Home > Yamaha > Motorcycle > Yamaha FZS6W 07 User Manual

Yamaha FZS6W 07 User Manual

    Download as PDF Print this page Share this page

    Have a look at the manual Yamaha FZS6W 07 User Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.

    Page
    of 394
    							
    VALVES AND VALVE SPRINGS
    5-22
    EAS24290
    CHECKING THE VALVES AND VALVE 
    GUIDES
    The following procedure applies to all of the 
    valves and valve guides.
    1. Measure: Valve-stem-to-valve-guide clearanceOut of specification  → Replace the valve 
    guide.
    2. Replace:  Valve guideNOTE:
    To ease valve guide removal and installation, 
    and to maintain the correct fit, heat the cylinder 
    head to 100 °C (212 °F) in an oven.
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Remove the valve guide with the valve 
    guide remover “1”.
    b. Install the new valve guide with the valve  guide installer “2” and valve guide remover 
    “1”.
    c. After installing the valve guide, bore the  valve guide with the valve guide reamer “3” 
    to obtain the proper valve-stem-to-valve-
    guide clearance.
    NOTE:
    After replacing the valve guide, reface the 
    valve seat.
     Valve-stem-to-valve-guide clearance =
    Valve guide inside diameter “a” -
    Valve stem diameter “b”
    Valve-stem-to-valve-guide clear-
    anceValve-stem-to-valve-guide clear-
    ance (intake) 0.010–0.037 mm (0.0004–
    0.0015 in)
    Limit 0.080 mm (0.0032 in)
    Valve-stem-to-valve-guide clear-
    ance (exhaust) 0.025–0.052 mm (0.0010–
    0.0020 in)
    Limit 0.100 mm (0.0039 in) 
    						
    							
    VALVES AND VALVE SPRINGS
    5-23
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    3. Eliminate: Carbon deposits
    (from the valve face and valve seat)
    4. Check: Valve face
    Pitting/wear  → Grind the valve face.
     Valve stem end Mushroom shape or diameter larger than 
    the body of the valve stem  → Replace the 
    valve.
    5. Measure:
     Valve margin thickness “a”Out of specification  → Replace the valve.
    6. Measure:  Valve stem runout Out of specification 
    → Replace the valve.
    NOTE:
     When installing a new valve, always replace 
    the valve guide.
     If the valve is removed or replaced, always 
    replace the oil seal.
    EAS24300
    CHECKING THE VALVE SEATS
    The following procedure applies to all of the 
    valves and valve seats.
    1. Eliminate:
     Carbon deposits(from the valve face and valve seat)
    2. Check:
    Valve seatPitting/wear  → Replace the cylinder head.
    3. Measure:
     Valve seat width “a”Out of specification  → Replace the cylinder 
    head.
    Valve guide remover (ø4) 90890-04111
    Valve guide remover (4.0 mm) YM-04111
    Valve guide installer (ø4) 90890-04112
    Valve guide installer (4.0 mm) YM-04112
    Valve guide reamer (ø4) 90890-04113
    Valve guide reamer (4.0 mm)
    YM-04113
    Valve margin thicknessValve margin thickness D
    (intake)
    0.60–0.80 mm (0.0236–0.0315
    in)
    Limit 0.5 mm (0.02 in)
    Valve margin thickness D
    (exhaust)
    0.60–0.80 mm (0.0236–0.0315
    in)
    Limit 0.5 mm (0.02 in)
    Valve stem runoutValve stem runout
    0.040 mm (0.0016 in)
    Valve seat widthValve seat width C (intake)
    0.90–1.10 mm (0.0354–0.0433
    in)
    Limit
    1.6 mm (0.06 in)
    Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433
    in)
    Limit 1.6 mm (0.06 in) 
    						
    							
    VALVES AND VALVE SPRINGS
    5-24
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face.
    b. Install the valve into the cylinder head.
    c. Press the valve through the valve guide  and onto the valve seat to make a clear 
    impression.
    d. Measure the valve seat width.
    NOTE:
    Where the valve seat and valve face contacted 
    one another, the blueing will have been 
    removed.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    4. Lap:
    Valve face
     Valve seat
    NOTE:
    After replacing the cylinder head or replacing 
    the valve and valve guide, the valve seat and 
    valve face should be lapped.
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Apply a coarse lapping compound “a” to  the valve face.
    CAUTION:
    ECA13790
    Do not let the lapping compound enter the 
    gap between the valve stem and the valve 
    guide. b. Apply molybdenum disulfide oil onto the 
    valve stem.
    c. Install the valve into the cylinder head.
    d. Turn the valve until the valve face and valve  seat are evenly polished, then clean off all 
    of the lapping compound.
    NOTE:
    For the best lapping results, lightly tap the 
    valve seat while rotating the valve back and 
    forth between your hands.
    e. Apply a fine lapping compound to the valve 
    face and repeat the above steps.
    f. After every lapping procedure, be sure to  clean off all of the lapping compound from 
    the valve face and valve seat.
    g. Apply Mechanic’s blueing dye (Dykem) “b”  onto the valve face. 
    						
