Fz6 manual pdf

NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. Therefore, do not remove the radiator cap when the Recommended antifreeze engine is hot. Scalding hot fluid and steam High-quality ethylene glycol Start the engine, warm it up for several minutes, and then stop it.

NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. Before the vehicle is operated, the air must be removed by bleeding the brake system. Operate the brake. Check: 2. Rear or replaced. Stand the vehicle on a level surface. Drive chain is loosened. Do not overtighten the lower ring nut. Never go beyond the maximum or minimum adjustment positions. Page No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle.

Tire tread depth 2. Side wall Front tire 3. Side cover Rear cowling For installation, reverse the removal proce- dure.

Left front cowling inner panel with cowling Right front cowling inner panel with cowling Front turn signal light coupler Disconnect. Front cowling Rear view mirrors Windshield Front cowling Front cowling inner panel center Rear view mirrors Front wheel axle Collar Front wheel Front brake disc For installation, reverse the removal proce- dure.

NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Do not attempt to disassemble it. If faulty, replace with a new one. Removing the front wheel sensor 1.

Front wheel sensor bolt 7 Nm 0. Release the front wheel. If the heavy spot does not stay in that posi- Wheel axle nut tion, install a heavier weight. Repeat steps b and c until the front wheel is balanced. Adjusting nut Loosen. Rear wheel axle nut Washer Rear wheel axle Washer Drive chain puller Rear wheel Rear brake caliper bracket For installation, reverse the removal proce- dure. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

Install: 5. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake lever Front brake light switch lead coupler Disconnect. Union bolt Copper washer Brake hose Brake caliper Brake pad Brake caliper bracket For installation, reverse the removal proce- dure. Union bolt Copper washer Brake hose Brake caliper Clamp Brake hose holder For installation, reverse the removal proce- dure.

Place the vehicle on a suitable stand so EWA that the front wheel is elevated. Before measuring the front brake disc Disc brake components rarely require dis- deflection, turn the handlebar to the left or assembly. Measure the brake disc deflection. If out of specification, repeat the adjust- a.

Therefore, always clean up any spilt brake fluid immediately. Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Union bolt Union bolt Copper washer Brake hose Rear brake caliper For installation, reverse the removal proce- dure.

Disc brake components rarely require dis- assembly. Therefore, always follow these Brake disc bolt 30 Nm 3. Loosen the bleed screw and push the 5. Tighten the bleed screw. The brake hoses to the front and rear brake 1. ABS warning light b. Left handlebar switch Clutch cable Clutch lever Right handlebar switch Throttle grip Throttle cable Front brake light switch connector Disconnect.

Front brake master cylinder holder Front brake master cylinder Upper handlebar holder Front fender Cap bolt Loosen. Upper bracket pinch bolt Loosen. Do not scratch the inner tube. A damaged oil seal or bush- ing must be replaced. Level Adjust: 1. Rear fender Drive chain Chain protector For installation, reverse the removal proce- dure. NOTE: 2. Correct 1.

Drive chain roller 2. Locknut Shift rod Shift arm Drive sprocket cover Drive sprocket nut Lock washer Drive sprocket For installation, reverse the removal proce- dure. Stator coil assembly coupler Disconnect. Oil level switch connector Disconnect. Neutral switch coupler Disconnect. Speed sensor coupler Disconnect. For assembly, reverse the removal proce- dure. Camshaft sprocket bolt Timing chain tensioner Timing chain tensioner gasket Timing chain guide exhaust side Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Turn the crankshaft clockwise.

Measure: 3. Camshaft cap bolt 10 Nm 1. Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal proce- dure. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner Intake valve stem seal Apply molybdenum disulfide oil onto the a. Install the valve into the cylinder head. Measure: i.

To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. After all of the bolts are fully loosened, remove them. Check: 12 Nm 1. Page Clutch Coolant hose Clutch cable Clutch cable holder Clutch cover Clutch cover gasket Dowel pin For installation, reverse the removal proce- dure.

Install: erratic clutch operation. NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. Place the engine upside down.

Remove: original place. Page Assembling The Crankcase Engine oil 2. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal proce- dure. Clean the big end bearings, crankshaft 0. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condi- tion.

Tighten the connecting rod bolts. Connecting rod bolt 15 Nm 1. Tighten: a. Crankshaft-journal-to-crank- shaft journal bearing clearance 0. To obtain the correct crankshaft e. Measure: 4. NOTE: Oil each gear, shaft, and bearing thoroughly. Apply compressed air to the rear of the radiator. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.

Impeller shaft tilt limit Mechanical seal installer 0. Straightedge 2. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. Intake air pressure sensor coupler Disconnect. Cylinder 1 injector coupler Disconnect. Cylinder 2 injector coupler Disconnect. Cylinder 3 injector coupler Disconnect. Cylinder 4 injector coupler Disconnect. Measure the throttle position sensor volt- age. Adjust the throttle position sensor angle so that the voltage is within the specified range.

