Yamaha FZS6W 07 User Manual
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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