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ENGINE REMOVAL I ENG 1 ' \ . 1ENGINE OVERHAUL

ENGINE REMOVALNOTE: __It is not necessaryto remove the engine in orderto remove the following components:.Cylinder head.Cylinder Piston Clutch.Water pump A.C. magneto

SIDE COWLINGS AND TOP COVER1. Remove: Side cowl ings (left and right) Upper cowling.Seats (front and rear).Top coverRefer to the "COWLING AND COVERSREMOVAL AND INSTALLATION" sec-tion in the CHAPTER 3.

FUEL TANK1. Remove: Fuel tank Air filter caseRefer to the "CARBUR ETOR - RE-MOVAL" section in the CHAPTER 6.

ENGINE OIL1. Drain: Engine oilRefer to the "ENGINE OIL REPLACE-MENT" section in the CHAPTER 3.

COOLANT1. Drain:.Coolant

Refer to the "COOLANT REPLACE-MENT"section in the CHAPTER 3.

AIR FI LTER CASE AND CARBURETOR1. Remove: CarburetorRefer to the "CARBURETOR - RE-MOVAL" section in the CHAPTER 6.

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ENGINE REMOVAL ENG 1 ' - 1RADIATOR1. Disconnect: Radiator hose (radiator - inlet) C D Radiator hose (radiator - outlet) C V

2. Disconnect: Fan motor coupler

3. Remove: Radiator assembly

. . . . . .b : .c~lJT,otf :- - - - - - - - - - - - - - - - - - - - -Cover the cylinder head cover and the fenderwith rugs to prevent a scratching.

4. Disconnect: Pipes (left and right) C D

5. Remove: Pipes (radiator - autlet) C D

MUFFLER ASSEMBLY1. Remove: Valve cover C D (FZR600WC only)

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" \

~~ . . . .;--. .

ENGINE REM OVAL I ENG 1 " - 12. Fully loosen the locknuts C D and turn inthe adjusters completely (FZR600WConly).

3. Disconnect: EXUP cables (FZR600WC only)

4. Remove: Nuts (exhaust pipe) C D Bolt (muffler bracket) Muffler assembly

CLUTCH CABLE AND DRIVE CHAIN1. Remove: Bolt (shift arm) c DPullout the shift arm.

Crankcase cover (left) Collar (shift shaft)

2. Disconnect: Clutch cable C D

3. Straighten: Lock washer tab C D

4. Remove: Nut (drive sprocket) Lock washer Drive sprocket

NOTE: _Loosen the nut (drive sprocket) wh iIeappling therear brake.

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ENGINE REMOVAL ENGLEADS1. Straighten:.Clamp Q)

2. Disconnect: Battery leads Q)

NOTE: ___Disconnect the negative lead Q) first, and tdisconnect the positive lead.

3. Disconnect: Lead (starter motor) C D

4. Remove: Cover

5. Disconnect: Coupler (oil level neutral switch) Coupler (A.C. generator) Coup ler (sidestand switch)

6. Disconnect:.Spark plug leads C D

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I . '. < ~ 'I f '

ENGINE REMOVAL ENG 1 ' - 1ENGINE REMOVAL1. Remove: Cover C D Starter lever

2. Place a suitable stand under the engine.3. Remove: Down tube frames (left and right) C D

4, Remove: Bolt (engine-mounting lower) C D Bolt (enqine-rnountinq upper) @Collars

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ENGINE REMOVAL [ENG 1 " - 15. Remove: Engine assemblyFrom right side.

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ENGINE DISASSEMBLY ENG 1 ' - 1ENGINE DISASSEMBLYCYLINDER HEAD COVER, CAMSHAFT ANDCYLINDER HEADNOTE: ___With the engine mounted, the cylinder headcover, camshaft and cylinder head can be maintained by removing the following parts.-Side cowlings (left and right)-Seats (front)-Top cover- Radiator- Air fIter case- Carburetor Muffler assembly- Down tube frame (right)

1. Remove:- Cylinder head cover C D-Gasket (cylinder head cover)- Spark plugs

2. Remove: Generator cover C D- Dowel pins

3. Align:- "T" mark C D Crankcasematching line

NOTE: _Turn the crankshaft counterclockwise and alignthe "T" mark C D on the rotor with the crank-case matching line C V when # 1 piston is atTOC on compression stroke.

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ENGINE DISASSEMBLY ENG I\.I4. Remove:.Timing chain tensioner C D Gasket (cam chain tensioner)

iw 5. Remove:.Union bolts C D.Oil delivery pipe Copper washersli~\

\

6. Remove: Timing chain guide (upper) C D Timing chain guide (exhaust side)

NOTE: ___ Select either of the two procedures explainedin this manual, asfollows:

Procedure 1.For engine service except cylinder head dis-assembly._..Disconnect the timing chain.The pistons and cylinder can be removedwithout removing the camshafts.

Procedure 2.For engine service including cylinder headdisassembIy.-+ Remove the cam capsand camshafts.The camshafts can be removed without dis-connecting the timing chain.

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ENGINE DISASSEMBLY ENG 1 " - 1Procedure 1.1. Disconnect:-Timing chainUse the Timing chain cutter C D

Timing chain cutter:YM-01112,90890-01112

2. Remove:- Rubbers (camshaft cap) C D

3. Remove:-Caps - Nuts (cylinder head)Use the Hexagon wrench 6 mm (0.24 in) C D .

4. Remove:- Cylinder head-Gasket (cylinder head)- Dowel pins5. Go to "CYLINDER AND PISTON".

Procedure 2.1. Remove:- Bolts (camshaft sprocket exhaust)

2. Push the camshaft sprocket with arrow direction and take of sprocket from its homeposition.

3. Remove:- Camshaft caps Dowel pinsNOTE: _

Remove the camshaft caps in a crisscross patternfrom outermost to inner caps.

Do not rotate the camshaft or valve damage mayoccur.4. Remove:-CamshaftsNOTE: __

Fasten safety wire C D to the cam chain to pre-vent it from falling into the crankcase.4 9

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ENGINE DISASSEMBLY ENG5. Remove: Nuts (Cylinder head)Usethe Hexagonwrench 6 mm (0.24 in ) C D .

