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Yamaha Fz6n Manual

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    							3-14
    ADJUSTING THE VALVE CLEARANCE
    CHK
    ADJ
    NOTE:
    NOTE:
    c. Round off the original valve pad number ac-
    cording to the following table.
    Last digit
    Rounded value
    0 or 20
    55
    810
    EXAMPLE:
    Original valve pad number 
    = 148 (thickness =1.48 mm (0.058 in))
    Rounded value = 150
    d. Locate the rounded number of the original
    valve pad and the measured valve clearance
    in the valve pad selection table. The point
    where the column and row intersect is the
    new valve pad number.
    The new valve pad number is only an approxi-
    mation. The valve clearance must be measured
    again and the above steps should be repeated if
    the measurement is still incorrect.
    e. Install the new valve pad 
    1 and the valve lift-
    er 
    2.
    Lubricate the valve pad with molybdenum dis-
    ulfide grease.
    Lubricate the valve lifter with molybdenum dis-
    ulfide oil.
    Install the valve lifter and the valve pad in the
    correct place.
    The valve lifter must turn smoothly when ro-
    tated by hand.
    f. Install the exhaust and intake camshafts,
    timing chain and camshaft caps.
    Camshaft cap bolt
    10 Nm (1.0 mkg, 7.2 ftlb) 
    						
    							3-15
    ADJUSTING THE VALVE CLEARANCE
    CHK
    ADJ
    NOTE:
    Refer to “CAMSHAFTS” in chapter 5.
    Lubricate the camshaft bearings, camshaft
    lobes and camshaft journals.
    First, install the exhaust camshaft.
    Align the camshaft marks with the camshaft
    cap marks.
    Turn the crankshaft counterclockwise several
    full turns to seat the parts.
    g. Measure the valve clearance again.
    h. If the valve clearance is still out of specifica-
    tion, repeat all of the valve clearance adjust-
    ment steps until the specified clearance is
    obtained. 
    						
    							3-16
    ADJUSTING THE VALVE CLEARANCE
    CHK
    ADJ
    VALVE CLEARANCE (cold):
      0.13  0.20 mm (0.0051  0.0079 in)
    Example: Installed is 175
      Measured clearance is 0.27 mm (0.0106 in)
    Replace 175 pad with 185 pad
      Pad number: (example)
      Pad No.175 = 1.75 mm (0.0689 in)
      Pad No.185 = 1.85 mm (0.0728 in)
    MEASURED
    CLEARANCEINSTALLED PAD NUMBER
    VALVE CLEARANCE (cold):
      0.23  0.30 mm (0.0091  0.0118 in)
    Example: Installed is 175
      Measured clearance is 0.35 mm (0.0138 in)
    Replace 175 pad with 185 pad
      Pad number: (example)
      Pad No.175 = 1.75 mm (0.0689 in)
      Pad No.185 = 1.85 mm (0.0728 in)
    MEASURED
    CLEARANCEINSTALLED PAD NUMBER
    STANDARD CLEARANCE
    STANDARD CLEARANCE
    INTAKE
    120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.00  0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
    0.03  0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
    0.08  0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
    0.13  0.20
    0.21  0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.26  0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.31  0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.36  0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.41  0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.46  0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.51  0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.56  0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.61  0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.66  0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.71  0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.76  0.80 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.81  0.85 185 190 195 200 205 210 215 220 225 230 235 240
    0.86  0.90 190 195 200 205 210 215 220 225 230 235 240
    0.91  0.95 195 200 205 210 215 220 225 230 235 240
    0.96  1.00 200 205 210 215 220 225 230 235 240
    1.01  1.05 205 210 215 220 225 230 235 240
    1.06  1.10 210 215 220 225 230 235 240
    1.11  1.15 215 220 225 230 235 240
    1.16  1.20 220 225 230 235 240
    1.21  1.25 225 230 235 240
    1.26  1.30 230 235 240
    1.31  1.35 235 240
    1.36  1.40 240
    EXHAUST
    120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.00  0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
    0.03  0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
    0.08  0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
    0.13  0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
    0.18  0.22 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
    0.23  0.30
    0.31  0.35 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.36  0.40 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.41  0.45 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.46  0.50 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.51  0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.56  0.60 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.61  0.65 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.66  0.70 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.71  0.75 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.76  0.80 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.81  0.85 175 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.86  0.90 180 185 190 195 200 205 210 215 220 225 230 235 240
    0.91  0.95 185 190 195 200 205 210 215 220 225 230 235 240
    0.96  1.00 190 195 200 205 210 215 220 225 230 235 240
    1.01  1.05 195 200 205 210 215 220 225 230 235 240
    1.06  1.10 200 205 210 215 220 225 230 235 240
    1.11  1.15 205 210 215 220 225 230 235 240
    1.16  1.20 210 215 220 225 230 235 240
    1.21  1.25 215 220 225 230 235 240
    1.26  1.30 220 225 230 235 240
    1.31  1.35 225 230 235 240
    1.36  1.40 230 235 240
    1.41  1.45 235 240
    1.46  1.50 240 
    						
