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Yamaha Fz6n Manual

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Page 301

5-81
CONNECTING RODS AND PISTONSENG
NOTE:
24.5 Nm (2.5 mkg, 17.7 ftlb)
CAUTION:
NOTE:
NOTE: 7. Tighten:
Install by carrying out the following procedures
in order to assemble in the most suitable condi-
tion.
connecting rod bolts.
a. Replace the connecting rod bolts with new
oncs.
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts.
b. Clean the connecting rod bolts.
c. After installing the big end bearing, assemble
the connecting rod and...

Page 302

5-82
CONNECTING RODS AND PISTONSENG
15 Nm (1.5 mkg, 11 ftlb) + 120
WARNING
CAUTION:
9. Tighten:
connecting rod bolts
a. Clean the connecting rod bolts.
b. Tighten the connecting rod bolts.
c. Put a mark 
1 on the corner of the connecting
rod bolt 
2 and the connecting rod 3.
d. Tighten the bolt further to reach the specified
angle (120).
e. After the installation, check that the section
shown 
a is flush with each other by touching
the surface.
Side machined face 
a
When the bolt is tightened more...

Page 303

5-83
Order Job / Part Q’ty Remarks
1
2
3Removing the crankshaft
Crankcase
Connecting rod caps
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing1
5
5Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND 
PISTONS”.
For installation, reverse the removal 
procedure.
CRANKSHAFTENG
EAS00381
CRANKSHAFT 

Page 304

5-84
CRANKSHAFTENG
CAUTION:
EAS00395
CHECKING THE CRANKSHAFT
1. Measure:
crankshaft runout
Out of specification  Replace the crank-
shaft.
Crankshaft runout
Less than 0.03 mm (0.0012 in)
2. Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches / wear  Replace the crankshaft.
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification  Replace the crank-
shaft journal bearings....

Page 305

5-85
CRANKSHAFTENG
NOTE:
NOTE:
NOTE:
NOTE: c. Install the crankshaft journal upper bearings
1 and the crankshaft into the upper crank-
case.
Align the projections 
a on the crankshaft jour-
nal upper bearings with the notches 
b in the up-
per crankcase.
d. Put a piece of Plastigauge
 2 on each
crankshaft journal.
Do not put the Plastigauge
 over the oil hole in
the crankshaft journal.
e. Install the crankshaft journal lower bearings
1 into the lower crankcase and assemble
the crankcase halves.
Align...

Page 306

5-86
CRANKSHAFTENG
NOTE:
g. Remove the lower crankcase and the crank-
shaft journal lower bearings.
h. Measure the compressed Plastigauge

width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specification,
select replacement crankshaft journal bear-
ings.
2. Select:
crankshaft journal bearings (J1  J5)
The numbers 
A stamped into the crankshaft
web and the numbers 
1 stamped into the low-
er crankcase are used to determine the re-...

Page 307

5-87
CRANKSHAFTENG
NOTE:
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:
crankshaft journal upper bearings 
1
(into the upper crankcase)
Align the projections 
a on the crankshaft jour-
nal upper bearings with the notches 
b in the
upper crankcase.
Be sure to install each crankshaft journal up-
per bearing in its original place.
2. Install:
crankshaft
3. Install:
crankcase (lower)
Refer to “CRANKCASE”. 

Page 308

5-88
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the transmission, shift 
drum assembly, and shift forks
Crankcase lower
Drive axle assembly
Circlip
Oil seal
Bearing
Shift drum retainer
Shift fork guide bar
Spring
Shift fork “L”
Shift fork “R”
Shift drum assembly
Shift fork “C”1
1
1
1
1
2
4
1
1
1
1Remove the part in the order listed.
Separate.
Refer to “CRANKCASE”.
12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb)...

Page 309

5-89
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
12
13
14
15
16Main axle assembly
Oil pipe
Oil baffle plate
Thrust plate
Washer1
1
1
1
1
For installation, reverse the removal 
procedure.
12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb) 

Page 310

5-90
Order Job / Part Q’ty Remarks
Disassembling the main axle 
assembly
Bearing
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle1
1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRANSMISSIONENG 
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