NOTE: ~ Loosen the nuts in their proper looseninesequence.

Follow numerical order shown inStart by loosening each nut 1/2all are loose.6. Remove: Cylinder head

NOTE: __Remove the cylinder head asa whole tothe valve lifters and adjusting pads from fallinto the crankcase.

7. Remove:.Gasekt (cylinder head) c D Dowel pins @

CYLINDER AND PISTONNOTE: ~With the engine mounted, the cylinder an dcan be maintained by removing the folparts. Side cowlings (left and right).Seat Top cover Radiator Air fi Iter case Carburetor Muffler assembly Down tube frame (right).Cylinder head

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~~~~~~~~~~~~E_N_G_IN_E_D_I_S_A_~_E_M_B_l_Y_IENGI~1. Remove:.Water pipe (I).0ings-Cylinder

2. Remove: Gasket (eyli nder) C D Dowel pins (2 )

NOTE: __Put identification marks on the each piston headfor reference reinstalation.

3. Remove: Circlips (piston pin) (i)NOTE: __

Before removing the piston pin circlip, cover thecrankcase with a clean rag to prevent the circlipfrom tailing into the crankcase cavity.

4. Remove: Piston pins (i) Pistons@

NOTE: _Before removing the piston pin, deburr the clipgrooved and pin hole area.. If the piston pingroove isdeburred and piston pin is still difficultto remove, usethe Piston pi n puIler (~).

Piston pin puller:YU-01304,90890-01304

Do not use a hammer to drive the piston pinout.

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ENGINE DISASSEMBLY ENG 1 ' - 1CLUTCHNOTE: _With the engine mounted, the clutch assemblycan be maintained by removing the followingparts. Side cowling (right).Crankcase cover (right)

1. Remove: Crankcase cover (right) C D Gasket (crankcase cover) Dowel pins

NOTE: _Working in a crisscross pattern, loosen bolts 1/4turn each. Remove them after all are loosened.

2. Remove: Bolts (clutch spring) C D.Clutch springs Pressure piate Friction plates C D Clutch plates Push rod #1 Ball (j) Pushrod #2 NOTE: __

Loosen the bolts in a crisscross pattern.

3. Straighten the lock washer tabs.4. Loosen: Nut (clutch boss) C D

Universal clutch holder:YM91 042,90890-04086

NOTE: _Loosen the nut C D (clutch boss) while holdingthe clutch boss with the Universal clutch holder

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ENGINE DISASSEMBLY ENG5. Remove: Nut (clutch boss) C D Lock washer .Clutch boss @ Thrust washer .Spacer @.Bearing .Clutch housing (J) Thrust washer .Collar

NOTE: _Install the 5 mm (0.2 in) screw into thespacer. Then, remove the spacer by pulling onthe screw.

STARTER MOTOR AND A.C. GENERATORNOTE: __With the engine mounted, the starter motor,can be maintained by removing the followingparts.-Seat-Top cover Fuel tank

1. Remove: Starter motor C D

2. Remove: Bolt (magneto) C D-Washer

Rotor holding tool :YS-01880,90890-01235

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3. Attach:- Rotor puller (1 )

Rotor puller:YM-Ol080.90890-01080

4. Remove:_Magneto @_Woodruff kev

5. Remove:- Startor coli assernb lv C D- Pickup coil @

OIL PAN AND OIL STRAINERNOTE: _With the engine mounted, the oil pan and oilstrainer can be maintained bv removing thefollowing parts.-Side cowlings (left and right)- Exhaust pipe assembly-Cowling stav

1. Disconnect:-Oil level switch lead C D- Neutra I switch lead@

Clamp2. Rernove:-Oil filter assernbly C D

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ENGINE DISASSEMBLY ENG 1 ' - 1

,

3. Remove: Drain plug C D Oil level switch @-ou pan .Gasket (oil pan) Dowel pins

4. Remove:-ou strainer cover C D Relief valve @ Oil strainer assembly

OIL PUMP AND SHIFT SHAFTNOTE: __With the engine mounted, the oil pumpshift shaft can be maintained by removingfollowing parts. Side cowlings Crankcase cover (right)-Clutch assembly

1. Remove: Oil pump assembly C D

2. Remove:.Gasket (oil pump assembly) C D-Dowel pin @ Shift shaft

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ENGINE DISASSEMBLY ENG 1 ' - 13. Remove: Stopper lever C D.Spring Stopper plate (shift shaft guide bar)

WATER PUMPNOTE: _With the engine mounted, the water pump canbe maintained by removing the following parts. Seat.Top cover.Side cowlings.Shift arm Crankcase cover (right) Radiator hose Water pump cover

1. Remove: Water pump cover C D.O-ring Water pump housing

CRANKCASE DISASSEMBLY1. Remove: Oil seal stopper C D

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ENGINE DISASSEMBLYA

ENG I'\.I3. Remove:

Bolts (crankcase)NOTE: __ Remove the bolts starting with the highestnumbered one .

The embossed numbers in the crankcasedesignate the crankcase tightening sequence.4. Place the engine upside down.5. Remove:

Crankcase (lower)U se a soft hammer.

/~~Q:tI f>NI: - - - - - - - - - - - - - - - - - - - - -Use a soft hammer to tap on the case half. Taponly on reinforced portions of the case, Do nottap on the gasket mating surface. Work slowlyand carefully. Make sure that the case halvesseparate evenly.

[ ' I I . J Upper casels i Lower caseTRANSMISSION, SHIFTER AND SHIFT CAM1. Remove:

Drive axle assembly C D Main axle assembly @ Dowel pins.Circlip @.Special washer @.Oil seal

2. Remove: Guide bars C D.Shift fork #1 (2 ) Shift fork #2 (3 ) Shift fork #3 (4 )

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3. Remove: Shift cam C D

CRANKSHAFT1. Remove: Crankshaft assembly

2. Remove: Main journal bearing C D

NOTE: _Identify each main journal bearing positionvery carefully so that it can be reinstalled inits original place.