    							3-17
    ADJUSTING THE VALVE CLEARANCE /
    SYNCHRONIZING THE THROTTLE BODIESCHK
    ADJ
    NOTE:
    NOTE:
    NOTE:
    7. Install:
    all removed parts
    For installation, reverse the removal procedure.
    SYNCHRONIZING THE THROTTLE BODIES
    Prior to synchronizing the throttle bodies, the
    valve clearance and the engine idling speed
    should be properly adjusted and the ignition tim-
    ing should be checked.
    1. Stand the motorcycle on a level surface.
    Place the motorcycle on a suitable stand.
    2. Remove:
    seat
    Refer to “SEAT”.
    front cowling inner panel (left and right)
    Refer to “COWLINGS”
    fuel tank
    Refer to “FUEL TANK”.
    air filter case
    Refer to “AIR FILTER CASE”.
    3. Install:
    vacuum gauge 
    1
    (onto the synchronizing hose 2)
    Vacuum gauge
    90890-03094, YU-08030
    4. Install:
    air filter case
    Refer to “AIR FILTER CASE”.
    fuel tank
    Refer to “FUEL TANK”.
    changing the meter display.
    Refer to “FEATURES” in chapter 1.
    5. Start the engine and let it warm up for several
    minutes. 
    						
    							3-18
    SYNCHRONIZING THE THROTTLE BODIES
    CHK
    ADJ
    NOTE:
    CAUTION:
    NOTE: 6. Measure:
    engine idling speed
    Out of specification  Adjust.
    Refer to “ADJUSTING THE ENGINE IDLING
    SPEED”.
    Engine idling speed
    1,250  1,350 r / min
    7. Adjust:
    throttle body synchronization
    a. With throttle body #1 as standard, adjust
    throttle bodies #2, #3, and #4 using the air
    screws 
    1.
    #1 
    2, #2 3, #3 4, #4 5
    After each step, rev the engine two or three
    times, each time for less than a second, and
    check the synchronization again.
    If the air screw is removed, turn the screw 3 / 4
    turn in and be sure to synchronize the throttle
    body.
    Do not use the throttle valve adjusting
    screws to adjust the throttle body synchro-
    nization.
    Vacuum pressure at engine 
    idling speed
    29 kPa
    (218 mmHg, 8.5827 inHg)
    The difference in vacuum pressure between
    two throttle bodies should not exceed 1.33 kPa
    (10 mmHg, 0.39 inHg). 
    						
    							3-19
    ADJUSTING THE ENGINE IDLING SPEED
    CHK
    ADJ
    NOTE:
    a
    b
    EAS00052
    ADJUSTING THE ENGINE IDLING SPEED
    Prior to adjusting the engine idling speed, the
    throttle bodies synchronization should be ad-
    justed properly, the air filter element should be
    clean, and the engine should have adequate
    compression.
    1. Start the engine and let it warm up for several
    minutes.
    2. Check:
    engine idling speed
    Out of specification  Adjust.
    Engine idling speed
    1250  1350 r / min
    3. Adjust:
    engine idling speed
    a. Turn the idle adjusting screw 
    1 in direction
    a or b until the specified engine idling
    speed is obtained.
    Direction
    Engine idling speed is
    increased.
    DirectionEngine idling speed is
    decreased.
    4. Adjust:
    throttle cable free play
    Refer to “ADJUSTING THE THROTTLE
    CABLE FREE PLAY”.
    Throttle cable free play
    (at the flange of the throttle grip)
    3  5 mm (0.12  0.20 in) 
    						
    							3-20
    ADJUSTING THE THROTTLE CABLE FREE PLAY
    CHK
    ADJ
    NOTE:
    NOTE:
    a
    b
    NOTE:
    EAS00055
    ADJUSTING THE THROTTLE CABLE FREE
    PLAY
    Prior to adjusting the throttle cable free play, the
    engine idling speed and throttle bodies synchro-
    nization should be adjusted properly.
    1. Check:
    throttle cable free play 
    a
    Out of specification  Adjust.
    Throttle cable free play
    (at the flange of the throttle grip)
    3  5 mm (0.12  0.20 in)
    2. Remove:
    seat
    Refer to “SEAT”.
    front cowling inner panel (left and right)
    Refer to “COWLINGS”.
    fuel tank
    Refer to “FUEL TANK”.
    air filter case
    Refer to “AIR FILTER CASE”.
    battery
    Refer to “CHECKING AND CHARGING THE
    BATTERY” in chapter 3.
    3. Adjust:
    throttle cable free play
    When the throttle is opened, the accelerator
    cable 
    1 is pulled.
    Throttle body
    a. Loosen the locknut 
    2 on the decelerator
    cable.
    b. Turn the adjusting nut 
    3 in direction a or b
    to take up any slack on the decelerator cable.
    Direction
    Throttle cable free play is
    increased.
    DirectionThrottle cable free play is
    decreased.
    c. Tighten the locknuts.
    If the specified throttle cable free play cannot be
    obtained on the carburetor side of the cable, use
    the adjusting nut on the handlebar side. 
    						
