Yamaha Fz6n Manual
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5-71 CONNECTING RODS AND PISTONSENG NOTE: NOTE: Piston ring side clearance Top ring 0.030 0.065 mm (0.0012 0.0026 in) : 0.115 mm (0.0045 in) 2nd ring 0.030 0.065 mm (0.0012 0.0026 in) : 0.125 mm (0.0049 in) 2. Install: piston ring (into the cylinder) Level the piston ring into the cylinder with the piston crown. a5 mm (0.20 in) 3. Measure: piston ring end gap Out of specification Replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap Top ring 0.25 0.35 mm (0.0098 0.0138 in) : 0.60 mm (0.0236 in) 2nd ring 0.7 0.8 mm (0.0276 0.0315 in) : 1.15 mm (0.0453 in) Oil ring 0.10 0.35 mm (0.0039 0.0138 in) CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins. 1. Check: piston pin Blue discoloration / grooves Replace the piston pin and then check the lubrication sys- tem.
5-72 CONNECTING RODS AND PISTONSENG 2. Measure: piston pin outside diameter a Out of specification Replace the piston pin. Piston pin outside diameter 15.991 16.000 mm (0.6296 0.6299 in) : 15.971 mm (0.6288 in) 3. Measure: piston pin bore inside diameter b Out of specification Replace the piston. Piston pin bore inside diameter 16.002 16.013 mm (0.6300 0.6304 in) : 16.043 mm (0.6316 in) 4. Calculate: piston-pin-to-piston clearance Out of specification Replace the piston pin and piston as a set. Piston-pin-to-piston clearance = Piston pin bore size – Piston pin outside diameter Piston-pin-to-piston clearance 0.002 0.022 mm (0.0001 0.0009 in) : 0.072 mm (0.0028 in) CHECKING THE BIG END BEARINGS 1. Measure: crankshaft-pin-to-big-end-bearing clear- ance Out of specification Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.028 0.052 mm (0.0011 0.0020 in) The following procedure applies to all of the connecting rods.
5-73 CAUTION: CONNECTING RODS AND PISTONSENG NOTE: NOTE: Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions. a. Clean the big end bearings, crankshaft pins, and the inside of the connecting rod halves. b. Install the big end upper bearing into the con- necting rod and the big end lower bearing into the connecting rod cap. Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. c. Put a piece of Plastigauge 1 on the crank- shaft pin. d. Assemble the connecting rod halves. Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Lubricate the bolt threads and nut seats with molybdenum disulfide grease. Make sure that the “Y” mark c on the connect- ing rod faces towards the left side of the crank- shaft. Make sure that the characters d on both the connecting rod and connecting rod cap are aligned.
5-74 CONNECTING RODS AND PISTONSENG CAUTION: WARNING CAUTION: NOTE: e. Tighten the connecting rod nuts (except for CAL) or bolts (for CAL). Connecting rod nut (except for CAL) 15 Nm (1.5 mkg, 11 ftlb) + 150 Connecting rod bolt (for CAL) 15 Nm (1.5 mkg, 11 ftlb) + 120 f. Replace the connecting rod bolts with new ones. Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. g. Clean the connecting rod bolts and nuts. (ex- cept for CAL) Clean the connecting rod bolts. (for CAL) h. Tighten the connecting rod nuts. (except for CAL) Tighten the connecting rod bolt. (for CAL) i. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3. (except for CAL) Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod 3.(for CAL) j. Tighten the nut (except for CAL) or bolt (for CAL) further to reach the specified angle (150 except for CAL, 120 for CAL). When the nut (except for CAL) or bolt (for CAL) is tightened more than the specified angle, do not loosen the nut (except for CAL) or bolt (for CAL) and then retighten it. Replace the bolt with a new one and perform the procedure again. Do not use a torque wrench to tighten the nut (except for CAL) or bolt (for CAL) to the specified angle. Tighten the nut (except for CAL) or bolt (for CAL) until it is at the specified angles. When using a hexagonal nut, note that the angle from one corner to another is 60 (except for CAL).
5-75 CONNECTING RODS AND PISTONSENG NOTE: k. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”. l. Measure the compressed Plastigauge width on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings. 2. Select: big end bearings (P1 P4) The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. “P1” “P4” refer to the bearings shown in the crankshaft illustration. For example, if the connecting rod “P 1” and the crankshaft web “P 1” numbers are “5” and “2” re- spectively, then the bearing size for “P1” is: “P 1” (connecting rod) – “P1” (crankshaft) = 5 – 2 = 3 (brown) BIG END BEARING COLOR CODE 1Blue 2Black 3Brown 4Green
5-76 CONNECTING RODS AND PISTONSENG NOTE: NOTE: INSTALLING THE CONNECTING ROD AND PISTON (except for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lower oil ring rail 5 Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. 2. Install: piston 1 (onto the respective connecting rod 2) piston pin 3 piston pin clip New 4 Apply engine oil onto the piston pin. Make sure that the “Y” mark a on the connect- ing rod faces left when the arrow mark b on the piston is pointing up. Refer to the illustra- tion. Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3. Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Engine oil
5-77 CONNECTING RODS AND PISTONSENG NOTE: 15 Nm (1.5 mkg, 11 ftlb) + 150 CAUTION: 4. Offset: piston ring end gaps aTop ring bLower oil ring rail cUpper oil ring rail d2nd ring eOil ring expander 5. Lubricate: crankshaft pins big end bearings connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: big end bearings connecting rod assembly (into the cylinder and onto the crankshaft pin) connecting rod cap (onto the connecting rod) Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. Be sure to reinstall each big end bearing in its original place. While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand. Make sure that the “Y” marks a on the con- necting rods face towards the left side of the crankshaft. Make sure that the characters b on both the connecting rod and connecting rod cap are aligned. 7. Align: bolt heads (with the connecting rod caps) 8. Tighten: connecting rod nuts a. Replace the connecting rod bolts and nuts with new ones. Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts.
5-78 CONNECTING RODS AND PISTONSENG WARNING CAUTION: NOTE: b. Clean the connecting rod bolts and nuts. c. Tighten the connecting rod nuts. d. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3. e. Tighten the nut further to reach the specified angle (150). When the nut is tightened more than the spe- cified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again. Do not use a torque wrench to tighten the nut to the specified angle. Tighten the nut until it is at the specified angles. When using a hexagonal nut, note that the angle from one corner to another is 60.
5-79 CONNECTING RODS AND PISTONSENG NOTE: NOTE: INSTALLING THE CONNECTING ROD AND PISTON (for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lower oil ring rail 5 Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up. 2. Install: piston 1 (onto the respective connecting rod 2) piston pin 3 piston pin clip New 4 Apply engine oil onto the piston pin. Make sure that the “Y” mark a on the connect- ing rod faces left when the arrow mark b on the piston is pointing up. Refer to the illustra- tion. Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3. Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Engine oil
5-80 CONNECTING RODS AND PISTONSENG NOTE: 4. Offset: piston ring end gaps aTop ring bLower oil ring rail cUpper oil ring rail d2nd ring eOil ring expander 5. Lubricate: crankshaft pins big end bearings connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: big end bearings connecting rod cap (onto the connecting rod) Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. Make sure that the characters a on both the connecting rod and connecting rod cap are aligned.