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Yamaha Fz6 N Service Manual

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    Page
    of 538
    							
    ENGINE
    3-18
    Refer to GENERAL CHASSIS on page 4-
    1.
    EAS21010
    CHECKING THE THROTTLE BODY JOINTS
    The following procedure applies to all of the 
    throttle body joints and intake manifolds.
    1. Remove: Throttle bodies Refer to THROTTLE BODIES on page 7-
    4.
    2. Check:  Throttle body joints “1”
    Cracks/damage  → Replace.
    3. Install:  Throttle bodies Refer to THROTTLE BODIES on page 7-
    4.
    EAS21030
    CHECKING THE FUEL LINE
    The following procedure applies to all of the 
    fuel, vacuum and breather hoses.
    1. Remove:Seat Refer to GENERAL CHASSIS on page 4-
    1.
     Fuel tank Refer to FUEL TANK on page 7-1.
    2. Check:
     Breather hose “1”
     Fuel hose “2” Cracks/damage  → Replace.
    Loose connection  → Connect properly.
    NOTE:
     Before removing the fuel hose, place a few 
    rags in the area under where it will be 
    removed.
     There is a white mark on the fuel tank  breather hose.
    Refer to CABLE ROUTING on page 2-47.
    CAUTION:
    ECA14940
    Make sure the fuel tank breather hose is 
    routed correctly.
    3. Install:Fuel tank Refer to FUEL TANK on page 7-1.
    Seat Refer to GENERAL CHASSIS on page 4-
    1.
    EAS21070
    CHECKING THE CRANKCASE BREATHER 
    HOSE
    1. Remove:Seat Refer to GENERAL CHASSIS on page 4-
    1.
    Fuel tank Refer to FUEL TANK on page 7-1.
    2. Check:
     Crankcase breather hose “1” Cracks/damage  → Replace.
    Loose connection  → Connect properly.
    CAUTION:
    ECA13450
    Make sure the crankcase breather hose is 
    routed correctly.
    3. Install:
    Fuel tank
    Refer to FUEL TANK on page 7-1. 
    						
    							
    ENGINE
    3-19
    SeatRefer to GENERAL CHASSIS on page 4-
    1.
    EAS21080
    CHECKING THE EXHAUST SYSTEM
    The following procedure applies to all of the 
    exhaust pipes and gaskets.
    1. Remove:Radiator
    Refer to RADIATOR on page 6-1.
    2. Check:  Exhaust pipe “1”
     Catalytic converter pipe “2”
     Muffler “3” Cracks/damage  → Replace.
    Gasket “4” Exhaust gas leaks  → Replace.
    3. Check:
     Tightening torque
     Exhaust pipe nut “5”
     Catalytic converter joint bolt “6”
     Muffler joint bolt “7”
     Muffler stay bolt “8”
     Exhaust pipe stay bolt “9”
     Catalytic converter pipe stay bolt “10” 4. Install:
    Radiator Refer to RADIATOR on page 6-1.
    EAS21110
    CHECKING THE COOLANT LEVEL
    1. Stand the vehicle on a level surface.
    NOTE:
     Place the vehicle on a suitable stand.
     Make sure the vehicle is upright.
    2. Check: Coolant level The coolant level should be between the 
    maximum level mark “a” and minimum level 
    mark “b”.
    Below the minimum level mark  → Add the 
    recommended coolant to the proper level.
    CAUTION:
    ECA13470
     Adding water instead of coolant lowers  the antifreeze content of the coolant. If 
    water is used instead of coolant check, 
    and if necessary, correct the antifreeze 
    concentration of the coolant.
     Use only distilled water. However, if dis- tilled water is not av ailable, soft water 
    may be used.
    Exhaust pipe nut
    20 Nm (2.0 m·kg, 15 ft·lb)
    Catalytic converter joint bolt 20 Nm (2.0 m·kg, 15 ft·lb)
    Muffler joint bolt 20 Nm (2.0 m·kg, 15 ft·lb)
    Muffler stay bolt
    20 Nm (2.0 m·kg, 15 ft·lb)
    Exhaust pipe stay bolt 20 Nm (2.0 m·kg, 15 ft·lb)
    Catalytic converter pipe stay 
    bolt 20 Nm (2.0 m·kg, 15 ft·lb) 
    						
