Yamaha Fz6n Manual

5-71
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Piston ring side clearance
Top ring
0.030 
 0.065 mm 
(0.0012 
 0.0026 in)
: 0.115 mm (0.0045 in)
2nd ring
0.030 
 0.065 mm 
(0.0012 
 0.0026 in)
: 0.125 mm (0.0049 in)
2. Install:

piston ring
(into the cylinder)
Level the piston ring into the cylinder with the
piston crown.
a5 mm (0.20 in)
3. Measure:

piston ring end gap
Out of specification 
 Replace the piston
ring.
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap...

5-72
CONNECTING RODS AND PISTONSENG
2. Measure:

piston pin outside diameter 
a
Out of specification 
 Replace the piston
pin.
Piston pin outside diameter
15.991 
 16.000 mm 
(0.6296 
 0.6299 in)
: 15.971 mm (0.6288 in)
3. Measure:

piston pin bore inside diameter 
b
Out of specification 
 Replace the piston.
Piston pin bore inside diameter
16.002 
 16.013 mm 
(0.6300 
 0.6304 in)
: 16.043 mm (0.6316 in)
4. Calculate:

piston-pin-to-piston clearance
Out of specification 
 Replace the piston pin
and...

5-73
CAUTION:
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.
Align the...

5-74
CONNECTING RODS AND PISTONSENG
CAUTION:
WARNING
CAUTION:
NOTE: e. Tighten the connecting rod nuts (except for
CAL) or bolts (for CAL).
Connecting rod nut
(except for CAL)
15 Nm (1.5 m
kg, 11 ft
lb) + 150
Connecting rod bolt (for CAL)
15 Nm (1.5 m
kg, 11 ft
lb) + 120
f. Replace the connecting rod bolts with new
ones.
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
g. Clean the connecting rod bolts and nuts. (ex-
cept for CAL)...

5-75
CONNECTING RODS AND PISTONSENG
NOTE:
k. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS AND PISTONS”.
l. Measure the compressed Plastigauge

width on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
placement big end bearings.
2. Select:

big end bearings (P1 
 P4)

The numbers 
A stamped into the crankshaft
web and the numbers 
1 on the connecting
rods are used to determine the replacement
big end...

5-76
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
INSTALLING THE CONNECTING ROD AND
PISTON (except for CAL)
The following procedure applies to all of the
connecting rods and pistons.
1. Install:

top ring 
1

2nd ring 2

upper oil ring rail 3

oil ring expander 4

lower oil ring rail 5
Be sure to install the piston rings so that the
manufacturer’s marks or numbers 
a face up.
2. Install:

piston 
1
(onto the respective connecting rod 2)

piston pin 
3

piston pin clip New 4

Apply engine oil onto the...

5-77
CONNECTING RODS AND PISTONSENG
NOTE:
15 Nm (1.5 m
kg, 11 ft
lb) + 150
CAUTION:
4. Offset:

piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
eOil ring expander
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:

big end bearings

connecting rod assembly
(into the cylinder and onto the crankshaft pin)

connecting rod cap
(onto the connecting rod)

Align...

5-78
CONNECTING RODS AND PISTONSENG
WARNING
CAUTION:
NOTE:
b. Clean the connecting rod bolts and nuts.
c. Tighten the connecting rod nuts.
d. Put a mark 
1 on the corner of the connecting
rod nut 
2 and the connecting rod 3.
e. Tighten the nut further to reach the specified
angle (150).
When the nut is tightened more than the spe-
cified angle, do not loosen the bolt and then
retighten it.
Replace the bolt with a new one and perform
the procedure again.

Do not use a torque wrench to tighten the
nut to...

5-79
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
INSTALLING THE CONNECTING ROD AND
PISTON (for CAL)
The following procedure applies to all of the
connecting rods and pistons.
1. Install:

top ring 
1

2nd ring 2

upper oil ring rail 3

oil ring expander 4

lower oil ring rail 5
Be sure to install the piston rings so that the
manufacturer’s marks or numbers 
a face up.
2. Install:

piston 
1
(onto the respective connecting rod 2)

piston pin 
3

piston pin clip New 4

Apply engine oil onto the piston pin....

5-80
CONNECTING RODS AND PISTONSENG
NOTE: 4. Offset:

piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
eOil ring expander
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:

big end bearings

connecting rod cap
(onto the connecting rod)

Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.

Make sure...