3. Remove: Timing chain guide (intake side) C D Qring

4. Remove: Neutral switch C D

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ENGINE DISASSEMBLY ENG I ' \ . I5. Remove:

Breather hose.Oil baffle plate

VALVE PAD AND VALVENOTE: _Before removing the internal parts (valve, valvespring, valve seat etc.) of the cylinder head, thevalve sealing should be checked.

1. Remove: Lifters C D Valve pads

NOTE: _Identify each lifter and pad position very care-fuly so that it can be reinstalled in its originalplace.

C D Lifters@ V alve pad s

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ENGINE DISASSEMBLY ENG I'\.I

I f ' e -w@ .. l ~@ 302023

2. Check: Valve sealingLeakage at valve seat ~ Inspect the valveface, valve seat and valve seat width.Refer to the "INSPECTION AND REPAIR- VALVE SEAT" section.

Checking steps:.Supply a clean solvent C D into the intakeand exhaust ports . Check the valve sealing. There should be noleakage at the valve seats .

3. Remove:.Valve cotters C D

NOTE: __Attach the valve spring compresser and attachment r 1 ) between the valve spring seat andcylinder head to remove the valve cotters.

Valve spring compresser:YM-04019,90890-04019

Attachment:YM-04018,90890-04108

4. Remove: Valve cotters C D Valve retainer .Oil seal .Valve spring .Valve Valve retainer

NOTE: __Identify each part position very carefully so thatit can be reinstalled in its original place.

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ENGINE DISASSEMBLY ENGCONNECTING ROD1. Remove:.Connecting rod Connecting rod bearing

NOTE: ___Identify each connectingvery carefully so that it can be reinstalled inoriginal place.

INNER ROTOR (OIL PUMP)1. Remove: Pump housing C D

2. Remove: Outer rotor C D Pin (2 ).Inner rotor .Washer Pump cover Pump shaft

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INSPECTION AND REPAI R

I\' . - . -.~ ," ' " ' " ~ ~ ...l

ENG 1 ' - 1INSPECTION AND REPAIRCYLINDER HEAD1. Eliminate: Carbon deposit(from combustion chamber)Use rounded scraper.NOTE: _

Do not use a sharp instru ment and avoid damag-ing or scratching: Spark plug threads Valve seat2. Inspect: Cyl inder headScratches/Damage .....Replace.

3. Measure: WarpageOut of specification --> Resurface.

Cylinder head warpage:Less than 0.03 mm (0.0012 in)

4. Resurface: Cyl inder head

Resurfacement steps:Place a 400 - 600 grit wet sandpaper on thesurface plate, and resurface the head using afigu re-eight sand ing pattern.NOTE: _Rotate the head several times to avoid remov-ing too much material from one side.

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INSPECTION AND REPAIR ENGVALVE AND VALVE GUIDE1. Measure:.Stem-to-guide clearanceStem-to-gu ide clearanceValve guide inside diameter -Valve stem diameter @

302029

302019

302020

Out of specification _".Replace valve guide.Stem-to-guide clearance:Intake:0.010 ~ 0.031 mm(0.0004 ~ 0.0015 in)< Limit> : 0.08 mm (0.0031 in )Exhaust:

0.025 ~ 0.052 mm(0.0010 - 0.0020 in)< Limit> : 0.10 mm (0.0039 in )

2. Replace:.Valve guide

Replacement steps:NOTE: ___Heat the cylinder head in an oven to 100C(212F) to ease guide removal and installationand to maintain correct interference fit. Remove the valve guide using the valve guideremover C D .

Install the valve guide (new) using the valveguide installer and valve guide removerC D After installing the valve guide, bore thevalve guide using the valve guide reamer @to obtain proper stern-to-guide clearance.

Valve guide remover:YM-0411690890-04116

Valve guide installer:YM-0411790890-04117

Valve guide reamer:YM-0411890890-04118NOTE: __

Reface the valve seat after replacing the valveguide.

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INSPECTION AND REPAIR ENG I ' \ . 1

.' 45"r 302000

//3 02 0 0. ::

3. Eliminate: Carbon deposit(from valve face)

4. Inspect: Valve facePitting/Wear --> Grind the face.

Valve stem endMushroom shape or diameter larger thanrest of stem --> Replace.

5. Measure: Margin thickness Out of specification --> Replace.

Margin Thickness:Limit: 0.7 mm (o.0276 in)

6. Measure: Runout (valve stem)Out of specification --> Replace.

Runout:Lessthan 0.02 mm (0.0008 in)

NOTE: __ Always replace the guide if the vaIve is re-placed.

Always replace the oil seal if the valve isremoved.

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~~~~~~~~~~~_IN_S_PE_C_T_IO_N~A_N_D_R_E_P_A_IR_IENGI~I

302 Q2!

VALVE SEAT1. Clean: Valve face Valve seatEliminate carbon deposit.

2. Inspect: Valve seatPitting/Wear~ Reface valve seat.

3. Measure: Valve seat width C DOut of specification _,. Reface va Ive seat.

Valve seat width measurement steps:.Apply the Mechanic's bluing dye (Dvkem)C D to the valve face . Install the valve into the cylinder head. Press the valve through the valve guide andonto the valve seat to make a clear pattern. Remove the valve from the cylinder head. Measure the valve seat width .When the valve seat and valve face makecontact, bluing will be applied to the valveface.

Valve seat width LimitIntakeExhaust

0.9 ~ 1.1 mm(0.035 ~ 0.043 in)

.If the valve seat width is too wide, toonarrow, or seat has not centered. The valveseat must be refaced.

4. Reface: Valve seatUse 20, 450 and 60 Valve Seat Cutter.

LhOAUTION: - - - - - - - - - - - - - - - - - - - - -Remove just enough material to achieve satis-factory seat.When twisting cutter, keep and even downwardpressure to prevent chatter marks.

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ENG 1 ' - 1NSPECTION AND REPAIR

30201,

A

Cut sections as followsI---~~- ~~-.~~~~ ..-.-- ---~-.----Section Cutter

Valve seat refacing steps:: . K J Valve face indicates that valve seat IScentered on valve face but is too wide.

