Yamaha Fz6 N Service Manual
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OIL PUMP 5-40 EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty RemarksEngine oil Drain. Refer to CHANGING THE ENGINE OIL on page 3-14. Coolant Drain. Refer to CHANGING THE COOLANT on page 3-20. Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5-1. Water pump Refer to WATER PUMP on page 6-9. 1 Oil level switch lead coupler 1 Disconnect. 2 Oil level switch 1 3 Oil level switch lead holder 1 4Oil pan 1 5 Oil pan gasket 1 6Dowel pin 2 7 Oil strainer 1 8 Oil strainer gasket 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Oil pump assembly 1 12 Dowel pin 2
OIL PUMP 5-41 13 Relief valve assembly 1For installation, reverse the removal proce- dure. Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks
OIL PUMP 5-42 Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks1Oil pump cover 1 2Pin 2 3 Oil pump inner rotor 1 4 Oil pump outer rotor 1 5Pin 1 6 Washer 1 7 Oil pump rotor housing 1 8 Oil pump driven sprocket 1 For assembly, reverse the removal proce- dure.
OIL PUMP 5-43 EAS24930 REMOVING THE OIL PAN 1. Remove: Oil level switch “1” Oil pan “2” Oil pan gasket Dowel pins 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. EAS24960 CHECKING THE OIL PUMP 1. Check: Oil pump driven gear “1” Oil pump rotor housing “2” Oil pump cover Cracks/damage/wear → Replace the defective part(s). 2. Measure: Inner-rotor-to-outer-rotor-tip clearance “a” Outer-rotor-to-oil-pump-housing clearance “b” 3. Check: Oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS24970 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). Inner-rotor-to-outer-rotor-tip clearance 0.030–0.090 mm (0.0012– 0.0035 in) Limit 0.15 mm (0.0059 in) Outer-rotor-to-oil-pump-hous- ing clearance 0.030–0.080 mm (0.0012– 0.0032 in) Limit 0.150 mm (0.0059 in) 1. Inner rotor 2. Outer rotor 3. Oil pump housing
OIL PUMP 5-44 EAS24980 CHECKING THE OIL DELIVERY PIPES 1. Check: Oil delivery pipe “1” Oil pipe “2” Damage → Replace. Obstruction → Wash and blow out with compressed air. EAS24990 CHECKING THE OIL STRAINER 1. Check: Oil strainer “1” Damage → Replace. Contaminants → Clean with solvent. EAS4S81016 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. EAS25010 ASSEMBLING THE OIL PUMP 1. Lubricate: Inner rotor Outer rotor Oil pump shaft (with the recommended lubricant) 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” Oil pump housing screw NOTE: When installing the inner rotor, align the pin “4” in the oil pump shaft with the groove “a” in the inner rotor “5”. Recommended lubricant Engine oil Oil pump housing screw12 Nm (1.2 m·kg, 8.7 ft·lb)
OIL PUMP 5-45 3. Check: Oil pump operation Refer to CHECKING THE OIL PUMP on page 5-43. EAS25030 INSTALLING THE OIL PUMP 1. Install: Oil pump drive chain Gear cover Oil pump Oil pump bolts CAUTION: ECA4S81018 After tightening the bolts, make sure the oil pump turns smoothly. EAS25040 INSTALLING THE OIL STRAINER 1. Install: Oil strainer “1” Relief valve “2” NOTE: Make sure to check the arrow mark “a” located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine. EAS25050 INSTALLING THE OIL PAN 1. Install: Oil pipe Oil delivery pipe 2. Install: Dowel pins Gasket Oil pan “1” Oil level switch “2” Engine oil drain bolt WARNING EWA12820 Always use new copper washers. NOTE: Tighten the oil pan bolts in stages and in a crisscross pattern. Lubricate the oil level switch O-ring with engine oil. Oil pump bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pan bolt12 Nm (1.2 m·kg, 8.7 ft·lb) Oil level switch bolt10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil drain bolt43 Nm (4.3 m·kg, 31 ft·lb) New
CLUTCH 5-46 EAS25060 CLUTCH * Yamaha bond No.1215 (Three Bond No.1215®) Removing the clutch cover Order Job/Parts to remove Q’ty RemarksEngine oil Drain Refer to CHANGING THE ENGINE OIL on page 3-14. Coolant Drain Refer to CHANGING THE COOLANT on page 3-20. 1 Coolant hose 1 2Clutch cable 1 3 Clutch cable holder 1 4Clutch cover 1 5 Clutch cover gasket 1 6Dowel pin 2 For installation, reverse the removal proce- dure.
CLUTCH 5-47 Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks1 Circlip 2 2 Washer 1 3 Pull lever 1 4 Pull lever spring 1 5 Washer 1 6 Oil seal 1 7 Bearing 2 8 Pull lever shaft 1 9 Washer 1 For installation, reverse the removal proce- dure.
CLUTCH 5-48 Removing the clutch Order Job/Parts to remove Q’ty Remarks1 Compression spring 6 2 Pressure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 6 6 Clutch plate 1 7 7 Friction plate 2 2 8 Clutch plate 2 1 9 Clutch boss nut 1 10 Lock washer 1 11 Clutch boss 1 12 Thrust plate 1 For assembly, reverse the removal proce- dure.
CLUTCH 5-49 EAS25070 REMOVING THE CLUTCH 1. Remove: Clutch cable holder “1” Clutch cover “2” Gasket 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. 2. Remove: Compression spring bolts “1” Compression springs Pressure plate “2” Pull rod “3” Friction plates Clutch plates 3. Straighten the lock washer tab. 4. Loosen: Clutch boss nut “1” NOTE: While holding the clutch boss “2” with the uni- versal clutch holder, loosen the clutch boss nut. 5. Remove: Clutch boss nut “1” Lock washer “2” Clutch boss “3” Thrust plate “4” EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: Friction plate thickness Out of specification → Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Universal clutch holder 90890-04086 YM-91042 Friction plate thickness2.92–3.08 mm (0.115–0.121 in) Wear limit 2.80 mm (0.1102 in)