    							
    ENGINE
    3-20
    3. Start the engine, warm it up for several minutes, and then turn it off.
    4. Check:  Coolant level
    NOTE:
    Before checking the coolant level, wait a few 
    minutes until it settles.
    EAS21120
    CHECKING THE COOLING SYSTEM
    1. Check:
     Radiator “1”
     Radiator inlet hose “2”
     Radiator outlet hose “3”
    Oil cooler “4”
     Oil cooler inlet hose “5”
     Oil cooler outlet hose “6”
     Water jacket joint “7”
     Water jacket joint hose “8”
     Oil cooler inlet pipe “9”
     Water pump outlet hose “10” Cracks/damage  → Replace.
    Refer to RADIATOR on page 6-1.
    EAS21130
    CHANGING THE COOLANT
    1. Remove:  Coolant reservoir “1”
     Coolant reservoir cap “2”
    2. Drain:  Coolant
    (from the coolant reservoir)
    3. Remove:  Radiator cap lock bolt “1”
     Radiator cap “2” 
    						
    							
    ENGINE
    3-21
    WARNING
    EWA13030
    A hot radiator is under pressure. Therefore, 
    do not remove the radiator cap when the 
    engine is hot. Scalding hot fluid and steam 
    may be blown out, which could cause seri-
    ous injury. When the engine has cooled, 
    open the radiator cap as follows:
    Place a thick rag or a towel over the radia-
    tor cap and slowly turn the radiator cap 
    counterclockwise toward the detent to 
    allow any residual pressure to escape. 
    When the hissing sound has stopped, 
    press down on the radiator cap and turn it 
    counterclockwise to remove.The following procedure applies to all of the 
    coolant drain bolts  and copper washers.
    4. Remove:  Coolant drain bolt (water pump) “1” (along with the copper washer)
    5. Drain:  Coolant (from the engine and radiator)
    6. Check:
     Copper washer “1” 
    7. Install:  Coolant drain bolt (water pump) “2”
    8. Install:  Coolant reservoir
    9. Fill:  Cooling system
    (with the specified amount of the recom-
    mended coolant)
    Handling notes for coolant
    Coolant is potentially harmful and should 
    be handled with special care.
    WARNING
    EWA13040
     If coolant splashes in your eyes, thor-
    oughly wash them with water and consult 
    a doctor.
     If coolant splashes on your clothes, 
    quickly wash it away with water and then 
    with soap and water.
     If coolant is swallowed, induce vomiting 
    and get immediate medical attention.
    CAUTION:
    ECA13480
     Adding water instead of coolant lowers 
    the antifreeze content of the coolant. If 
    water is used instead of coolant check, 
    and if necessary, correct the antifreeze 
    concentration of the coolant.
     Use only distilled water. However, if dis-
    tilled water is not av ailable, soft water 
    may be used.
     If coolant comes into contact with painted 
    surfaces, immediately wash them with 
    water.
     Do not mix different types of antifreeze.
    10. Install:Radiator cap
    11. Fill:
     Coolant reservoir (with the recommended coolant to the max-
    imum level mark “a”)
    Coolant drain bolt (water pump)10 Nm (1.0 m·kg, 7.2 ft·lb)
    New
    Recommended antifreezeHigh-quality ethylene glycol
    antifreeze containing corrosion
    inhibitors for aluminum engines
    Mixing ratio1:1 (antifreeze:water)
    Radiator capacity (including all
    routes) 2.00 L (2.11 US qt) (1.76
    Imp.qt)
    Coolant reservoir capacity (up
    to the maximum level mark) 0.25 L (0.26 US qt) (0.22
    Imp.qt) 
    						
    							
    ENGINE
    3-22
    12. Install: Coolant reservoir cap
    13. Start the engine, warm it up for several  minutes, and then stop it.
    14. Check:  Coolant level Refer to CHECKING THE COOLANT 
    LEVEL on page 3-19.
    NOTE:
    Before checking the coolant level, wait a few 
    minutes until the coolant has settled. 
    						
