Yamaha Fz6n Manual

							5-51
CLUTCHENG
NOTE:
NOTE: 2. Measure:

clutch spring free length 
a
Out of specification 
 Replace the clutch
springs as a set.
Clutch spring free length
55 mm (2.17 in)
: 52.3 mm (2.06 in)
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:

clutch housing dogs 
Damage / pitting / wear 
 Deburr the clutch
housing dogs or replace the clutch housing.
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check:

bearing 
Damage / wear 
 Replace the bearing and
clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:

clutch boss splines
Damage / pitting / wear 
 Replace the clutch
boss.
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate 
1
Cracks / damage 
 Replace.

bearing 
2
Damage / wear 
 Replace. 
						

							5-52
CLUTCHENG
90 Nm (9.0 m
kg, 65 ft
lb)
NOTE:
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth 
a

pull rod teeth b
Damage / wear 
 Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing 
Damage / wear 
 Replace.
EAS00299
INSTALLING THE CLUTCH
1. Install:

thrust plate 
1

clutch boss 2

lock washer 3 New

clutch boss nut 
4
While holding the clutch boss 2 with the clutch
holding tool 
5, tighten the clutch boss nut.
Universal clutch holder
90890-04089, YM-91042
2. Bend the lock washer tab along a flat side of
the nut.
3. Lubricate:

friction plates

clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil 
						

							5-53
CLUTCHENG
NOTE:
NOTE:
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE: 4. Install:

friction plates

clutch plates
First, install a clutch plate and then alternate be-
tween a friction plate and a friction plate.
a. Install the clutch plate and friction plate as
shown in the illustration.
Clutch plate 
1: t=2.3 mm (0.09 in)
Clutch plate 
2: t=2.0 mm (0.08 in)
Friction plate 
3
Friction plate 4: Color / Brown
5. Install:

pressure plate 
1
Align the punch mark b in the pressure plate
with the punch mark 
a in the clutch boss.
6. Install:

bearing 
1

pull rod 2

pressure plate 3

clutch springs

clutch pressure plate screw
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
7. Install:

pull lever 
						

							5-54
CLUTCHENG
NOTE:
8. Install:

clutch cover

gasket 
New

clutch cable holder

Install the pull rod so that the teeth a face to-
wards the rear of the motorcycle. Then, install
the clutch cover.

Apply oil onto the bearing.

Apply molybdenum disulfide grease onto the
pull rod.

When installing the clutch cover, push the pull
lever and check that the punch mark 
a on the
pull lever aligns with the mark 
b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.

Tighten the clutch cover bolts in stages and in
a crisscross pattern.
9. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3. 
						

							5-55
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the oil pan and oil pump
Engine oil
Coolant
Exhaust pipe assembly
Water pump
Oil level switch coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Oil strainer
Oil strainer gasket1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “ENGINE”.
Refer to “WATER PUMP” in chapter 6.
Disconnect.
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)43 Nm (4.3 m
kg, 31 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
OIL PAN AND OIL PUMPENG
EAS00356
OIL PAN AND OIL PUMP 
						

							5-56
Order Job / Part Q’ty Remarks
9
10
11
12
13Oil pipe
Oil delivery pipe
Oil pump assembly
Dowel pin
Relief valve assembly1
1
1
2
1
For installation, reverse the removal 
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)43 Nm (4.3 m
kg, 31 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
OIL PAN AND OIL PUMPENG 
						

							5-57
OIL PAN AND OIL PUMPENG
Order Job / Part Q’ty Remarks
Disassembling the oil pump 
assembly
Oil pump cover
Pin
Oil pump inner rotor
Oil pump outer rotor
Pin
Washer
Oil pump rotor housing
Oil pump driver sprocket1
2
1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
4
5
6
7
8
12 Nm (1.2 m
kg, 8.7 ft
lb) 
						

							5-58
OIL PAN AND OIL PUMPENG
NOTE:
EAS00362
REMOVING THE OIL PAN
1. Remove:

oil level switch 
1

oil pan 2

oil pan gasket

dowel pins
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.
EAS00364
CHECKING THE OIL PUMP
1. Check:

oil pump driven gear 
1

oil pump rotor housing 2

oil pump cover 
Cracks / damage / wear 
 Replace the de-
fective part(s).
2. Measure:

inner-rotor-to-outer-rotor-tip clearance 
a

outer-rotor-to-oil-pump-housing clearance
b
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip 
clearance
0.03 
 0.09 mm 
(0.0012 
 0.0035 in)
: 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing 
clearance
0.03 
 0.08 mm 
(0.0012 
 0.0032 in)
: 0.15 mm (0.0059 in) 
						

							5-59
OIL PAN AND OIL PUMPENG
3. Check:

oil pump operation
Rough movement 
 Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:

relief valve body 
1

relief valve 2

spring 3

O-ring 4
Damage / wear 
 Replace the defective
part(s).
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:

oil delivery pipe 
1

oil pipe 2
Damage 
 Replace.
Obstruction 
 Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:

oil strainer 
1
Damage 
 Replace.
Contaminants 
 Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:

oil nozzle 
1
Damage / wear 
 Replace the oil nozzle.

O-ring 
2
Damage / wear 
 Replace.

oil nozzle passage
Obstruction 
 Blow out with compressed air. 
						

							5-60
OIL PAN AND OIL PUMPENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
CAUTION:
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:

inner rotor

outer rotor

oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Install:

oil pump housing 
1

oil pump shaft 2

washer 3

pin 4

inner rotor 5

outer rotor 6

dowel pins 7

oil pump cover 8
When installing the inner rotor, align the pin 4 in
the oil pump shaft with the groove in the inner ro-
tor 
5.
3. Check:

oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP
1. Install:

oil pump drive chain

gear cover

oil pump
After tightening the bolts, make sure the oil
pump turns smoothly.