Valve seat cutter set Desired result_._ . . . . .Use 20 cutter To reduce valve seat_ . . . . _ . . . . . . . _ .. _ . . . . . ._- width to 1.0 mmlightly 60 cutter (0.04 in)]J Valve seat is in the middle of the valveface but too narrow.Valve seat cutter set Desired resu It --To achieve a uniformUse 45 cutter valve seat width of1.0 mm (0.04 in)

i : J Valve seat is too narrow and right upnear valve margin,

Valve seat cutter set Desired result--20 cutter To center the seat andUse 45 cutter to achieve its width of1.0 mm (0.04 in)

~ Valve seat is too narrow and is locateddown near the bottom edge of the valveface.

Valve seat cutter set Desired resu It.,._- f----60 cutter, To center the seat andUse first~---- increase its width.45 cutter

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INSPECTION AND REPAIR ENG 1 ' - 1

NOTE: _To obtain the best lapping result, lightly tapthe valve seat while rotating the valve back

302024 and forth between your hand .

302017

3020'7

5. Lap:.Valve face Valve seatNOTE: __

After refacing the valve seat or replacing thevalve and valve guide, the valve seat and valveface should be lapped.

Valve lapping steps:.Apply a coarse lapping compound C D to thevalve face.

Be sure no compound enteres the gap betweenthe valve stem and guide. Apply a molybdnum disulfide oil to thevalve stem .

Install the valve into the cylinder head . Turn the valve until the valve face andvalve seat are evenly polished, then cleanoff all compound.

Apply a fine lapping compound to the valveface and repeat the above steps.

NOTE: __Be sure to clean off all compound from thevalve face and valve seat after every lappingoperation .

Apply the Mechanic's bluing dye (dykem)C D to the valve face . Install the valve into the cylinder head.

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INSPECT ION AND REPA IR I ENG 1 " - 1

3 D : 2 D O S

302 000

302028

Press the valve through the valve guide andonto the valve seat to make a clear pattern .

Measure the valve seat width C D again. Ifthe valve seat width is out of specification,reface and lap the valve seat.

VALVE SPRING1. Measure: Valve spring free length C DOut of specification - > - Replace.

Valve spring free length:43.15 mm (1.70 in)

2. Measure: Valve spring installed force @Out of specification - > - Replace.

C D I ns ta lle d le ng th

Valve spring installed force:c vt---~-.~-~-r-----~~-~---I14.2 ~ 16.4 kg(31.3 ~ 36.2 Ib)7.5 mm (1.48 in)

3. Measure:.Spring tilt Out of specification -+ Replace.

Spring tiIt:Less than 1.8 mm (0.0709 in)

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INSPECTION AND REPAIR I ENG 1 ' - 1VALVE LIFTER1" In sp e ct:

V alv e lifters"' Replace both lifters

and camshaft case.

CAMSHAFT, TIMING CHAIN, AND CAMSPROCKET

Inspect:

lue discoloration -r r

2. Measure:.Cam lobes

Cam lobe2 {limit)

IntakeExhaust

3. Measure:'* Camshaft runoutUse the MicrorneteL

of

Camshaft runout limit:0.03 mm (0,,0012 in)

clearance measurementInstall:e Carnshaft {intake andPosition:

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INSPECTION AND REPAIR ENG 1 ' - 13. Install: Dowel pins Camshaft caps

4. Tighten: Camshaft cap bolts

Bolts (camshaft cap):10 Nm (1.0 m- kg, 7.2 ft lb)

NOTE: _ Tighten the camshaft caps in a crisscrosspattern from innermost to outer caps .

Do not turn the camshaft when measuringcleara nee with the [email protected]. Remove: Camshaft caps

6. Measure: Width of Plastigage@ C DOut of specification --? Fa Ilow step 7.

Camshaft-to-cap clearance:0.020 ~ 0.054 mm(0.0008 ~ 0.0021 in)

7. Measure: Camshaft outside diameter C DUse a micrometer.Out of specification --> Replace the cam-shaft.Within specification --> Replace the cylinderhead.

Camshaft outside diameter:Standard: 22.967 ~ 22.980 mm

(0.9042 ~ 0.9047 in)Cam cap inside diameter:

Standard: 23.000 ~ 23.021 mm(0.9056 ~ 0.9063 in)

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INSPECTION AND REPAI R ENG I ' \ . ITiming chain1. Inspect: Timing chainChain stretch/Cracks -+ Replace.

Cam sprockets1. Inspect: Cam sprocketsWear/Damage -+ Replace.

Timing chain guide1. Inspect:.Timing chain guide (upper) C D Timing chain guide (exhaust side) @ Timing chain guide (intake side) @Wear -+ Replace.

Timing chain tensioner1. Check: One-way cam C D operationUnsmooth operation -+ Replace.

2. Inspect: All partsDamage/Wear -+ Replace. End plug Tensioner body Washer Tensioner rodC D Springs

CYLIN DER AN D PISTON1. Inspect: Cylinder and piston wallsVertical scratches -+ Reborecylinder and piston.

2. Measure: Piston-to-cylinder clearance

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1ENG 1 ' - 1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -INSPECTION AND REPAIR- .'1

a p

307 OOE

Measurement steps:First step: Measure the cylinder bore "C" with a cvlin-der bore gauge.

40 mm (1.57 in) from the cylinder top.NOTE:Measure the cylinder bore "C" in parallel toand at right angles to the crankshaft. Then,find the average of the measurements.

~ Standard Wear limit.~~--~--~-----"-.-.~-~----.~~-.~-----Cylinder 59.00 ~ 59.01 mm 59.15 mmBore HC" (2.3228 ~ 2.3232 in) (2.3288 in)f-. --.~------X+yC= 2 If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.2nd step:.Measure the piston skirt diameter "P" witha micrometer.

@ 5 mm (0.20 in) from the piston bottom edge.

