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Yamaha Fz6n Manual

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    Page
    of 432
    							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. 
    						
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