Yamaha Fz6n Manual
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5-11 CAMSHAFTSENG NOTE: CAUTION: EAS00198 REMOVING THE CAMSHAFTS 1. Remove: pickup rotor cover Refer to “CRANKSHAFT POSITION SEN- SOR AND PICKUP ROTOR”. 2. Align: “T” mark a on the pickup rotor (with the crankcase mating surface b) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark a on the pick- up rotor with the crankcase mating surface b. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. 3. Loosen: camshaft sprocket bolts 1 4. Loosen: cap bolt 2 5. Remove: timing chain tensioner 3 gasket 6. Remove: timing chain guide (exhaust side) camshaft caps 4 dowel pins To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
5-12 CAMSHAFTSENG NOTE: 7. Remove: intake camshaft 1 exhaust camshaft 2 To prevent the timing chain from falling into the crankcase, fasten it with a wire a. 8. Remove: camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: camshaft lobes Blue discoloration / pitting / scratches Re- place the camshaft. 2. Measure: camshaft lobe dimensions a and b Out of specification Replace the cam- shaft. Camshaft lobe dimension limit Intake camshaft a 32.45 32.55 mm (1.278 1.282 in) : 32.40 mm (1.276 in) b 24.95 mm 25.05 mm (0.982 0.986 in) : 24.90 mm (0.980 in) Exhaust camshaft a 32.45 32.55 mm (1.278 1.282 in) : 32.40 mm (1.276 in) b 24.95 25.05 mm (0.982 0.986 in) : 24.90 mm (0.980 in)
5-13 CAMSHAFTSENG NOTE: 3. Measure: camshaft runout Out of specification Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: camshaft-journal-to-camshaft-cap clear- ance Out of specification Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 0.062 mm (0.0011 0.0024 in) : 0.08 mm (0.0032 in) a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position strip of Plastigauge 1 onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge . Camshaft cap bolt 10 Nm (1.0 mkg, 7.2 ftlb) d. Remove the camshaft caps and then mea- sure the width of the Plastigauge 2. 5. Measure: camshaft journal diameter a Out of specification Replace the cam- shaft. Within specification Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 22.967 22.980 mm (0.9042 0.9047 in)
5-14 CAMSHAFTSENG NOTE: EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: timing chain 1 Damage / stiffness Replace the timing chain and camshaft sprockets as a set. 2. Check: camshaft sprocket More than 1 / 4 tooth wear a Replace the camshaft sprockets and the timing chain as a set. a1 / 4 tooth bCorrect 1Timing chain roller 2Camshaft sprocket 3. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2 timing chain guide (top side) 3 Damage / wear Replace the defective part(s). EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: timing chain tensioner Cracks / damage Replace. 2. Check: one-way cam operation Rough movement Replace the timing chain tensioner assembly. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
5-15 CAMSHAFTSENG NOTE: b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. 3. Check: cap bolt aluminum washer New gasket New Damage / wear Replace the defective part(s). EAS00215 INSTALLING THE CAMSHAFTS 1. Align: “T” mark a on the pickup rotor (with the crankcase mating surface b) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC, align the “T” mark a with the crankcase mating surface b. 2. Install: exhaust camshaft 1 intake camshaft 2 (with the camshaft sprocket temporarily tightened) Make sure the match mark a on the camshaft sprocket is aligned with the cylinder head edge b.
5-16 CAMSHAFTSENG NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) NOTE: CAUTION: NOTE: 3. Install: dowel pins exhaust camshaft caps intake camshaft caps Make sure each camshaft cap is installed in its original place. Make sure the arrow mark a on each cam- shaft cap points towards the right side of the engine. 4. Install: camshaft cap bolts Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. I1, I2: Intake side camshaft cap mark E1, E2: Exhaust side camshaft cap mark Lubricate the camshaft cap bolts with the engine oil. The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. 5. Install: timing chain guide (exhaust side) When installing the timing chain guide, be sure to keep the timing chain as tight as possible on the exhaust side.
5-17 CAMSHAFTSENG WARNING 20 Nm (2.0 mkg, 15 ftlb) CAUTION: 6. Install: timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful- ly clockwise with a thin screwdriver 1. b. With the timing chain tensioner rod turned all the way into the timing chain tensioner hous- ing (with the thin screwdriver still installed), install the gasket and the timing chain ten- sioner 2 onto the cylinder block. Always use a new gasket. c. Tighten the timing chain tensioner bolts 3 to the specified torque. Timing chain tensioner bolt 12 Nm (1.2 mkg, 8.7 ftlb) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Cap bolt 7 Nm (0.7 mkg, 5.1 ftlb) 7. Turn: crankshaft (several full turns clockwise) 8. Check: “T” mark a Make sure the “T” mark on the pickup rotor is aligned with the crankcase mating sure face b. camshaft sprocket match mark c Make sure the match marks on the camshaft sprockets are aligned with the crankcase mating surface d. Out of alignment Adjust. Refer to the installation steps above. 9. Tighten: camshaft sprocket bolts 1 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine.
5-18 CAMSHAFTSENG 10. Measure: valve clearance Out of specification Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” in chapter 3.
5-19 Order Job / Part Q’ty Remarks 1 2 3Removing the cylinder head Intake and exhaust camshaft Engine bracket Cylinder head Cylinder head gasket Dowel pin1 1 2Remove the parts in the order listed. Refer to “CAMSHAFTS”. Refer to “ENGINE”. For installation, reverse the removal procedure. 12 Nm (1.2 mkg, 8.7 ftlb) 19 Nm (1.9 mkg, 14 ftlb) 50 Nm (5.0 mkg, 36 ftlb) 1st 2nd CYLINDER HEADENG EAS00221 CYLINDER HEAD
5-20 CYLINDER HEADENG NOTE: NOTE: NOTE: EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: cylinder head bolts Loosen the bolts in the proper sequence as shown. Loosen each bolt 1 / 2 of a turn at a time. After all of the bolts are fully loosened, remove them. EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: combustion chamber carbon deposits (with a rounded scraper) Do not use a sharp instrument to avoid damag- ing or scratching: spark plug bore threads valve seats 2. Check: cylinder head Damage / scratches Replace. cylinder head water jacket Mineral deposits / rust Eliminate. 3. Measure: cylinder head warpage Out of specification Resurface the cylin- der head. Maximum cylinder head warpage 0.05 mm (0.002 in) a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. To ensure an even surface, rotate the cylinder head several times.