Yamaha Fz6n Manual
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5-61 OIL PAN AND OIL PUMPENG NOTE: 12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb) 43 Nm (4.3 mkg, 31 ftlb) WARNING NOTE: EAS00378 INSTALLING THE OIL STRAINER 1. Install: oil strainer 1 relief valve 2 Make sure to check the arrow mark a located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine. EAS00380 INSTALLING THE OIL PAN 1. Install: oil pipe oil delivery pipe 2. Install: dowel pins gasket New oil pan 1 oil level switch 2 engine oil drain bolt Always use new copper washers. Tighten the oil pan bolts in stages and in a crisscross pattern. Lubricate the oil level switch O-ring with en- gine oil.
5-62 Order Job / Part Q’ty Remarks 1 2 3 4 5Removing the crankcase Engine Cylinder head Starter clutch and generator Shift shaft Crankshaft position sensor and pickup rotor Clutch Water pump assembly Oil pan and oil pump Timing chain Oil pump drive chain Oil pump drive chain guide Lower crankcase Dowel pin1 1 1 1 3Remove the parts in the order listed. Refer to “ENGINE”. Refer to “CYLINDER HEAD”. Refer to “STARTER CLUTCH AND GENERATOR”. Refer to “SHIFT SHAFT”. Refer to “CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR”. Refer to “CLUTCH”. Refer to “WATER PUMP” in chapter 6. Refer to “OIL PAN AND OIL PUMP”. 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CRANKCASEENG CRANKCASE
5-63 Order Job / Part Q’ty Remarks 6 7 8Thrust plate Washer Plate1 1 1 For installation, reverse the removal procedure. 12 Nm (1.2 mkg, 8.7 ftlb) 12 Nm (1.2 mkg, 8.7 ftlb) CRANKCASEENG
5-64 CRANKCASEENG NOTE: CAUTION: NOTE: EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: crankcase bolts 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. Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration). The numbers embossed on the crankcase in- dicate the crankcase tightening sequence. M8 85 mm (3.3 in) bolts: 1 7, 10 M8 115 mm (4.5 in) bolts: 8, 9 M8 65 mm (2.6 in) bolts: 11, 12 M6 65 mm (2.6 in) bolts: 13, 14 M6 55 mm (2.2 in) bolts: 15, 22 26 M6 45 mm (1.8 in) bolts: 16, 19, 20 M6 65 mm (2.6 in) bolts: 17, 27 M6 75 mm (3.0 in) bolt: 18 M6 100 mm (3.9 in) bolts: 21 3. Remove: lower crankcase Tap on one side of the crankcase with a soft- face hammer. Tap only on reinforced por- tions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves sepa- rate evenly. 4. Remove: dowel pins 5. Remove: crankshaft journal lower bearing (from the lower crankcase) Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place.
5-65 CRANKCASEENG EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: crankcase Cracks / damage Replace. oil delivery passages Obstruction Blow out with compressed air. EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement Replace. 2. Check: oil seals Damage / wear Replace. CHECKING THE TIMING CHAIN 1 Check: timing chain 2 Damage / stiffness Replace the timing chain and crankshaft sprocket as a set. oil / water pump assembly drive chain 1 Damage / stiffness Replace the oil / water pump assembly drive chain and oil / water pump assembly drive sprocket as a set. ASSEMBLING THE CRANKCASE 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: sealant Yamaha bond No. 1215 90890-85505, ACC-1109-05-01
5-66 CRANKCASEENG NOTE: CAUTION: NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 3 mm of the crankshaft journal bearings. 3. Install: dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: lower crankcase 1 (onto the upper crankcase 2) Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 6. Install: crankcase bolts Lubricate the bolt threads with engine oil. Install a washer on bolts 1 10. Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase. M8 85 mm (3.3 in) bolts: 1 7, 10 M8 115 mm (4.5 in) bolts: 8, 9 M8 65 mm (2.6 in) bolts: 11, 12 M6 65 mm (2.6 in) bolts: 13, 14 M6 55 mm (2.2 in) bolts: 15, 22 26 M6 45 mm (1.8 in) bolts: 16, 19, 20 M6 65 mm (2.6 in) bolts: 17, 27 M6 75 mm (3.0 in) bolt: 18 M6 100 mm (3.9 in) bolt: 21 Crankcase bolt Bolt 1 10 1st: 12 Nm (1.2 mkg, 8.7 ftlb) 2nd: 25 Nm (2.5 mkg, 18 ftlb) *3rd: 27 Nm (2.7 mkg, 20 ftlb) Bolt 11, 12 24 Nm (2.4 mkg, 17 ftlb) Bolt 13, 14 14 Nm (1.4 mkg, 1.0 ftlb) Bolt 15 27 12 Nm (1.2 mkg, 8.7 ftlb) * Loosen the bolts following the tightening order and then tighten to specification torque.
5-67 Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10Removing the connecting rods and pistons Lower crankcase Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod Top ring 2nd ring Oil ring4 4 4 8 4 4 4 4 4 4Remove the parts in the order listed. Refer to “CRANKCASE”. For installation, reverse the removal procedure. 15 Nm (1.5 mkg, 11 ftlb) +120 15 Nm (1.5 mkg, 11 ftlb) +150 CONNECTING RODS AND PISTONSENG EAS00252 CONNECTING RODS AND PISTONS
5-68 CONNECTING RODS AND PISTONSENG NOTE: CAUTION: NOTE: NOTE: EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: connecting rod cap 1 big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remove: piston pin clips 1 piston pin 2 piston 3 Do not use a hammer to drive the piston pin out. For reference during installation, put identifica- tion marks on the piston crown. Before removing the piston pin, deburr the pis- ton pin clip groove and the piston pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set 4. Piston pin puller set 90890-01304, YU-01304 3. Remove: top ring 2nd ring oil ring When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
5-69 CONNECTING RODS AND PISTONSENG NOTE: NOTE: EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: crankshaft assembly crankshaft journal upper bearings (from the upper crankcase) Refer to “CRANKSHAFT”. Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00261 CHECKING THE CYLINDER AND PISTON 1. Check: piston wall cylinder wall Vertical scratches Replace the cylinder, and the piston and piston rings as a set. 2. Measure: piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cyl- inder. Then, find the average of the measure- ments.
5-70 CONNECTING RODS AND PISTONSENG NOTE:Cylinder bore “C” 65.50 65.51 mm (2.5787 2.5791 in) Wear limit65.56 mm (2.5811 in) Taper limit “T”0.05 mm (0.002 in) Out of round “R”0.05 mm (0.002 in) “C” = maximum of D1 D6 “T” = maximum of D1 or D2 – maximum of D 5 or D6 “R” = maximum of D1 D3 or D5 – minimum of D 2 D4 or D6 b. If out of specification, replace the cylinder, and the pistons and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer. a4 mm (0.16 in) from the bottom edge of the piston Piston size “P” 65.475 65.490 mm (2.5778 2.5783 in) d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.010 0.035 mm (0.0004 0.0014 in) : 0.055 mm (0.0022 in) f. If out of specification, replace the cylinder, and the piston and piston rings as a set. EAS00263 CHECKING THE PISTON RINGS 1. Measure: piston ring side clearance Out of specification Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.