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Yamaha Fz6n Manual

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Page 231

5-11
CAMSHAFTSENG
NOTE:
CAUTION:
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:
pickup rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR AND PICKUP ROTOR”.
2. Align:
“T” mark 
a on the pickup rotor
(with the crankcase mating surface 
b)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark 
a on the pick-
up rotor with the crankcase mating surface
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other....

Page 232

5-12
CAMSHAFTSENG
NOTE:
7. Remove:
intake camshaft 
1
exhaust camshaft 2
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 
a.
8. Remove:
camshaft sprockets
EAS00204
CHECKING THE CAMSHAFTS
1. Check:
camshaft lobes
Blue discoloration / pitting / scratches  Re-
place the camshaft.
2. Measure:
camshaft lobe dimensions 
a and b
Out of specification  Replace the cam-
shaft.
Camshaft lobe dimension limit
Intake camshaft
a 32.45  32.55 mm
(1.278  1.282 in)
: 32.40 mm...

Page 233

5-13
CAMSHAFTSENG
NOTE:
3. Measure:
camshaft runout
Out of specification  Replace.
Camshaft runout limit
0.06 mm (0.0024 in)
4. Measure:
camshaft-journal-to-camshaft-cap clear-
ance
Out of specification  Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028  0.062 mm 
(0.0011  0.0024 in)
: 0.08 mm (0.0032 in)
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position strip of Plastigauge
 1 onto the
camshaft journal as...

Page 234

5-14
CAMSHAFTSENG
NOTE:
EAS00208
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:
timing chain 
1
Damage / stiffness  Replace the timing
chain and camshaft sprockets as a set.
2. Check:
camshaft sprocket
More than 1 / 4 tooth wear 
a  Replace the
camshaft sprockets and the timing chain as a
set.
a1 / 4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
3. Check:
timing chain...

Page 235

5-15
CAMSHAFTSENG
NOTE: b. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
3. Check:
cap bolt
aluminum washer 
New
gasket 
New
Damage / wear  Replace the defective
part(s).
EAS00215
INSTALLING THE CAMSHAFTS
1. Align:
“T” mark 
a on the pickup rotor
(with the crankcase mating surface 
b)
a. Turn the...

Page 236

5-16
CAMSHAFTSENG
NOTE:
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
CAUTION:
NOTE: 3. Install:
dowel pins
exhaust camshaft caps
intake camshaft caps
Make sure each camshaft cap is installed in its
original place.
Make sure the arrow mark 
a on each cam-
shaft cap points towards the right side of the
engine.
4. Install:
camshaft cap bolts
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
I1, I2: Intake side camshaft cap mark
E1, E2: Exhaust side camshaft...

Page 237

5-17
CAMSHAFTSENG
WARNING
20 Nm (2.0 mkg, 15 ftlb)
CAUTION:
6. Install:
timing chain tensioner
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver 
1.
b. With the timing chain tensioner rod turned all
the way into the timing chain tensioner hous-
ing (with the thin screwdriver still installed),
install the gasket and the timing chain ten-
sioner 
2 onto the cylinder block.
Always use a new gasket.
c. Tighten the timing...

Page 238

5-18
CAMSHAFTSENG
10. Measure:
valve clearance
Out of specification  Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3. 

Page 239

5-19
Order Job / Part Q’ty Remarks
1
2
3Removing the cylinder head
Intake and exhaust camshaft
Engine bracket
Cylinder head
Cylinder head gasket
Dowel pin1
1
2Remove the parts in the order listed.
Refer to “CAMSHAFTS”.
Refer to “ENGINE”.
For installation, reverse the removal 
procedure.
12 Nm (1.2 mkg, 8.7 ftlb)
19 Nm (1.9 mkg, 14 ftlb)
50 Nm (5.0 mkg, 36 ftlb)
1st
2nd
CYLINDER HEADENG
EAS00221
CYLINDER HEAD 

Page 240

5-20
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:
cylinder head bolts
Loosen the bolts in the proper sequence as
shown.
Loosen each bolt 1 / 2 of a turn at a time. After
all of the bolts are fully loosened, remove
them.
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:
spark plug bore threads
valve seats
2. Check:
cylinder head
Damage /...
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