Yamaha Fz6n Manual
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5-41 SHIFT SHAFTENG 22 Nm (2.2 mkg, 16 ftlb) NOTE: NOTE: EAS00328 CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 Bends / damage / wear Replace. shift shaft spring 2 Damage / wear Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: stopper lever 1 Bends / damage Replace. Roller turns roughly Replace the stopper lever. EAS00332 INSTALLING THE SHIFT SHAFT 1. Install: shift shaft spring stopper 1 washers shift shaft 2 Apply LOCTITE to the threads of the shift shaft spring stopper. Hook the ends 3 of the stopper lever spring onto the stopper lever 4 and the crankcase boss. Mesh the stopper lever with the shift drum seg- ment assembly. 2. Install: shift shaft cover Lubricate the oil seal lips with lithium-soap- based grease.
5-42 Order Job / Part Q’ty Remarks 1 2 3 4Removing the crankshaft position sensor and pickup rotor Seat Front cowling inner panel (left and right) Fuel tank Engine oil Generator cover Crankshaft position sensor lead coupler Pickup rotor cover Pickup rotor cover gasket Dowel pin1 1 1 2Remove the parts in the order listed. Refer to “SEAT” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “STARTER CLUTCH AND GENERATOR”. Disconnect. 10 Nm (1.0 mkg, 7.2 ftlb) 15 Nm (1.5 mkg, 11 ftlb) 35 Nm (3.5 mkg, 25 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
5-43 CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG Order Job / Part Q’ty Remarks 5 6 7Crankshaft position sensor Pickup rotor Plug screw1 1 1 For installation, reverse the removal procedure. 10 Nm (1.0 mkg, 7.2 ftlb) 15 Nm (1.5 mkg, 11 ftlb) 35 Nm (3.5 mkg, 25 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb)
5-44 CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG NOTE: NOTE: NOTE: REMOVING THE PICKUP ROTOR 1. Remove: pickup rotor cover 1 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. 2. Remove: pickup rotor bolt 1 washer 2 pickup rotor 3 While holding the generator rotor 4 with the ro- tor holding tool 5, loosen the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A INSTALLING THE PICKUP ROTOR 1. Install: pickup rotor 1 washer pickup rotor bolt When installing the pickup rotor, align the groove 2 in the crankshaft sprocket with the point a in the pickup rotor.
5-45 CRANKSHAFT POSITION SENSOR AND PICKUP ROTORENG 35 Nm (3.5 mkg, 25 ftlb) NOTE: NOTE: 2. Tighten: pickup rotor bolt 1 While holding the generator rotor 2 with the sheave holder 3, tighten the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A 3. Apply: sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-5-01 4. Install: pickup rotor cover gasket New When installing the pickup rotor cover, align the timing chain guide (intake side) pin 1 with the hole 2 in the pickup rotor cover. Tighten the pickup rotor cover bolts in stages and in a crisscross pattern.
5-46 Order Job / Part Q’ty Remarks 1 2 3 4 5 6Removing the clutch cover Engine oil Coolant Coolant hose Clutch cable Clutch cable holder Clutch cover Clutch cover gasket Dowel pin1 1 1 1 1 2Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Disconnect. Disconnect. For installation, reverse the removal procedure. 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CLUTCHENG : YAMAHA BOND No. 1215 EAS00273 CLUTCH CLUTCH COVER
5-47 CLUTCHENG Order Job / Part Q’ty Remarks Disassembling the clutch cover Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer2 1 1 1 1 1 2 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 7 8 9
5-48 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12Removing the clutch Compression spring Pressure plate Pull rod Bearing Friction plate (Brown) Clutch plate (t=2.0 mm, 0.08 in) Friction plate Clutch plate (t=2.3 mm, 0.09 in) Clutch boss nut Lock plate Clutch boss Thrust plate6 1 1 1 6 7 2 1 1 1 1 1Remove the parts in the order listed. For installation, reverse the removal procedure. 90 Nm (9.0 mkg, 65 ftlb) 8 Nm (0.8 mkg, 5.8 ftlb) CLUTCHENG EAS00274 CLUTCH
5-49 CLUTCHENG NOTE: NOTE: EAS00276 REMOVING THE CLUTCH 1. Remove: clutch cable holder 1 clutch cover 2 gasket 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. 2. Remove: compression spring bolts 1 compression springs pressure plate 2 pull rod 3 friction plates clutch plates 3. Straighten the lock washer tab. 4. Loosen: clutch boss nut 1 While holding the clutch boss 2 with the univer- sal clutch holder, loosen the clutch boss nut. Universal clutch holder 90890-04086, YM-91042 5. Remove: clutch boss nut 1 lock washer 2 clutch boss 3 thrust plate 4 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: friction plate Damage / wear Replace the friction plates as a set.
5-50 CLUTCHENG NOTE: 2. Measure: friction plate thickness Out of specification Replace the friction plates as a set. Measure the friction plate at four places. Friction plate thickness 2.9 3.1 mm (0.114 0.122 in) : 2.8 mm (0.110 in) EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: clutch plate Damage Replace the clutch plates as a set. 2. Measure: clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification Replace the clutch plates as a set. Clutch plate warpage limit 0.1 mm (0.0039 in) EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: clutch spring Damage Replace the clutch springs as a set.