Yamaha Fz6n Manual

							5-31
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
CAUTION:
NOTE: 
Make sure that each valve is installed in its
original place.

Install the valve springs with the larger pitch 
a
facing up.
bSmaller pitch
4. Install:

valve cotters 
1
Install the valve cotters by compressing the
valve springs with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor 
attachment
90890-04108, YM-01253
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
Hitting the valve tip with excessive force
could damage the valve.
6. Install:

valve pad 
1

valve lifter 2

Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.

The valve lifter must move smoothly when ro-
tated with a finger.

Each valve lifter and valve pad must be rein-
stalled in its original position. 
						

							5-32
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the stator coil assembly
Seat and fuel tank
Coolant
Coolant reservoir tank
Engine oil
Stator coil assembly coupler
Generator rotor cover
Generator rotor cover gasket
Dowel pin
Stator coil assembly lead holder1
1
1
2
1Remove the parts in the order listed.
Refer to “SEAT” and “FUEL TANK” in 
chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
32 Nm (3.2 m
kg, 23 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
75 Nm (7.5 m
kg, 54 ft
lb)
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
STARTER CLUTCH AND GENERATORENG
EAS00341
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY 
						

							5-33
STARTER CLUTCH AND GENERATORENG
Order Job / Part Q’ty Remarks
6
7
8
9
10
11
12
13Stator coil assembly
Generator rotor bolt
Washer
Generator rotor
Starter clutch assembly
Idler gear shaft
Idler gear
Starter clutch drive gear1
1
1
1
1
1
1
1
For installation, reverse the removal 
procedure.
Refer to “REMOVING / INSTALLING
THE GENERATOR”.
32 Nm (3.2 m
kg, 23 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
75 Nm (7.5 m
kg, 54 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb) 
						

							5-34
STARTER CLUTCH AND GENERATORENG
NOTE:
NOTE:
EAS00347
REMOVING THE GENERATOR
1. Remove:

seat
Refer to “SEAT” in chapter 3.

front cowling inner panel (left and right)
Refer to “COWLINGS” in chapter 3.

fuel tank
Refer to “FUEL TANK” in chapter 3.
2. Drain:

coolant
Refer to “CHANGING THE COOLANT” in
chapter 3.

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
3. Remove:

generator rotor cover
Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
4. Remove:

generator rotor bolt 
1

washer

While holding the generator rotor 
2 with the
sheave holder 
3, loosen the generator rotor
bolt.

Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A 
						

							5-35
STARTER CLUTCH AND GENERATORENG
CAUTION:
NOTE:
NOTE:
5. Remove:

generator rotor 
1
(with the flywheel puller 2 and flywheel pull-
er attachment)

woodruff key
To protect the end of the crankshaft, place
an appropriate sized socket between the fly-
wheel puller set’s center bolt and the crank-
shaft.
Make sure the flywheel puller is centered over
the generator rotor.
Flywheel puller
90890-01362, YU-33270
Flywheel puller attachment
90890-04089, YM-33282
REMOVING THE STARTER CLUTCH
1. Remove:

starter clutch bolt 
1

While holding the generator rotor with the
sheave holder, remove the starter clutch bolt.

Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A 
						

							5-36
STARTER CLUTCH AND GENERATORENG
32 Nm (3.2 m
kg, 23 ft
lb)
LOCTITE
NOTE:
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:

starter clutch rollers 
1
Damage / wear 
 Replace.
2. Check:

starter clutch idle gear 
1

starter clutch drive gear 2
Burrs / chips / roughness / wear 
 Replace
the defective part(s).
3. Check:

starter clutch gear’s contacting surfaces 
a
Damage / pitting / wear 
 Replace the starter
clutch gear.
4. Check:

starter clutch operation
a. Install the starter clutch drive gear 
1 onto
the starter clutch 
2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
clockwise 
A, the starter clutch and the start-
er clutch drive gear should engage, other-
wise the starter clutch is faulty and must be
replaced.
c. When turning the starter clutch drive gear
counterclockwise 
B, it should turn freely,
otherwise the starter clutch is faulty and must
be replaced.
EAS00355
INSTALLING THE STARTER CLUTCH
1. Install:

starter clutch

While holding the generator rotor 
1 with the
sheave holder 
2, tighten the starter clutch
bolt. 
						

							5-37
STARTER CLUTCH AND GENERATORENG
NOTE:
75 Nm (7.5 m
kg, 54 ft
lb)
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)

Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
EAS00354
INSTALLING THE GENERATOR
1. Install:

generator rotor

washer 
New

generator rotor bolt

Clean the tapered portion of the crankshaft
and the generator rotor hub.

Replace the washer with a new one.
2. Tighten:

generator rotor bolt 
1

While holding the generator rotor 2 with the
sheave holder 
3, tighten the generator rotor
bolt.

Do not allow the sheave holder to touch the
projection on the generator rotor.
Sheave holder
90890-01701, YS-01880-A
3. Apply:

sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No.1215
90890-85505, ACC-11001-05-01
4. Install:

stator coil
5. Install:

generator rotor cover 
						

							5-38
STARTER CLUTCH AND GENERATORENG
NOTE:
Tighten the generator rotor cover bolts in stages
and in a crisscross pattern.
6. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.

coolant
Refer to “CHANGING THE COOLANT” in
chapter 3.
7. Install:

fuel tank
Refer to “FUEL TANK” in chapter 3.

front cowling inner panel (left and right)
Refer to “COWLINGS” in chapter 3.

seat
Refer to “SEAT” in chapter 3. 
						

							5-39
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the shift shaft and stopper
lever
Coolant
Coolant reservoir tank
Drive sprocket cover
Shift shaft cover
Shift shaft cover gasket
Dowel pin
Oil seal
Shift shaft
Shift shaft spring
Collar
Stopper lever spring
Circlip
Washer1
1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “ENGINE”.
Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
22 Nm (2.2 m
kg, 16 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
SHIFT SHAFTENG
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER 
						

							5-40
SHIFT SHAFTENG
Order Job / Part Q’ty Remarks
11
12
13
14Stopper lever
Collar
Washer
Shift shaft spring stopper1
1
1
1
For installation, reverse the removal 
procedure.
22 Nm (2.2 m
kg, 16 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)