~ Piston size P-~-~Standard 58.940 - 58.955 mm(2.321 - 2.322 in)~Oversize 2 59.5 mm (2.343 in).If out of specification, replace piston andpiston rings as a set.3rd step:.Calculate the piston-to-cyli nder clearancewith following formula:Piston-to-cylinder clearance =Cylinder bore "C" -Piston skirt diameter "P"

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3G7-005

]20mm" (O.Bin)

If out of specification, rebore or replacecylinder, and replace piston and piston ringsasa set.

Piston-to-cylinder clearance:0.045 ~ 0.070 mm(0.0018 ~ 0.0028 in)

Limit: 0.15 mm (0.006 in)

PISTON RING AND PISTON PINPiston ring1. Measure:.Side clearanceUsethe feeler gauge C D .Out of specification -+ Replace the pistonand/or rings.NOTE: ___

Eliminate the carbon deposits from the pistonring grooves and rings before measuring theside clearance.

Side clearance:

Top ring 0.03 ~ 0.07 mm(0.0012 ~ 0.0028 in)Standard Limit

0.10 mm(0.004 in)---r--------------~---0.10 mm

(0.004 in)nd ring0.02 ~ 0.06 mm

(0.0008 ~ 0.0024 in)2. Position: Piston ringInto cylinder.

NOTE: __Insert the ring into the cylinder, and push itapproximately 20 mm (0.8 in) into the cylinder.Push the ring with the piston crown so that thering will be at a right angle to the cylinder bore.3. Measure:.End gapUsea feeler gauge.Out of specification .....Replace.

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INSPECT ION ANO REPA IR 1 ENG 1 " - - 1

t

30 '1-018

End Gap (Installed):. .. .. .. .. .. - .. _. _ _ .__ _ - -1Standard

0.15 ~..0.30 mm(0.0059 ~ 0.0118 in)......----...-...-----10.15 ~~0.30 mm(0.0059 ~. 0.0118 in)

~- - - - - - - - - - ~ - - - - ----- _ .0.2~" 0.6 mm(O.0079~ 0.0236 in)

2nd ringOil control(Rails)

Piston ring oversize Top and 2nd piston ringOversize top and middle ring size is stampedon the top of ring.

Oversize 2 [ 0.50 mm (0.0197 in)

Oil control ringExpander spacer of bottom ring (oil controlring) iscolor-coded to identify sizes.

PISTON PIN1. Inspect: Piston pinBlue discoloration/Groove --).Replace,theninspect Iubrication system.

2. Measure: Outside diameter (piston pin)Out of specification --. Replace.

Outside diameter (piston pin):15.991 ~ 16.000 mm(0.6296 ~ 0.6300 in)

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ENGINSPECTION AND REPAIR

30ll00S

3. Measure: Piston pin-to-piston clearance @Out of specification -+ Replace piston.

Piston pin-to-piston clearance '"bore size (piston pin) @ -outside diameter (piston pin) Piston pin-to-piston clearance:0.002 ~ 0.022 mm(0.0001 ~ 0.0009 in)< Limit: 0.07 mm (0.003 in) >

CRANKSHAFT AND CONNECTING ROD1. Measure: Runout (crankshaft)Out of specification -7 Replace.

Runout:Lessthan 0.03 mm (0.0012 in)

2. Inspect: Crankshaft bearing surfacesWear/Scratches + Replace.

Main journal oil clearance1. Clean all parts.2. Position:.Crankcase half (upper)Place it on a bench in an upside downtion.

3. Install: Bearings(into upper crankcase).

Crankshaft4. Attach: Plastigage C D(onto crankshaft journal surface).

NOTE: _Do not tu rn the cran kshaft unti Imeasurement hasbeen completed.5. Install: Bearings(into lower crankcase).

Crankcase (lower)

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INSPECTION AND REPAIR ENG '-6. Tighten: Bolts

Tighten the bolts to specified torque. Tighteningsequence is casted on the crankcase.

9 mm (0.35 in) bolt:32 Nm (3.2 m- kg, 23 ft lb)

7. Remove: BoltsReverse assembly procedure.

Crankcase (Lower)Use care in removing.

8. Measure: Plastigage width Out of specification ~ Replace the bearinqs:replace the crankshaft if necessary.

Main journal oil clearance:0.020 ~ 0.044 mm(0.0008 ~ 0.0017 in)

Connecting rod bearings1. Inspect: BearingsBurns/F laki ng/Roughness/Scratches ~Replace.

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Connecting Rod Oil Clearance1. Cleanall parts thoroughly.2. Install: Connecting rod bearings(into connecting rod and cap)

3. Attach: PlastigageC D(onto crank pin)

4. Install: Connecting rod Connecting rod cap


NOTE: _ Be sure the "Y" marks C D on the connectingrods face toward left crankshaft end .

Be sure the letters on both components alignto form a perfect character.

5. Lubricate: Bolt threads (Connecting rod) Nut seats(Connecting rod)

Molybdenum Disulfide Grease

6. Tighten: Nuts (connecting rod cap)NOTE: _Do not turn the connecting rod untilclearancemeasurement hasbeencompleted.

' 1 1 . l Q ; t I O N i . - - - - - - - - - - - - - - - - - - - - -Tighten to full torque specification withoutpausing. Apply continuous torque between1.2 and 2.3 m kg. Once you reach 1.2 mkgDO NOT STOP TIGHTENING until final torqueis reached. If tightening is interrupted between1.2 and 2.3 mkg, loosen nut to less than1.2 m- kg, and start again.

Nuts (connecting rod):36 Nm (3.6 m kg, 25 ft Ib)

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INSPECTION AND REPAIR ENG 1 ' - 17. Remove:-Connecting rod capUse care in removing.

8. Measure: Width of Plastigage C DOut of specification -+ Replace the bearingsand/or replace the crankshaft if necessary.

Crank pin oil clearance:0.032 ~ 0.056 mm(0.0013 ~ 0.0022 in)

Crankshaft main journal and crank pin bearingselection.Numbers used to indicate crankshaft journalsizes are stamped on the LH crankweb. Thefirst five (5) are main journal bearing numbers,starting with the left journal. The four (4)crank pin bearing numbers follow in the samesequence.

