voltage Rectifier capacity Withstand voltage () 14.1 14.9 V 18 A 240 V Battery Battery type Battery voltage / capacity Specific gravity Manufacturer Ten hour rate amperage GT12B-4 12 V / 10 Ah 1.320 GS 1.0 A Headlight typeHalogen bulb Bulbs (voltage / wattage quantity) Headlight Tail / brake light Front turn signal / position light Rear turn signal light Licence light Meter light 12V 60 W/55 W 1 12 V 55 W 1 12 V 5 W/21 W 1 12 V 21 W / 5 W 2 12 V 21 W 2 12 V 5 W 1 EL
2-15 ELECTRICAL SPECIFICATIONSSPEC ItemStandardLimit Indicator light (voltage / wattage quantity) Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Engine trouble warning light LED 1 LED 1 LED 1 LED 2 LED 1 Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Armature coil resistance Commutator diameter Mica undercut Constant mesh SM-14 (MITSUBA) 0.6 kW 10 mm (0.39 in) 7.16 9.52 N (730 971 g, 25.77 34.27 oz) 0.0012 0.0022 Ω at 20C (68F) 28 mm (1.1 in) 0.7 mm (0.03 in) 3.5 mm (0.14 in) 27 mm (1.06 in) Starter relay Model (manufacturer) Amperage Coil resistance MS5F-441 (JIDECO) 180 A 4.18 4.62 Ω at 20C (68F) Horn Horn type Model (manufacturer) quantity Max. amperage Performance Coil resistance Plain HF-12 (NIKKO) 1 3 A 105 118 db/2 m 1.01 1.11 Ω at 20C (68F) Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Full transistor FE246BH (DENSO) No 75 95 cycles / min. 21 W 2 + 3.4 W Oil level switch Model (manufacturer) 5VX (SOMIC ISHIKAWA)
2-16 ELECTRICAL SPECIFICATIONSSPEC ItemStandardLimit Fuses (amperage quantity) Main fuse Fuel injection system fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse (odometer and clock) Taillight fuse Reserve fuse 30 A 1 10 A 1 20 A 1 10 A 1 10 A 1 20 A 1 10 A 1 10 A 1 30 A, 20 A, 10 A Fuel level sender Model (manufacture) Sender unit resistance-full Sender unit resistance-empty 5VX (DENSO) 20 26 Ω 134 140 Ω Starting circuit cut-off relay Model (manufacture) Coil resistance G8R-30Y-S (OMRON) 162 198 Ω Headlight relay, Radiator fan motor relay Model (manufacture) Coil resistance ACM33211M05 (MATSUSHITA) 86.4 105.6 Ω Fuel injection system relay Model (manufacture) Coil resistance G8R-30Y-R (OMRON) 162 198 Ω Water temperature sensor Model (manufacture) Resistance K003T20191 (MITSUBISHI) 0.290 0.354 Ω at 80C (176F)
2-17 EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid war- page, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Un- less otherwise specified, tightening torque specifications require clean, dry threads. Com- ponents should be at room temperature. A: Distance between flats B: Outside thread diameter A (nut)B (bolt)General tightening torques 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm6 mm 8 mm 10 mm 12 mm 14 mm 16 mmNm mkg 6 15 30 55 85 1300.6 1.5 3.0 5.5 8.5 13.0 ftlb 4.3 11 22 40 61 94 CONVERSION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL ** mm 0.03937 = ** in 2 mm 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unitMultiplierImperial unit Tighten- ing torquemkg mkg cmkg cmkg7.233 86.794 0.0723 0.8679ftlb inlb ftlb inlb Weightkg g2.205 0.03527lb oz Speedkm / hr0.6214mph Distance km m m cm mm0.6214 3.281 1.094 0.3937 0.03937mi ft yd in in Volume / Capacity cc (cm3) cc (cm3) lt (liter) lt (liter)0.03527 0.06102 0.8799 0.2199oz (IMP liq.) cuin qt (IMP liq.) gal (IMP liq.) Misc. kg / mm kg / cm2 Centigrade (C) 55.997 14.2234 9 / 5+32lb / in psi (lb / in2) Fahrenheit (F)
