Yamaha Fz6 N Service Manual
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3 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE......................................................................... 3-1 INTRODUCTION ........................... ......................................................... 3-1 ENGINE ......................................................................................................... 3-4 ADJUSTING THE VALVE CLEARANCE ................................................ 3-4 SYNCHRONIZING THE THROTTLE BODIES ....................................... 3-6 ADJUSTING THE EXHAUST GAS VOLUME (STANDARD) .................. 3-8 ADJUSTING THE EXHAUST GAS VOLUME (HIGH-GRADE) .............. 3-8 ADJUSTING THE ENGINE ID LING SPEED .......................................... 3-9 ADJUSTING THE THROTTLE CABLE FREE PLAY ............................ 3-10 CHECKING THE SPARK PLUGS ......................................................... 3-11 MEASURING THE COMPRESSION PRESSURE ............................... 3-12 CHECKING THE ENGINE OI L LEVEL ................................................. 3-13 CHANGING THE ENGINE OIL ............................................................. 3-14 MEASURING THE ENGINE OI L PRESSURE ..................................... 3-15 ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-16 CLEANING THE AIR FILTER ELEMENT ............................................. 3-17 CHECKING THE THROTTLE BODY JOINTS ...................................... 3-18 CHECKING THE FUEL LINE ............................................................... 3-18 CHECKING THE CRANKCASE BREATHER HOSE ............................ 3-18 CHECKING THE EXHAUST SYSTEM ................................................. 3-19 CHECKING THE COOLANT LEVEL .................................................... 3-19 CHECKING THE COOLING SYSTEM ................................................. 3-20 CHANGING THE COOLANT ................................................................ 3-20 CHASSIS .................................................................................................... 3-23 ADJUSTING THE FRONT DISC BRAKE ............................................. 3-23 ADJUSTING THE REAR DISC BRAKE ............................................... 3-23 CHECKING THE BRAKE FLUID LEVEL .............................................. 3-24 CHECKING THE FRONT BRAKE PADS .............................................. 3-24 CHECKING THE REAR BRAKE PADS ................................................ 3-25 CHECKING THE FRONT BRAKE HOSES........................................... 3-25 CHECKING THE REAR BRAKE HOSE ............................................... 3-25 ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................. 3-25 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................. 3-26 ADJUSTING THE SHIFT PEDAL ......................................................... 3-28 ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-28 LUBRICATING THE DRIVE CHAIN ...................................................... 3-29 CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-29 CHECKING THE FRONT FORK .......................................................... 3-30 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................ 3-31 CHECKING THE TIRES ....................................................................... 3-31 CHECKING THE WHEELS .................................................................. 3-34 CHECKING AND LUBRICATING THE CABLES .................................. 3-34 LUBRICATING THE LEVER S ............................................................... 3-34 LUBRICATING THE PEDAL ................................................................. 3-34 LUBRICATING THE SIDESTAND ......................................................... 3-34 LUBRICATING THE CENTERSTAND .................................................. 3-34 LUBRICATING THE REAR SUSPENSION .......................................... 3-34
ELECTRICAL SYSTEM.............................................................................. 3-35 REPLACING THE HEADLIGHT BULBS............................................... 3-35 ADJUSTING THE HEADLIGHT BEAMS .............................................. 3-35
PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly ov erhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be perform ed by a Yamaha dealer as they require special tools, data and technical skills. NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READ- ING (X 1000 km) Annual check 1 10203040 1 * Fuel line Check fuel hoses for cracks or dam- age. √√√√ √ 2 * Spark plugs Check condition. Clean and regap. √√ Replace. √√ 3 * Valves Check valve clearance. Adjust. Every 40000 km 4 Air filter ele- ment Replace. √ 5Clutch Check operation. Adjust. √√√√√ 6 * Front brake Check operation, fluid level and vehi- cle for fluid leakage. √√√√√ √ Replace brake pads. Whenever worn to the limit 7*Rear brake Check operation, fluid level and vehi- cle for fluid leakage. √√√√√ √ Replace brake pads. Whenever worn to the limit 8 * Brake hoses Check for cracks or damage. √√√√ √ Replace. Every 4 years 9 * Wheels Check runout and for damage. √√√√ 10 * Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. √√√√ √ 11 * Wheel bearings Check bearing for looseness or dam- age. √√√√ 12 * Swingarm Check operation and for excessive play. √√√√ Lubricate with lithium-soap-based grease. Every 50000 km
PERIODIC MAINTENANCE 3-2 13 Drive chain Check chain slack, alignment and condition. Adjust and lubricate chain with a special O-ring chain lubricant thor- oughly. Every 1000 km and after wash- ing the vehicle or riding in the rain 14 * Steering bear- ings Check bearing play and steering for roughness. √√√√√ Lubricate with lithium-soap-based grease. Every 20000 km 15 * Chassis fasten- ers Make sure that all nuts, bolts and screws are properly tightened. √√√√ √ 16 Sidestand, cen- terstand Check operation. Lubricate. √√√√ √ 17 * Sidestand switch Check operation. √√√√√ √ 18 * Front fork Check operation and for oil leakage. √√√√ 19 * Shock absorber assembly Check operation and shock absorber for oil leakage. √√√√ 20 * Fuel injection Adjust engine idling speed and syn- chronization. √√√√√ √ 21 Engine oil Change. Check oil level and vehicle for oil leakage. √√√√√ √ 22 Engine oil filter cartridge Replace. √√√ 23 * Cooling system Check coolant level and vehicle for coolant leakage. √√√√ √ Change. Every 3 years 24 * Front and rear brake switches Check operation. √√√√√ √ 25 Moving parts and cables Lubricate. √√√√ √ 26 * Throttle grip housing and cable Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. √√√√ √ 27 * Air induction system Check the air cut-off valve, reed valve, and hose for damage. Replace the entire air induction sys- tem if necessary. √√√√ √ 28 * Muffler and exhaust pipe Check the screw clamp for loose- ness. √√√√√ 29 * Lights, signals and switches Check operation. Adjust headlight beam. √√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READ- ING (X 1000 km) Annual check 1 10203040
PERIODIC MAINTENANCE 3-3 NOTE: Air filter This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.