    							
    VALVES AND VALVE SPRINGS
    5-25
    h. Install the valve into the cylinder head.
    i. Press the valve through the valve guide and onto the valve seat to make a clear 
    impression.
    j. Measure the valve seat width “c” again. If  the valve seat width is out of specification, 
    reface and lap the valve seat.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    EAS24310
    CHECKING THE VALVE SPRINGS
    The following procedure applies to all of the 
    valve springs.
    1. Measure:
     Valve spring free length “a”Out of specification  → Replace the valve 
    spring. 2. Measure:
     Compressed valve spring force “a”Out of specification  → Replace the valve 
    spring.
    Inner spring
    Free length (intake) 37.04 mm (1.46 in)
    Limit 35.20 mm (1.39 in)
    Free length (exhaust)
    41.79 mm (1.65 in)
    Limit 39.70 mm (1.56 in)
    Outer spring
    Free length (intake) 38.40 mm (1.51 in)
    Limit 36.50 mm (1.44 in)
    b. Installed length
    Inner spring
    Installed compression spring
    force (intake)69–79 N (15.51–17.76 lbf)
    (7.04–8.06 kgf)
    Installed compression spring
    force (exhaust)
    160–184 N (35.97–41.36 lbf)
    (16.32–18.76 kgf)
    Outer spring
    Installed compression spring
    force (intake) 114–132 N (25.63–29.67 lbf)
    (11.62–13.46 kgf)
    Inner spring
    Installed length (intake)
    30.02 mm (1.18 in)
    Installed length (exhaust)
    36.12 mm (1.42 in)
    Outer spring
    Installed length (intake) 32.52 mm (1.28 in) 
    						
    							
    VALVES AND VALVE SPRINGS
    5-26
    3. Measure: Valve spring tilt “a”Out of specification  → Replace the valve 
    spring.
    EAS24320
    CHECKING THE VALVE LIFTERS
    The following procedure applies to all of the 
    valve lifters.
    1. Check:  Valve lifterDamage/scratches  → Replace the valve 
    lifters and cylinder head.
    EAS24340
    INSTALLING THE VALVES
    The following procedure applies to all of the 
    valves and related components.
    1. Deburr:
     Valve stem end(with an oil stone)
    2. Lubricate: Valve stem “1”
     Valve stem seal “2”(with the recommended lubricant)
    3. Install: Valve “1”
     Lower spring seat “2”
     Valve stem seal “3”
     Valve spring inner (intake only) “4”
     Valve spring outer “5”
     Upper spring seat “6”(into the cylinder head)
    NOTE:
     Make sure each valve is installed in its origi-nal place.
     Install the valve springs with the larger pitch 
    “a” facing up.
    Spring tilt limit Spring tilt (intake) 2.5  °/1.6 mm (0.06 in)
    Spring tilt (exhaust) 2.5  °/1.8 mm (0.07 in)
    Spring tilt (intake)
    2.5  °/1.7 mm (0.07 in)
    Recommended lubricant
    Molybdenum disulfide oil 
    						
    							
    VALVES AND VALVE SPRINGS
    5-27
    4. Install: Valve cotters “1”
    NOTE:
    Install the valve cotters by compressing the 
    valve spring with the valve spring compressor 
    “2” and the valve spring compressor attach-
    ment “3”.
    5. To secure the valve cotters onto the valve  stem, lightly tap the valve tip with a soft-
    face hammer.
    CAUTION:
    ECA13800
    Hitting the valve tip with excessive force 
    could damage the valve.
    6. Lubricate: Valve pad “1”
     Valve lifter “2”
    (with the recommended lubricant)
    NOTE:
     Lubricate the valve lifter and valve pad with molybdenum disulfide oil.
     The valve lifter must move smoothly when  rotated with a finger.
     Each valve lifter and valve pad must be rein-
    stalled in its original position.
    b. Smaller pitch
    Valve spring compressor
    90890-04019
    YM-04019
    Valve spring compressor 
    attachment 90890-04108
    Valve spring compressor 
    adapter 22 mm
    YM-04108 
    						
