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Yamaha Fz6n Manual

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Page 311

5-91
Order Job / Part Q’ty Remarks
Bearing housing
Bearing1
1
For installation, reverse the removal 
procedure.
15
16
TRANSMISSIONENG 

Page 312

5-92
Order Job / Part Q’ty Remarks
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
Collar
3rd wheel gear
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip1
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 

Page 313

5-93
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
6th wheel gear
Circlip
Washer
2nd wheel gear
Collar
Collar
Oil seal
Bearing
Circlip
Drive axle1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal 
procedure.
15
16
17
18
19
20
21
22
23
24 

Page 314

5-94
TRANSMISSIONENG
WARNING
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
main axle assembly 
1
(with the Torx wrench T30)
a. Insert two bolts 
2 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crank-
case surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1....

Page 315

5-95
TRANSMISSIONENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
shift drum grooves
Damage / scratches / wear  Replace the
shift drum assembly.
shift drum segment 
1
Damage / wear  Replace the shift drum as-
sembly.
shift drum bearing 
2
Damage / pitting  Replace the shift drum
assembly.
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
main axle runout
(with a centering device and dial gauge 
1)
Out of specification  Replace the main
axle.
Main axle runout limit
0.02 mm (0.0008 in)
2....

Page 316

5-96
TRANSMISSIONENG
NOTE:
NOTE: 4. Check:
transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect  Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement  Replace the defective
part(s).
6. Check:
circlips
Bends / damage / looseness  Replace.
EAS00430
INSTALLING THE TRANSMISSION
1. Install:
oil pipe 
1
main axle assembly 2
(with the Torx wrench T30)
Make sure to caulk the bolts at three positions
after installing the...

Page 317

5-97
TRANSMISSIONENG
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
NOTE: 3. Install:
shift fork “R” 
1 and “L” 2
drive axle 3
shift fork guide bar
shift drum retainer
Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
Make sure that the drive axle bearing circlip 
a
is inserted into the grooves in the upper crank-
case.
4. Check:
transmission
Rough movement  Repair.
Oil each gear, shaft, and bearing thoroughly. 

Page 318

6-1
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the radiator
Seat
Front cowling inner panel (left and right)
Fuel tank
Air filter case
Coolant
Coolant reservoir hose
Throttle body hose
Water pump breather hose
Radiator outlet hose
Radiator inlet hose
Oil cooler outlet hose
Radiator
Radiator cap1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
Refer to “COWLINGS”
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING...

Page 319

6-2
6
RADIATORCOOL
Order Job / Part Q’ty Remarks
9 Radiator fan 1
For installation, reverse the removal
procedure.
10 Nm (1.0 mkg, 7.2 ftlb)7 Nm (0.7 mkg, 5.1 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb) 

Page 320

6-3
RADIATORCOOL
NOTE:
EAS00455
CHECKING THE RADIATOR
1. Check:
radiator fins
Obstruction  Clean.
Apply compressed air to the rear of the radia-
tor.
Damage  Repair or replace.
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:
radiator hoses
radiator pipes
Cracks / damage  Replace.
3. Measure:
radiator cap opening pressure
Below the specified pressure  Replace the
radiator cap.
Radiator cap opening pressure
93  123 kPa
(0.93  1.23 kg / cm
2, 
13.2  17.5 psi)
a....
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