Yamaha Fz6 N Service Manual

CLUTCH
5-50
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch plates.
1. Check: Clutch plate Damage  → Replace the clutch plates as a 
set.
2. Measure:  Clutch plate warpage
(with a surface plate and thickness gauge 
“1”)
Out of specification  → Replace the clutch 
plates as a set.
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the 
clutch springs.
1. Check: Clutch spring
Damage  → Replace the clutch springs as a 
set.
2....

CLUTCH
5-51
NOTE:
Pitting on the clutch boss splines will cause 
erratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
 Pressure plate “1” Cracks/damage  → Replace.
 Bearing “2” Damage/wear  → Replace.
EAS25220
CHECKING THE PULL LEVER SHAFT AND 
PULL ROD
1. Check:
 Pull lever shaft pinion gear teeth “1”
 Pull rod teeth “2” Damage/wear  → Replace the pull rod and 
pull lever shaft pinion gear as a set.
2. Check:  Pull rod bearing Damage/wear  → Replace.
EAS25270
INSTALLING THE...

CLUTCH
5-52
5. Install: Friction plates
 Clutch plates
NOTE:
First, install a friction plate and then alternate 
between a clutch plate and a friction plate.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the clutch plate and friction plate as 
shown in the illustration.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install: Pressure plate “1”
NOTE:
Align the punch mark “a” in the pressure plate 
with the punch mark “b” in the clutch boss.
7. Install: Bearing “1”
 Pill rod “2”
 Pressure plate “3”
 Clutch springs...

SHIFT SHAFT
5-53
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty RemarksDrive sprocket cover Refer to ENGINE REMOVAL on page 5-1.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3Dowel pin 2
4 Oil seal 1
5 Shift shaft 1
6 Shift shaft spring 1
7 Collar 1
8 Stopper lever spring 1
9 Circlip 1
10 Washer 1
11 Stopper lever 1
12 Collar 1
13 Washer 1
14 Shift shaft spring stopper 1 For installation, reverse the removal proce-
dure. 

SHIFT SHAFT
5-54
EAS25420
CHECKING THE SHIFT SHAFT
1. Check: Shift shaft “1”
Bends/damage/wear  → Replace.
 Shift shaft spring “2” Damage/wear  → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
 Stopper lever “1” Bends/damage  → Replace.
Roller turns roughly  → Replace the stopper 
lever.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:  Shift shaft spring stopper “1”
 Washers
 Shift shaft “2”
NOTE:
 Apply LOCTITE® to the threads of the shift shaft spring stopper.
 Hook the ends of the...

CRANKCASE
5-55
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty RemarksEngine Refer to ENGINE REMOVAL on page 5-1.
Cylinder head Refer to CYLINDER HEAD on page 5-16.
Generator Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
Starter clutch Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
Shift shaft Refer to SHI FT SHAFT on page 5-53.
Crankshaft position sensor Refer to PICKUP ROTOR on page 5-33.
Pickup rotor Refer to PICKUP ROTOR on page 5-33.
Clutch Refer to CLUTCH on...

CRANKCASE
5-56
8Plate 1For installation, reverse the removal proce-
dure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks 

CRANKCASE
5-57
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove: Crankcase bolts
NOTE:
 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.
 Loosen the bolts in decreasing numerical  order (refer to the numbers in the illustration).
 The numbers embossed on the crankcase 
indicate the crankcase tightening sequence.
M8  × 85 mm (3.3 in) bolts: “1”–“7”, “10”
M8  × 115 mm (4.5 in) bolts:...

CRANKCASE
5-58
EAS25660
ASSEMBLING THE CRANKCASE
1. Lubricate: Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:  Sealant (onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm of 
the crankshaft journal bearings.
3. Install:
Dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:  Lower crankcase “1”
(onto...

CRANKCASE
5-59