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