_ The upper crankcase half is numbered J 1, J2,J3, J4 and J5 on the rear right bosse as shown.

-The numbers are stamped in ink on the rodcap C D .

BEARING COLOR CODE-~.- . . . . . . . ~. - - - ---------~-No.1 Blue....No.2 Black.. .No.3 BrownNo.4 Green----..~~* No.5 Yellow

* NO.5 applies only to the main journal bear-ing selection.4-39

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INSPECTION AND REPAIR ENG 1 ' \ . 1

A

B

Example 1:Selection of the main journal bearings:- jf the crankcase J 1 and crankshaft J 1 sizesare NO.4 and No.1, respectively, the bearingsize No. is:

Bearing Size No. =Crankcase No. - Crankshaft No. =4 - 1 = 3 (Brown)

BEARING COLOR CODENO.1 Blue

. . . . . . . . . . . _ .. _ ... _- -No.2 BlackNO.3 Brown_ .. .._ - - _ .._ ._ . . . . . _ ...-......... -..~---No.4 Green-_.+-NO.5 Yellow

Example 2:Selection of the crank pin bearing:- If the connecti ng rod P 1 and crankshaft Plsizes are NO.5 and No.1, respective Iy, thebearing size No. is:

Bearing Size No. :::Connecting rod No. - Crankshaft No. ""5 - 1 = 4 (Gteen)

BEAR ING COLOR CODENo.1 Blue.. . _ ... ,,--_ ......... _ .. _ ._.- .........._._-No.2 Black.~.. -NO.3 Brown_.__ . . . . . . . . . . . . . . . . . . . . GreenO.4

OIL PUMP1. Measure:

.Tip clearance "A"Between the inner rotor C D and the outerrotor @ .

-Side clearance "B"Between the outer rotor @ and the pumphousing .Use the filler gauge and straight edge.Out of specification ~ Replace the oilpump assembly.

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< f . l~~ , " "

INSPECTION AND REPAIR 1ENG 1 " \ . 1

2

Tip clearance" A" limit:0.15 mm (0.006 in)

Side clearance"9" limit:0.15 mm (0.006 in)

2. Lubricate: Inner rotors Outer rotors Oil seal Pump shaftI ' d SAE lOW30 motor oil

3. Install:Reverseremoval procedure.NOTE: _

Align the pins in the pump shaft and the grooveon the inner rotors dualing assembly.4. Check: Oil pump operationWith a finger.Unsmooth operation '7 Repeat step 2. orreplace.

5. Inspect: Oil pump drive gear C D Oil pump driven gearWear/Cracks/Damage _,.Replace.

PRIMARY DR IVE1. Inspect: Primary drive gear {crank shaft) C D Primary driven gearWear/Damage --> Replace both gears.Excessivenoisesduring operation -->Replace both gears.

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,

STARTER DRIVES1. Inspect: Starter clutch rollerWear/Damage ~ Replace.

2. Inspect: Starter idle gear teeth C D Starter drive gear teeth Burrs/Chi ps/R oughness/Wear -+ Replace.

3. Inspect: Contacti ng surfaces (starter clutch gear)Pitting/Wear/Damage ~ Replace.

4. Check: Starter clutch operation

Checking steps: Install the starter clutch gear to the starterclutch, and hold the starter clutch . When turning the starter clutch gear clock-wise the starter clutch and the wheel gearshou Id be engaged.If not, the sta rter clutch is tau ltv, Replaceit .

When turning the starter clutch gear counter-clockwise, the starter clutch gear shouldturn freely.It not, the starter clutch is faulty. Replace it.

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_~~~~~~~~~~~IN~~_E_C_T_IO~N_A_N_D~R_E_M~IR_IENGI~I

JP 002

CLUTCHClutch Housing1. Inspect: Dogs on the housingCracks/Wear/Damage -- + Deburr or replace.

Clutch housing bearingChafing/Wear/Damage -- + Replace.NOTE: __

Wear on the friction plate dogs of the clutchhousing will cause an erratic operation.Clutch Boss1. Inspect:.Clutch boss splines C DScoring/Wear/Damage .... Replace clutchboss assembly.NOTE: __

Scoring on the clutch plate splines will causeerratic operation.

Friction Plates1. Inspect: Friction plateDamage/Wear"'> Replace the friction platesas a set.

2. Measure: Friction plate thicknessMeasure at all four points.Out of specification --> Replace the frictionplates as a set.

Wear limit:2.8 mm (0.11 in)

Clutch Plates1. Measure: Clutch plate warpageUse the surface plate and feeler gauge C D .Out of specification _,. Replace.

Warp limit:0.1 mm (0.004 in)

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INSPECTION AND REPAIR ENG 1 ' - 12. Inspect: Pressure plateDamage --+ Replace.

Push Rod1. Inspect: Push rod 1 C D.Boll .Push rod 2 Wear/Cracks/Damage --+ Replace.

Push lever assembly and push rod1. Inspect: Push lever assemblyUnsmooth --+ Replace.

2. Measure: Push rod runoutUse the V-Blocks and dial gauge.Out of specification --+ Replace.

Bending limit:0.5 mm (0.020 in)

Clutch spring1. Measure: Clutch spring free lengthOut of specification -+ Replace the sprias a set.

Clutch Spring Minimum Free Length:32.6 mm (1.28 in)

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INSPECTION AND REPAIR I ENG 1 ' \ . 1TRANSM ISSIONShift Fork1. Inspect:

Shift fork cam follower C D Shift fork pawl Wear/Chafi ng/Bends/Damage -+ Replace.

2

2. Inspect: Guide barRoll the guide bar on a flat surface.Bends -+ Replace.

ILWARNING:Do not attempt to straighten a bent guide bar.

3. Check: Shift fork movementOn its guide bar.Unsmooth operation -+ Replace the forkand/guide bar.

Shift Cam1. Inspect: Shift cam groovesWear/Damage/Scratches -+ Replace. Shift cam segmentDamage/Wear -+ Replace .

Shift cam bearingPitting/Damage .... Replace.

