Yamaha Fz6n Manual

5-61
OIL PAN AND OIL PUMPENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
43 Nm (4.3 m
kg, 31 ft
lb)
WARNING
NOTE:
EAS00378
INSTALLING THE OIL STRAINER
1. Install:

oil strainer 
1

relief valve 2
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.
EAS00380
INSTALLING THE OIL PAN
1. Install:

oil pipe

oil delivery pipe
2....

5-62
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the crankcase
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Crankshaft position sensor and pickup
rotor
Clutch
Water pump assembly
Oil pan and oil pump
Timing chain
Oil pump drive chain
Oil pump drive chain guide
Lower crankcase
Dowel pin1
1
1
1
3Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND 
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION 
SENSOR AND...

5-63
Order Job / Part Q’ty Remarks
6
7
8Thrust plate
Washer
Plate1
1
1
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)
CRANKCASEENG 

5-64
CRANKCASEENG
NOTE:
CAUTION:
NOTE:
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:

crankcase bolts

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 or-
der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M8  85 mm (3.3 in) bolts: 
1 
 7, 10
M8  115 mm...

5-65
CRANKCASEENG
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks / damage 
 Replace.

oil delivery passages
Obstruction 
 Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement 
 Replace.
2. Check:

oil seals
Damage / wear 
...

5-66
CRANKCASEENG
NOTE:
CAUTION:
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 the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is...

5-67
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the connecting rods and
pistons
Lower crankcase
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Top ring
2nd ring
Oil ring4
4
4
8
4
4
4
4
4
4Remove the parts in the order listed.
Refer to “CRANKCASE”.
For installation, reverse the removal 
procedure.
15 Nm (1.5 m
kg, 11 ft
lb) +120
15 Nm (1.5 m
kg, 11 ft
lb) +150
CONNECTING RODS AND PISTONSENG
EAS00252
CONNECTING RODS AND...

5-68
CONNECTING RODS AND PISTONSENG
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

connecting rod cap 
1

big end bearings
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:

piston pin clips 
1

piston pin 2

piston 3
Do not use a hammer to drive the piston pin
out.

For reference during installation, put identifica-
tion marks on...

5-69
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
EAS00387
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:

crankshaft assembly

crankshaft journal upper bearings
(from the upper crankcase)
Refer to “CRANKSHAFT”.
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
EAS00261
CHECKING THE CYLINDER AND PISTON
1. Check:

piston wall

cylinder wall
Vertical scratches 
 Replace the cylinder,
and the piston and piston rings as a set.
2. Measure:...

5-70
CONNECTING RODS AND PISTONSENG
NOTE:Cylinder bore “C”
65.50 
 65.51 mm
(2.5787 
 2.5791 in)
Wear limit65.56 mm
(2.5811 in)
Taper limit “T”0.05 mm (0.002 in)
Out of round “R”0.05 mm (0.002 in)
“C” = maximum of D1 
 D6
“T” = maximum of D1 or D2 – maximum
of D
5 or D6
“R” = maximum of D1 D3 or D5 –
minimum of D
2 D4 or D6
b. If out of specification, replace the cylinder,
and the pistons and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a4 mm (0.16 in) from the bottom...