2-18 TIGHTENING TORQUESSPEC Yamaha bond No.1215 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks Spark plugs–M104181.813 Cylinder headBoltM10101st 19 2nd 501.9 5.014 36 BoltM62121.28.7 Camshaft capsBoltM620101.07.2 Cylinder head coverBoltM66121.28.7 Camshaft cap oil check boltBoltM81202.015 Air indication system reed valve coverBoltM64101.07.2 Air-cut valve stayBoltM61101.07.2 Camshaft sprocketsBoltM74202.015 Connecting rod caps (except for CAL)NutM7815 + 1501.5 + 15011 + 150 Connecting rod caps (for CAL)BoltM7815 + 1201.5 + 12011 + 120 Generator rotorBoltM121757.554 Timing chain tensionerBoltM62121.28.7 Timing chain tensioner cap boltBoltM617.00.75.1 Thermostat coverBoltM62121.28.7 Coolant hose jointBoltM62101.07.2 Water pump coverBoltM62101.07.2 Water pumpBoltM62121.28.7 Thermo sensorBoltM121181.813 Coolant hose drain bolt (water pump)BoltM61101.07.2 Radiator and frameBoltM627.00.75.1 Radiator stay and crankcaseBoltM61101.07.2 Oil pump coverBoltM63121.28.7 Oil pumpBoltM63121.28.7 Oil panBoltM612121.28.7 Oil pan (center)BoltM61121.28.7 Oil coolerBoltM201636.346 Engine oil drain boltBoltM141434.331 Oil filter union boltBoltM201707.051 Oil filter–M201171.712 Oil pump chain guideBoltM62121.28.7 Oil pipeBoltM62121.28.7 Throttle body jointBoltM68101.07.2 Air filter case coverScrewM561.20.120.9 Throttle body and throttle body jointClampM443.00.32.2 Throttle body and air filter caseClampM543.00.32.2 Exhaust pipe and cylinder headNutM88202.015 Exhaust pipe and exhaust pipe stayBoltM81202.015 Catalyst pipe and catalyst pipe stayBoltM81202.015 Muffler jointBoltM81202.015See NOTE 1 Catalyst jointBoltM81202.015See NOTE 1 Exhaust stay and frameBoltM81343.425 Catalyst pipe stay and frameBoltM81202.015 Muffler stay and frameBoltM82202.015
2-19 Yamaha bond No.1215 Use a lock washer Use a lock washer Left thread NOTE 1: TIGHTENING TORQUESSPEC NOTE 2: ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks Crankcase (main journal)BoltM810See NOTE 2 CrankcaseBoltM62141.41.0 CrankcaseBoltM613121.28.7 CrankcaseBoltM82242.417 Generator rotor coverBoltM69121.28.7 Clutch coverBoltM67121.28.7 Clutch coverBoltM61121.28.7 Pickup coil rotor coverBoltM67121.28.7 Clutch cable holderBoltM62121.28.7 Pickup coil rotor coverBoltM81151.511 Shift shaft coverBoltM66121.28.7 Breather plateScrewM63121.28.7 Stator coilScrewM63101.07.2 Pickup rotor cover and clampScrewM617.00.75.1 Drive sprocket coverBoltM63101.07.2 Oil gallery bolt–M16280.85.8 Generator rotor cover and stator coil lead clampScrewM61101.07.2 Breather hose coverBoltM64121.28.7 Oil pipeBoltM62121.28.7 Crankshaft position sensorBoltM62101.07.2 Starter clutchScrewM83323.223 Starter motor cover boltBoltM623.40.342.5 Clutch pressure plateScrewM668.00.85.8 Clutch bossNutM201909.065 Drive sprocketNutM181909.065 Transmission bearing housingScrewM63121.28.7 Shift drum retainerBoltM62101.07.2 Shift shaft spring stopperScrewM81222.216 Shift rodNutM6170.75.1 Shift rodNutM6170.75.1 Shift rod jointBoltM61101.07.2 Shift armBoltM61101.07.2 Pickup coil rotorBoltM81353.525 Starter motorBoltM62101.07.2 Neutral switch–M101202.014 Oil level switchBoltM62101.07.2 Speed sensorBoltM61101.07.2 Retighten the bolt at 1000 km (600 ml). 1. First, tighten the bolts to approximately 12 Nm (1.2 mkg, 8.7 ftlb) with a torque wrench. (Following the tightening order) 2. Retighten the bolts 25 Nm (2.5 mkg, 18 ftlb) with a torque wrench. 3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7 mkg, 20 ftlb) again.
2-20 TIGHTENING TORQUESSPEC Cylinder head tightening sequence: Crankcase tightening sequence.
