Yamaha Fz6n Manual

5-41
SHIFT SHAFTENG
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE:
NOTE:
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:

shift shaft 
1
Bends / damage / wear 
 Replace.

shift shaft spring 
2
Damage / wear 
 Replace.
EAS00330
CHECKING THE STOPPER LEVER
1. Check:

stopper lever 
1
Bends / damage 
 Replace.
Roller turns roughly 
 Replace the stopper
lever.
EAS00332
INSTALLING THE SHIFT SHAFT
1. Install:

shift shaft spring stopper 
1

washers

shift shaft 
2

Apply LOCTITE to the threads of the shift
shaft spring...

5-42
Order Job / Part Q’ty Remarks
1
2
3
4Removing the crankshaft position
sensor and pickup rotor
Seat
Front cowling inner panel (left and right)
Fuel tank
Engine oil
Generator cover
Crankshaft position sensor lead coupler
Pickup rotor cover
Pickup rotor cover gasket
Dowel pin1
1
1
2Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “STARTER CLUTCH AND...

5-43
CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG
Order Job / Part Q’ty Remarks
5
6
7Crankshaft position sensor
Pickup rotor
Plug screw1
1
1
For installation, reverse the removal 
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
15 Nm (1.5 m
kg, 11 ft
lb)
35 Nm (3.5 m
kg, 25 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb) 

5-44
CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG
NOTE:
NOTE:
NOTE: REMOVING THE PICKUP ROTOR
1. Remove:

pickup rotor cover 
1
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:

pickup rotor bolt 
1

washer 2

pickup rotor 3
While holding the generator rotor 4 with the ro-
tor holding tool 
5, loosen the pickup rotor bolt.
Sheave holder
90890-01701, YS-01880-A
INSTALLING THE PICKUP ROTOR
1. Install:...

5-45
CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG
35 Nm (3.5 m
kg, 25 ft
lb)
NOTE:
NOTE: 2. Tighten:

pickup rotor bolt 
1
While holding the generator rotor 2 with the
sheave holder 
3, tighten the pickup rotor bolt.
Sheave holder
90890-01701, YS-01880-A
3. Apply:

sealant
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No.1215
90890-85505, ACC-11001-5-01
4. Install:

pickup rotor cover

gasket 
New

When installing the pickup rotor cover, align
the timing chain guide (intake side) pin...

5-46
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the clutch cover
Engine oil
Coolant
Coolant hose
Clutch cable
Clutch cable holder
Clutch cover
Clutch cover gasket
Dowel pin1
1
1
1
1
2Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
For installation, reverse the removal 
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CLUTCHENG
: YAMAHA BOND No. 1215
EAS00273...

5-47
CLUTCHENG
Order Job / Part Q’ty Remarks
Disassembling the clutch cover
Circlip
Washer
Pull lever
Pull lever spring
Washer
Oil seal
Bearing
Pull lever shaft
Washer2
1
1
1
1
1
2
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
9 

5-48
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12Removing the clutch
Compression spring
Pressure plate
Pull rod
Bearing
Friction plate (Brown)
Clutch plate (t=2.0 mm, 0.08 in)
Friction plate
Clutch plate (t=2.3 mm, 0.09 in)
Clutch boss nut
Lock plate
Clutch boss
Thrust plate6
1
1
1
6
7
2
1
1
1
1
1Remove the parts in the order listed.
For installation, reverse the removal 
procedure.
90 Nm (9.0 m
kg, 65 ft
lb)
8 Nm (0.8 m
kg, 5.8 ft
lb)
CLUTCHENG
EAS00274
CLUTCH 

5-49
CLUTCHENG
NOTE:
NOTE:
EAS00276
REMOVING THE CLUTCH
1. Remove:

clutch cable holder 
1

clutch cover 2

gasket
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
While holding the clutch boss 2 with the univer-
sal clutch...

5-50
CLUTCHENG
NOTE:
2. Measure:

friction plate thickness
Out of specification 
 Replace the friction
plates as a set.
Measure the friction plate at four places.
Friction plate thickness
2.9 
 3.1 mm (0.114 
 0.122 in)
: 2.8 mm (0.110 in)
EAS00281
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 
...