    							3-21
    ADJUSTING THE THROTTLE CABLE FREE PLAY
    CHK
    ADJ
    a
    b
    WARNING
    NOTE:
    NOTE: Handlebar side
    a. Loosen the locknut 
    1.
    b. Turn the adjusting nut 
    2 in direction a or b
    until the specified throttle cable free play is
    obtained.
    Direction
    Throttle cable free play is
    increased.
    DirectionThrottle cable free play is
    decreased.
    c. Tighten the locknut.
    4. Install:
    battery assembly
    Refer to “CHECKING AND CHARGING THE
    BATTERY” in chapter 3.
    air filter case
    Refer to “AIR FILTER CASE”.
    fuel tank
    Refer to “FUEL TANK”.
    front cowling inner panel (left and right)
    Refer to “COWLINGS”.
    seat
    Refer to “SEAT”.
    After adjusting the throttle cable free play,
    start the engine and turn the handlebar to
    the right and to the left to ensure that this
    does not cause the engine idling speed to
    change.
    ADJUSTING THE EXHAUST GAS VOLUME
    Be sure to set the carbon monoxide density to
    standard, and then adjust the exhaust gas.
    1. Turn the main switch to “OFF” and engine
    stop switch “ON”.
    2. While keeping the “SELECT” and “RESET”
    buttons pressed simultaneously, turn “ON”
    the main switch (keep them pressed for 8 se-
    conds or more).
    All indications on the meter disappear except
    the clock and trip indications.
    Letters “dIAG” appear on the odo meter LCD. 
    						
    							3-22
    ADJUSTING THE EXHAUST GAS VOLUME
    CHK
    ADJ
    NOTE:
    NOTE: 3. Using the “SELECT” button, select either the
    Co adjustment mode (which appears as
    “Co”) or the diagnosis mode (which appears
    as “dIAG”)
    4. After “Co” appears as a result of pressing the
    “SELECT” button, simultaneously press the
    “SELECT” and “RESET” buttons for 2 se-
    conds or more to excute the selection.
    5. Press the “SELECT” or “RESET” buttons to
    select the “C1” or “C2”.
    C1=“#1” and “#4”
    C2=“#2” and “#3”
    The adjustment cylinder appears on the odo-
    meter LCD.
    “RESET” button = decrement
    “SELECT” button = increment
    6. Execute the selection of the cylinder by si-
    multaneously pressing the “SELECT” and
    “RESET” buttons for approximately 2 se-
    conds.
    7. After selecting the adjustment cylinder,
    change the “Co” adjustment volume by
    pressing the “SELECT” and “RESET” but-
    tons.
    The Co adjustment volume appears on the
    odo meter LCD.
    “RESET” button = decrement
    “SELECT” button = increment
    8. The selection is executed upon releasing the
    finger from the switch.
    9. Simultaneously press the “SELECT” and
    “RESET” buttons to return to the cylinder
    selection. (step 5)
    10. Cancel the mode by turning “OFF” the main
    switch. 
    						
    							3-23
    A
    B
    CHECKING THE SPARK PLUGS
    CHK
    ADJ
    CAUTION:
    EAS00059
    CHECKING THE SPARK PLUGS
    The following procedure applies to all of the
    spark plugs.
    1. Remove:
    radiator lower bolt 
    1
    radiator lower hose bracket bolt 2
    2. Remove:
    spark plug caps
    spark plugs
    ARight side #1 and #2 and #3
    BLeft side #4
    Before removing the spark plugs, blow away
    any dirt accumulated in the spark plug wells
    with compressed air to prevent it from fal-
    ling into the cylinders.
    3. Check:
    spark plug type
    Incorrect  Change.
    Spark plug type (manufacturer)
    CR9EK (NGK)
    4. Check:
    electrode 
    1
    Damage / wear  Replace the spark plug.
    insulator 
    2
    Abnormal color  Replace the spark plug.
    Normal color is medium-to-light tan.
    5. Clean:
    spark plug
    (with a spark plug cleaner or wire brush)
    6. Measure:
    spark plug gap 
    a
    (with a wire Thickness gauge)
    Out of specification  Regap.
    Spark plug gap
    0.6  0.7 mm 
    (0.0236  0.0276 in) 
    						
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