2-21 TIGHTENING TORQUESSPEC See NOTE 3 CHASSIS TIGHTENING TORQUES ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks Upper bracket pinch boltM8303.022 Steering stem nutM2211 01180 Upper bracket and upper handlebar holderM8232.317 Under bracket pinch bolt–303.022 Lower ring nutM25181.813See NOTE 1 Front fork cap boltM35242.417 Damper rod assembly boltM10232.317 Pinch bolt (front wheel axle)M8232.317 Front brake master cylinder and master cylinder bracketM6101.07.2 Front brake master cylinder cap screwM420.21.4 Front brake hose union boltM10303.022 Front brake hose holder and front forkM6101.07.2 Front cowling stay and frameM8333.324 Front cowling bracket and frameM670.75.1 Front fender and front forkM660.64.3 Clutch lever holder pinch boltM6111.18.0 Engine mount bolts (left of front side)M10555.540 Engine mount bolts (left of rear side)M10555.540 Engine mount bolts (right of front side)M10555.540See NOTE 2 Engine mount self locking nut (upper)M10555.540 Engine mount self locking nut (lower)M10555.540 Fornt frame and rear frame (upper)M10414.130 Front frame and rear frame (lower)M10414.130 Pivot shaft and frameM181201287 Rear shock absorber and frameM10404.029 Rear shock absorber and rear armM10404.029 Seal guard and rear armM670.75.1 Rear fender and rear armM670.75.1 Rear brake hose holder and rear armM670.75.1 Fuel tank bracket and frameM670.75.1 Fuel tank bracket and fuel tankM670.75.1 Fuel tank and rear frameM670.75.1 Fuel tank and fuel tank capM560.64.3 Fuel pump and fuel tankM540.42.9 Ignition coil and battery boxM670.75.1 Seat lock and frameM670.75.1 Rotor and mud guardM630.32.2 Licence plate light and flapM540.42.9 Front side reflector and front brake hose holderM540.42.9 Rear side reflector and stayM530.32.2 Rear reflector and flapM540.42.9 Flap and bracket 6M670.75.1 Blacket 6 and rear frameM6191.914 Seat handle and tail / brake right unitM630.32.2 Rear fender cover and seat handleM540.42.9 Seat handle boltM8232.317 Muffler and rear fenderM670.75.1
2-22 TIGHTENING TORQUESSPEC NOTE 1: NOTE 2: NOTE 3: ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks Side cover and rear frameM6101.07.2 Rear mud guard and rear frameM670.75.1 Engine stop switch and frameM420.21.4 Coolant reserver tank bracket and stay 1, 2M6101.07.2 Stay 1, 2 and frameM6101.07.2 Coolant reserver tank bracket and coolant reserver tankM640.42.9 Canister and canister bracket (for CAL)M670.75.1 Canister bracket and coolant reserver tank bracket (forCAL)M670.75.1 Front wheel axle shaft and boltM18727.252 Front wheel axle pinch boltM8232.317 Front brake caliper and front forkM10404.029 Front brake disc and front wheelM6181.813 Brake caliper bleed screwM760.64.3 Rear wheel axle nutM241201287 Rear brake disc and rear wheelM8303.022 Rear brake caliper bolt front and rear brake caliper bracketM8272.720 Rear brake caliper bolt rear and rear brake caliper bracketM8222.216 Rear wheel sprocket and rear wheel drive hubM101001072 Chain adjusting bolt lock nutM8161.612 Rear brake hose union boltM10303.022 Sidestand bolt lock nutM10464.633 Sidestand bracket and frameM10636.346 Sidestand switch screwM540.42.9 Footrest bracket and frameM8303.022 Rear brake reserver tank and coolant reserver tank bracketM630.32.2 Rear master cylinder and footrest bracketM8232.317 Mainstand and nutM10737.353 Footrest and footrest boltM8101.07.2 Brake pedal and brake shaftM680.85.8 1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg, 38 ftlb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut to specification. Refer to “INSTALLING THE ENGINE” in chapter 5. To repair, make sure to apply the liquid fixing agent to the bolt without fixing agent (90149 – 10001) and use it.
2-23 LUBRICATION POINTS AND LUBRICANT TYPESSPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings and bushes Crankshaft pins Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surface Piston cooler (O-ring) Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surfaceYamaha bond No.1215 Cylinder head cover semicircularYamaha bond No.1215 Crankcase mating surfaceYamaha bond No.1215 Generator rotor cover (stator coil assembly lead grommet)Yamaha bond No.1215 Pickup rotor cover (crankshaft position sensor lead grommet)Yamaha bond No.1215