Air cut-off valve 2. Reed valve 3. To air filter case A. To cylinder 1 and 2 B. To cylinder 3 and 4 From the air filter case B. To the reed valve Air injection The air induction system burns unburned 1. Main switch 7. Main fuse Battery Starting circuit cut-off relay Sidestand switch Neutral switch Lean angle sensor Crankshaft position sensor ECU engine control unit Spark plugs Engine stop switch Clutch switch Seat 2.

Fuel tank 3. Side cowlings 1. Check the fuses. Check the engine stop switch. Check the neutral switch. Main fuse 8. Starter relay 9. Starter motor Start switch Front cowling inner panel 3. Fuel tank 4. Main and ignition Replace the fuse s. Check the sidestand switch. AC magneto 3. Fuel tank 1. Check the fuse. High beam indicator light Headlight fuse Tail fuse License plate light Pass switch Dimmer switch Headlight relay Auxiliary light Headlight high beam Headlight low beam Side cover 1.

Fuel pump Rear wheel sensor Fuel level warning light Oil level warning light Neutral indicator light Tachometer Multi-function meter Coolant temperature warning light Left turn signal indicator light Right turn signal indicator light Check the hazard switch. The oil level warning light fails to come. The speedometer fails to operate. Check the speed sensor. Coolant temperature sensor Radiator fan motor fuse Radiator fan motor relay Radiator fan motor Main switch 3.

Backup fuse 5. Fuel injection system fuse 7. Throttle position sensor Intake air pressure sensor O sensor Intake air temperature sensor Coolant temperature sensor If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Disconnect the wire harness coupler from the fuel pump.

Verify the operation of the sensor or actuator. If the display value changes, the perfor- mance is OK. Intake air temperature No normal signals are received from the crankshaft posi- Fault code No. Diagnostic code No. Intake air pressure sensor-pipe system malfunction clogged or detached hose.

Fault code No. Intake air pressure sensor-open or short circuit detected. Learn more about Amazon Prime. Amazon Renewed Refurbished products with a warranty.

Throttle cables B Route the branched lead behind the main switch Right handlebar switch lead and immobilizer lead. Kanual a problem loading this menu right now. Remove the connecting rod and big end bearings. There seems to be a problem completing the request at present. Clean the connecting rod bolts and nuts. Dimmer manuql S Disconnect the dimmer relay from the cou- pler.

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These cookies do not store any personal information. Previous Page. Next Page. First edition, November All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U. Printed in U. Page 3: Important Manual Information If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model.

This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

INFO Symbols 1 to 9 indicate the subject of each chapter. This information will be needed to order spare parts. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. The pressure regulator maintains the fuel pressure that is applied to the injector at only kPa 2.

Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Page Important Information 5. Keep all parts away from any source of fire. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture! Dry with an air blower. Connect and disconnect sev- eral times. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques.

Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Page 27 This tool is used to check the ignition system components. Yamaha bond No. Point the tip of the clamp downward in Clutch cable front of the handlebars. Throttle cables B Clamp the horn lead and main switch lead to the in- Right handlebar switch lead ner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm 0.

G Pass the throttle cables through the wire guide. Crankshaft position sensor lead F Pull down the mark-painted sections of the fuel tank breather hose, fuel tank drain hose and coolant res J To the starter motor. K Install the right handlebar switch lead coupler through the hole of the bracket 2 from the downside. L Route the starter motor lead by the inner side of the air cut-off valve hose.

K Clamp the rear turn signal lead and license plate B Route the main switch lead above the clutch cable. Hook the clamp to the brack- C Line up the left handlebar switch lead coupler and et. Y Clamp the seat lock wire to the frame as shown in T Route it behind the starter motor lead. U Coolant reservoir tank hose Fuel tank drain hose Battery cover Cover Connecter cover Starter relay lead Fuel tank breather hose Battery negative lead Brake fluid reservoir hose Battery negative lead coupler Lean angle cut-off switch I To the sidestand switch.

B Point the L-shape terminal to the front side of the ve- J To the speed sensor. U Insert the enwinding clamp of the wire harness into AE Pass the spark plug leads 1 and 4 through the the hole of the rear frame.

AM Route the spark plug leads 2 and 3 behind the air cut-off valve hose. It is inserted until it makes a click sound the connec- Fuel hose tor, and it checks that a connector does not fail out.

Coolant breather hose B Pass the coolant reservoir tank hose hangs down Coolant reservoir tank downward from back of the bolt. Coolant reservoir tank hose C Insert this portion securely. Clamp D Spittle is turned back.