ENGINE 3-4 EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-114. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Battery box Battery box bracket Refer to GENERAL CHASSIS on page 4- 1. Throttle bodies Refer to THROTTLE BODIES on page 7- 4. Air cut-off valve Refer to AIR INDUCTION SYSTEM on page 7-9. Radiator Radiator fan motor Refer to RADIATOR on page 6-1. 2. Remove: Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5-8. 3. Remove: Pickup rotor cover “1” 4. Measure: Valve clearance Out of specification → Adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark “a” on the pickup rotor with the crankcase mating sur- face “b”. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thick-ness gauge “1”. NOTE: If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance (cold) Intake 0.13–0.20 mm (0.0051–0.0079 in) Exhaust 0.23–0.30 mm (0.0091–0.0118 in)
ENGINE 3-5 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: Camshafts NOTE: Refer to CAMSHAFTS on page 5-8. When removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. b. Select the proper valve pad from the follow- ing table. NOTE: The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Valve clearance measuring sequence Cylinder #1 → #2 → #4 → #3 A. Front A. Degrees that the crankshaft is turned counterclockwise B. Cylinder C. Combustion cycle Cylinder #2 180 ° Cylinder #4 360 ° Cylinder #3 540 ° Valve lapper 90890-04101 Valve lapping tool YM-A8998 Valve pad range Nos. 120–240 Valve pad thickness 1.20–2.40 mm (0.0472–0.0945 in) Available valve pads 25 thicknesses in 0.05 mm (0.002 in) increments
ENGINE 3-6 Since valve pads of various sizes are origi-nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original. c. Round off the original valve pad number according to the following table. EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approxi- mation. The valve clearance must be mea- sured again and the above steps should be repeated if the measurement is still incorrect. e. Install the new valve pad “1” and the valve lifter “2”. NOTE: Lubricate the valve pad with molybdenum disulfide grease. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Install the valve lifter and the valve pad in the correct place. f. Install the exhaust and intake camshafts, timing chain and camshaft caps. NOTE: Refer to CAMSHAFTS on page 5-8. Lubricate the camshaft bearings, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft marks with the camshaft cap marks. Turn the crankshaft counterclockwise several full turns to seat the parts. g. Measure the valve clearance again. h. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance adjustment steps until the specified clear- ance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: All removed parts NOTE: For installation, reverse the removal proce- dure. EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. 2. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Last digit Rounded value 0 or 2 0 55 810 Camshaft cap bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
ENGINE 3-7 Air filter caseRefer to GENERAL CHASSIS on page 4- 1. 3. Install: Vacuum gauge “1” (onto the synchronizing hose “2”) 4. Install: Air filter case Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. 5. Start the engine and let it warm up for sev- eral minutes. 6. Check: Engine idling speed Out of specification → Adjust. Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3-9. 7. Adjust: Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. With throttle body #1 “2” as standard, adjust throttle bodies #2 “3”, #3 “4”, and #4 “5” using the air screw “1”. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. If the air screw is removed, turn the screw 3/ 4 turn in and be sure to synchronize the throttle body. CAUTION: ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body syncroni- zation. NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. Measure: Engine idling speed Out of specification → Adjust. Make sure that the vacuum pressure is within specification. 9. Stop the engine and remove the measuring equipment. 10. Adjust: Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-10. Vacuum gauge90890-03094 Carburetor synchronizer YU-44456 Engine idling speed1250–1350 r/min Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456 Intake vacuum29.0 kPa (8.6 inHg) (218 mmHg)