    							
    GENERATOR AND STARTER CLUTCH
    5-28
    EAS4S81014
    GENERATOR AND STARTER CLUTCH
    Removing the generator and starter clutch
    Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
    Fuel tank Refer to FUEL TANK on page 7-1.
    Coolant Drain
    Refer to CHANGING THE COOLANT on 
    page 3-18.
    Coolant reservoir tank Refer to RADIATOR on page 6-1.
    Engine oil Drain
    Refer to CHANGING THE ENGINE OIL on 
    page 3-12.
    1 Startor coil assembly lead coupler 1 Disconnect.
    2 Generator rotor cover 1
    3 Generator rotor cover gasket 1
    4Dowel pin 2
    5 Startor coil assembly lead holder 2
    6 Startor coil assembly 1
    7 Generator rotor bolt 1
    8 Washer 1
    9 Generator rotor 1
    10 Starter clutch assembly 1 
    						
    							
    GENERATOR AND STARTER CLUTCH
    5-29
    11 Idler gear shaft 1
    12 Idler gear 1
    13 Starter clutch drive gear 1For installation, reverse the removal proce-
    dure.
    Removing the generator and starter clutch
    Order Job/Parts to remove Q’ty Remarks 
    						
    							
    GENERATOR AND STARTER CLUTCH
    5-30
    EAS24490
    REMOVING THE GENERATOR
    1. Remove:SeatRefer to GENERAL CHASSIS on page 4-
    1.
     Fuel tank Refer to FUEL TANK on page 7-1.
    2. Drain:
     CoolantRefer to CHANGING THE COOLANT on 
    page 3-18.
     Engine oil Refer to CHANGING THE ENGINE OIL 
    on page 3-12.
    3. Remove:  Generator rotor cover
    NOTE:
    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.
    4. Remove: Generator rotor bolt “1”
     Washer
    NOTE:
     While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor 
    bolt.
     Do not allow the sheave holder to touch the 
    projection on the generator rotor.
    5. Remove:  Generator rotor “1”(with the flywheel puller “2” and flywheel 
    puller attachment)
     Woodruff key
    CAUTION:
    ECA13880
    To protect the end of the crankshaft, place 
    an appropriate sized socket between the 
    flywheel puller set’s center bolt and the 
    crankshaft.
    NOTE:
    Make sure the flywheel puller is centered over 
    the generator rotor.
    EAS24560
    REMOVING THE STARTER CLUTCH
    1. Remove:  Starter clutch bolt “1”
    NOTE:
     While holding the generator rotor with the sheave holder, remove the starter clutch bolt.
     Do not allow the sheave holder to touch the 
    projection on the generator rotor.
    Sheave holder 90890-01701
    Primary clutch holder YS-01880-A
    Flywheel puller90890-01362
    Heavy duty puller YU-33270-B
    Flywheel puller attachment
    90890-04089
    Crankshaft protector YM-33282
    Sheave holder90890-01701
    Primary clutch holder YS-01880-A 
    						
    							
    GENERATOR AND STARTER CLUTCH
    5-31
    EAS24570
    CHECKING THE STARTER CLUTCH
    1. Check: Starter clutch rollers “1”Damage/wear  → Replace.
    2. Check:  Starter clutch idle gear “1”
     Starter clutch drive gear “2”Burrs/chips/roughness/wear  → Replace 
    the defective part(s).
    3. Check:
     Starter clutch gear’s contacting surfaces “a”
    Damage/pitting/wear  → Replace the starter 
    clutch gear.
    4. Check:  Starter clutch operation
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Install the starter clutch drive gear “1” onto  the starter clutch “2” and hold the starter 
    clutch.
    b. When turning the starter clutch drive gear  clockwise “A”, the starter clutch and the 
    starter clutch drive gear should engage,  otherwise the starter clutch is faulty and 
    must be replaced.
    c. When turning the starter clutch drive gear 
    counterclockwise “B”, it should turn freely, 
    otherwise the starter clutch is faulty and 
    must be replaced.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    EAS24600
    INSTALLING THE STARTER CLUTCH
    1. Install: Starter clutch
    NOTE:
     While holding the generator rotor “1” with the sheave holder “2”, tighten the starter clutch 
    bolt.
     Do not allow the sheave holder to touch the 
    projection on the generator rotor.
    Starter clutch bolt 32 Nm (3.2 m·kg, 23 ft·lb)
    LOCTITE
    ®
    Sheave holder
    90890-01701
    Primary clutch holder YS-01880-A 
    						
    All Yamaha manuals Comments (0)

    Related Manuals for Yamaha FZS6W 07 User Manual