Main and Drive Axles1. Measure: Axle runout (main and drive) C DUse the centering device and dial gauge .Out of specification -+ Replace.

Runout limit:0.08 mm (0.0031 in)

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_~~~~~~~~~IENGI~INSPECTION AND REPAIR _ _ ... _2. Inspect: Gear teethBlue discoloration/Pitting/Wear -.. Replace .

Mated dogsRounded edges/Cracks/Missing portions -+Replace.

3. Check: Proper gear engagement (each gear)(to its counter part)Incorrect -'> Reassemble.

Gear movementRoughness -'> Replace.

4. Inspect: CirclipsDamage/Looseness/Bends -.. Replace.

SHIFT SHAFT AND STOPPER LEVER1. Inspect: Shift shaft C D Shift pawls Bend/Wear/Damage -.. Replace.

2. Inspect: Stopper lever Roller turns roughly _.. Replace.Bend/Damage _.. Replace.

3. Inspect: Return spring (shift shaft) Return spring (shift pawls) Return spring (stopper lever) Wear/Damage _.. Replace.

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_ _ _ _ _ _ _ _ _ _ _ I _ N _ S _ P E _ C _ T _ I O _ N _ A _ N _ D _ R _ E _ P _ A _ I R _ ~ N G I ~ IOllJET NOZZLE1. Check: Oi l-Jet nozzles Q).Orings @-Check ball @Damage/Wear -+ Replace.- Oil jet passageClog-* Blowout with compressed air.

RELIEF VALVE AND PIPE1. Check:eRelief valve body-Cover.Spring.OringDamageIWear -* Replace.

2. Check:-ou pipe Q)Damage -+ Replace.Comtamination -* Wash and blowoutthe passage.

3. Check:_Water pipe C D.VVaterjacketjoint C ? )eO-rings @Damage - - > Replace.

CRANKCASE1. Thoroughly wash the case halves in mildsolvent.

2. Clean all the gasket mating surfaces andcrankcase mating surfaces thoroughly.

3. Inspect: CrankcaseCracks/Damage - -> Replace .

Oi I delivery passagesClog --'> Blowout with compressed air.447

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INSPECTION AND REPAIR [ENG 1 ' - 1r---------------~ BEARING AND OIL SEAL

1. Inspect: BearingsClean and lubricate, then rotate inner racewith finger.Roughness --* Replace the bearing (see Re-moval).

2. Inspect:.Oil sealsDamage/Wear --* Replace the (see Removal),

EXUP VALVE AND CABLES(FZR600WC ONLY)1. Check: EXUP valve smooth movementSticks -+ Repair or replace.

EXUP cablesSticks/Damage + Heplace.

///

::0--'2. Inspect:-Valve (EXUP) C D Housing (valve) .Gasket (steel) Wear/Cracks/Damage _,. Replace.

Bush @ )Wear -> Replace.

NOTE:When installing the valve (EXUP), apply themolybdenum disulfied grease on the valve.

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ENGINE ASSEMBLY AND ADJUSTMENT ENG 1 ' - 1ENGINE ASSEMBLY ANDADJUSTMENTINNER ROTOR (OIL PUMP)1. Install: Pump shaft C D Pump cover @Washer Inner rotor G).Pin Outer rotor

NOTE: __Insert the inner rotor C D into the outer rotor @.Then with the pump shaft dowel pin in theinner rotor slit.

2. Install: Pump housing C D

CONNECTING ROD1. Clean: Crankshaft Connecting rods

2. Install:.Connecting rod bearings(into the connecting rod and cap.)NOTE: _

Align the projection of bearing with thegroove of cap. ldentifv each bearing position very carefullyso that it can be reinstalled in its originalplace.3. Lubricate:.Connecting rod bolt threads Connecting rod nuts

~ Molybdenum disulfide oil

4. Apply engine oil to the crankshaft pins.4-49

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ENGINE ASSEMBLY AND ADJUSTMENT ENG I\.I5. Install: Connecting rods Connecting rod capsNOTE: _

The stamped "Y" mark on the connecting rodsC D should face towards the left side of thecrankcase .

Be sure the letter on both components align toform a perfect character.

6. Install: Connecting rod boltsAlign the bolt head C D and connecting rodcap.

7. Tighten: Connecting rod nuts

Tighten to full torque specification withoutpausing. Apply continuous torque between1.2 and 2.3 m-kg. Once you reach 1.2 m-kg.DO NOT STOP TIGHTENING until final torqueis reached. If the tightening is interruptedbetween 1.2 and 2.3 mkg, loosen the nut tolessthan 1.2 rn- kg and start again.

Nut (connecting rod):23 Nm (2.3 m- kg, 17 ftlb)

VALVE PAD AND VALVENOTE: __Deburr any deformed valve stem end. Use an oilstone to smooth the stem end.CDDebur rC VV alve stem

1 . Eliminate: Carbon depositFrom the combustion chamber.Use a rounded scraper.

NOTE: __Do not use a sharp instrument and avoid damaging or scratching: Spark plug threads.Valve seat Cylinder head

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ENGINE ASSEMBLY AND ADJUSTMENT ENG,,"----_ . . . . . . . ._----"CRANKSHAFT( D CrankshaftI : ? ) Oil seal(~) Main journal bear ing(~ JConnecting rod assemblv(5)Connecting rod bolt(~)Connecting rod bearing(7JNut

MAIN JOURNAL OIL CLEARANCE:C 0,025 .'~0.043 rnrn

(O.OOlO'~ 0,0017 in)