Clip B Point the paint marking upward. Roll over valve C Pass the canister hose and balance hose behind Canister hoes the bolt. Balance hose D Pass the canister hose outside, pass the balance Coolant reservoir tank hose inside. L It may open and close to direction of which. All notches gear at the time of attachment.

M Pass the coolant reservoir tank hose and the fuel tank drain hose inside of the clamp. N Point the knob of clamp downward. Page Chk Adj Air induction system hose for damage. See page S Replace any damaged parts if necessary. Page 79 See page Lubricate the throttle grip housing and cable.

NOTE: From mi km or 36 months, repeat the maintenance intervals starting from mi km or 12 months. Seat For installation, reverse the removal procedure. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Do not forcefully disconnect the hose with tools. Install: S fuel pump 4 Nm 0. S Always use a new fuel pump gasket.

S Install the fuel pump as shown in the illustra- tion. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center TDC on the compression stroke. Measure: S valve clearance Out of specification! Valve clearance cold Intake valve 0. Turn the crankshaft counterclockwise. S When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase. Round off the original valve pad number ac- cording to the following table.

S Lubricate the camshaft bearings, camshaft lobes and camshaft journals. S First, install the exhaust camshaft. S Align the camshaft marks with the camshaft cap marks. S Turn the crankshaft counterclockwise several full turns to seat the parts. Measure: S engine idling speed Out of specification! Adjust: S throttle body synchronization a. With throttle body 1 as standard, adjust throttle bodies 2, 3, and 4 using the air screws 1.

Check: S throttle cable free play a Out of specification! Loosen the locknut 1. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free play is Direction increased. Remove: S radiator lower bolt 1 S radiator lower hose bracket bolt 2 2. Install: S spark plug 18 Nm 1.

If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and mea- sure again. Refer to the following table.

Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than Stand the motorcycle on a level surface. S Make sure the motorcycle is upright. Start the engine, warm it up for several min- utes, and then turn it off. If the oil filter cartridge is also to be replaced, perform the following procedure. Remove the oil filter cartridge 1 with an oil filter wrench 2.

Oil filter wrench , YU b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. Install: S engine oil filler cap Check: S engine for engine oil leaks Measure: S engine oil pressure at the following conditions Engine oil pressure kPa 2. Check: S clutch cable free play a Out of specification! Clutch cable free play at the end of the clutch lever 10 X 15 mm 0.

Check: S coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket outlet joint 7 S water jacket hose 8 S water pump outlet pipe Disconnect: S coolant reservoir cap 1 4.

Drain: S coolant from the coolant reservoir tank 5. Therefore, do not remove the radiator cap when the en- gine is hot. Install: S coolant reservoir tank Connect: S coolant reservoir hose Fill: S cooling system with the specified amount of the recom- mended coolant Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio antifreeze:water Quantity However, if dis- tilled water is not available, soft water may be used. S If coolant comes into contact with painted surfaces, immediately wash them with wa- ter.

S Do not mix different types of antifreeze. Adjust: S brake lever position distance a from the throttle grip to the brake lever NOTE: S While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. Check: S brake pedal position distance a from the top of the rider footrest to the top of the brake pedal Out of specification!

Brake pedal position below the top of the rider footrest Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

S a brake hose is loosened, disconnected or replaced. S the brake fluid level is very low. S brake operation is faulty.

Tighten the bleed screw and then release the brake lever or brake pedal. Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swin- garm or cause an accident. Tighten both locknuts to specification. Locknut 16 Nm 1. Tighten the wheel axle nut to specification.

NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Loosen the lower ring nut 6 completely, then tighten it to specification. Lower ring nut final tightening torque 18 Nm 1.

Check the steering head for looseness or binding by turning the front fork all the way in both directions. Repeat the above procedure on the opposite handlebar. If the steering head tension is out of specifi- cation both handlebars should be within specification , remove the upper bracket and loosen or tighten the upper ring nut. S The tire pressure and the suspension must be adjusted according to the total weight including cargo, rider, passenger and ac- cessories and the anticipated riding speed.

Page Ltd. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Recommended lubricant Molybdenum disulfide grease Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.

Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging. Install: S battery 7. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

Disconnect: S headlight bulb cover S headlight coupler 1 3. Remove: S headlight bulb holder 1 4. Adjust: S headlight beam vertically a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Headlight beam is Direction lowered. Oil seal left and right Wheel bearing left and right Spacer For assembly, reverse the disassembly procedure.

Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits! Remove the wheel bearings 3 with a gener- al bearing puller. Install the new wheel bearings and oil seals in the reverse order of disassembly.

Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification! Brake disc thickness limit minimum Front: 4. Insert the wheel axle. NOTE: Install the tire and wheel with the mark 1 point- ing in the direction of wheel rotation. Lower the front wheel so that it is on the ground. Spin the front wheel. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

Replace: S rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.

S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.