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_~~~~~~_EN_G_I_N_E_A_S_S_E_M_B_LY~A_N_D_A_D_J_U_~_M~EN_T_IEN

~~~ -~~ /C I -~ 0 C 0. . . --

~---_~~--"=~=~"---J-----"'-:~ __

1

2. Install: Valve retainer C D-ou seal

3. Install:.Valve

NOTE: _Apply molybdenum disulfide oil.

4. Install: Valve spring C D

NOTE: _Install springs with wider-gapped coils facingupwards, as shown. Larger pitch Smaller pitch5. Attach:- Valve spring compressor C D Attachment

Valve spring compressor:YM-0401990890-04019

Attachment:YM-0410890890-04108

6. Install:- Valve cotters

7. Settle the valve cotter by lightly patting thevalve seat with a piece of wood inbetween.

NOTE: __Do not hit so much as to damage the valve.

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ENGINE ASSEMBLY AND ADJUSTMENT I ENG I ~ 1..------------------ a.lnstall:

Valve pads C D

. '.il1 1 : = f:~:II'....... ~~*.-'""'-'_......,.."""'-'-~~~,,~~J"'W"-

NOTE: _Apply molybdnum disulfide oil.

9. Install: Lifters C D

CRANKSHAFT1. Install: Oil baffle plate Breather hose

Oil baffle plate bolts:7 Nm (0.7 m- kg, 5.1 ftlb)

2. Install: Neutral switch assembly C D

3. Install:.Timing chain guide (intake side) C D.O-ring

Bolts (chain guide):10 Nm (1.0 m- kg, 7.2 ft-Jb)

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ENG INE ASSEMBLY AND ADJUSTMENT I EN G I ' \ . . lCRANKCASE

C D Crankcase assembly@ Oil level window@ Crankcase ventilation hoseo O-ring

[8 J Crankcase sequence tightening

~-->~-----.-- ..-.....-- ..-----.- ..~......---_A

--~r---->------~-24 Nm (2.4 m- kg, 11 ft Ib)12 Nm (1.2 m- kg, 8.1 ftlb)

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ENGINE ASSEMBLY AND ADJUSTMENT ENG I'\.ITRANSMISSIONC D Main axleC V 5th pinion gear@ Circlip( 4 ) 3rd pinion gear 6th pinion geare ) 2nd pinion gear(7 ) Bearing@ Circlip

Orive axle@2nd wheel gear(l])6th wheel gear@3rd wheel gear@4th wheel gear@5th wheel gear 1st wheel gear@WasherC ! 1 l Special washer

0.08 mm (0.0031 in)

~

T- -.--..............----- ~.J -I MAIN AXLE RUNOUT LIMIT:

'-' I 0.08 mm (0.0031 in)~ _ . _ _ 'm . "c_ . ,~- - " ~_ ~"" ~"" - - 7

?

5

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ENGINE ASSEMBLY AND ADJUSTMENT ENG I\.I4. Install: Main journal bearing c D(to crankcase (lower) @ )

NOTE: ___.Apply engine oil..Identify each bearing posrtion very carefullyso that it can be reinstalled in its original place.

5. Install: Timing chain c D(onto the crankshaft)

Crankshaft assembly @NOTE: __ The stepped crankshaft end should face tothe left. Passthe timing chain through the timing chaincavity. Be sure to attach a retaining wire @to the timing chain.

TRANSMISSION, SHIFTER AND SHIFT CAM1. Install: Shift cam assembly C D Guide bars @ Shift fork #1 Shift fork #2 Shift fork #3

NOTE: ___All shift fork letters should face to the left sideand be in sequence (1, 2, 3) beginning fromthe left.

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ENG IN E ASSEMBLY AND ADJUSTMENT ENG I\.I2. Install: Circlip (new) C D(to crankcase (lower))

NOTE: __Be sure the circli ps C D are inserted into thelower crankcase positioning grooves.

3. Install:.4th wheel gear C D.1t wheel gear C V.Washer Bearing @ Special washer (to drive axle @)

4. Install: Main axle assembly C D Drive axIe assembly C V.Oil seal (push rod)

NOTE: _ Be sure the manufacture mark on oil seal (pushrod) face outward.

Be sure the main axle bearing pin @ shouldface to front and the drive axle bearing pins should face to rear.

Be sure the circlips are inserted into the bear-ings positioning groove.

Mesh the shift fork # 1 with the 4th wheel gear and #3 with the 5th wheel gear (@ on thedrive axle.

Mesh the shift fork #2 with the 3rd piniongear on the main axle.

Carefully guide the shift forks so that theymeshsmoothly with transmission gears.CRANKCASE ASSEMBLY1. Apply:.Yamaha bond No. 1215 or Quick gasket(to crankcase matching surfaces.)

Yamaha bond No. 1215:PIN 90890-85505

Quick gasket :PIN ACC-11 001-05-01

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ENG INE ASSEMBLY AND ADJUSTMENT _~ "'-I/ l '{CAVTlON.:.

B

Before tightening the crankcase bolts. checkthe following points:.Be sure the gear shifts correctly while hand-turning the shift cam.

,. Lower crankcase bolt lA ]lit crankcase bolt [~j"'Clamp (big)-Clamp (small)(follow the proper tiqhtening sequenca.]

~ - ~ - ; - . ~ - ) ~ ~ ; ~ n ; kg ~ r~ Ib)t 6 mm bolt, (31; - :.12 Nm (1.2 m- kg. 8.7 ftlb).--~--- ..-~--.-----. __ ...tNOTE; __ ._._~ _

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ENG IN E ASSEMBLY AND ADJUSTMENT ENG '\.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -SHIFT SHAFT0) Shift shah(I) Chance I ink shaft( . . i ) Chanqe pedal(4 ) Oil seal(5 ) Sprinq

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,

WATER PUMP1. Install: Water pump housing C D

2. Install: O-ring (new) Water pump cover C D

Bolts (water pump cover):10 Nm (1.0 m- kg, 7.2 ftlb)

SHIFT SHAFT AND OIL PUMP1. Install: Stopper plate (shift cam) C D Stopper lever

Bolts (stopper plate):10 Nm (1.0 m - kg, 7.2 ftlb)Use LOCTITE

Bolt (stopper lever):10 Nm (1.0 rn- kg, 7.?. ttlb)Use LOCTITE

NOTE: _ Install the boss of the bolt (stopper lever)into the stopper lever hole correctly.

Mesh the stopper lever roller @ with the shiftcam stopper.

Hook the spring ends on the stopper lever andcrankcase boss .2. Install: Shift shaft assembly C D

fzr600 chap 4 pt1

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