    							
    CHASSIS
    3-23
    EAS21140
    CHASSIS
    EAS21160
    ADJUSTING THE FRONT DISC BRAKE
    1. Adjust: Brake lever position (distance “a” from the throttle grip to the 
    brake lever)
    NOTE:
     While pushing the brake lever forward, turn 
    the adjusting dial “1” until the brake lever is in 
    the desired position.
     Be sure to align the setting on the adjusting  dial with the arrow mark “2” on the brake 
    lever holder.
    WARNING
    EWA13060
     After adjusting the brake lever position, make sure the pin on the brake lever 
    holder is firmly inserted in the hole in the 
    adjusting dial.
     A soft or spongy feeling in the brake lever  can indicate the presence of air in the 
    brake system. Before the vehicle is oper-
    ated, the air must be removed by bleeding 
    the brake system. Air in the brake system 
    will considerably reduce in loss of control 
    and possibly an accident. Therefore, 
    check and if necessary, bleed the brake 
    system.
    CAUTION:
    ECA13490
    After adjusting the brake lever position, 
    make sure there is no brake drag.
    EAS21190
    ADJUSTING THE REAR DISC BRAKE
    1. Check: Brake pedal position
    (distance “a” from the top of the rider foot-
    rest to the top of the brake pedal)
    Out of specification  → Adjust.
    2. Adjust:  Brake pedal position
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Loosen the locknut “1”.
    b. Turn the adjusting bolt “2” in direction “a” or  “b” until the specified brake pedal position 
    is obtained.
    WARNING
    EWA13070
    After adjusting the brake pedal position, 
    check that the end of the adjusting bolt “c” 
    is visible through the hole “d”.
    c. Tighten the locknut “1” to specification.
    Position #1
    Distance “a” is the largest.
    Position #5 Distance “a” is the smallest.
    Brake pedal position (below the
    top of the rider footrest)25.8 mm (1.02 in)
    Direction “a”
    Brake pedal is raised.
    Direction “b” Brake pedal is lowered. 
    						
    							
    CHASSIS
    3-24
    WARNING
    EWA4S81005
    A soft or spongy feeling in the brake pedal 
    can indicate the presence of air in the brake 
    system. Before the vehicle is operated, the 
    air must be removed by bleeding the brake 
    system. Air in the brake system will consid-
    erably reduce braking performance.
    CAUTION:
    ECA13510
    After adjusting the brake pedal position, 
    make sure there is no brake drag.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    3. Adjust: Rear brake light switch Refer to ADJUSTING THE REAR BRAKE 
    LIGHT SWITCH on page 3-25.
    EAS21240
    CHECKING THE BRAKE FLUID LEVEL
    1. Stand the vehicle on a level surface.
    NOTE:
     Place the vehicle on a suitable stand.
     Make sure the vehicle is upright.
    2. Check:
     Brake fluid level Below the minimum level mark “a”  → Add 
    the recommended brake fluid to the proper 
    level.
    WARNING
    EWA13090
     Use only the designated brake fluid. 
    Other brake fluids may cause the rubber 
    seals to deteriorate, causing leakage and 
    poor brake performance.
     Refill with the same type of brake fluid  that is already in the system. Mixing brake 
    fluids may result in a harmful chemical 
    reaction, leading to poor brake perfor-
    mance.
     When refilling, be careful that water does  not enter the brake fluid reservoir. Water 
    will significantly lower the boiling point of 
    the brake fluid and could cause vapor 
    lock.
    CAUTION:
    ECA13540
    Brake fluid may damage painted surfaces 
    and plastic parts. 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.
    EAS21250
    CHECKING THE FRONT BRAKE PADS
    The following procedure applies to all of the 
    brake pads.
    1. Operate the brake.
    2. Check: Front brake pad Wear indicators “a” almost touch the brake 
    disc  → Replace the brake pads as a set.
    Refer to FRONT BRAKE on page 4-23.
    Locknut 18 Nm (1.8 m·kg, 13 ft·lb)
    Recommended fluidDOT 4
    A. Front brake
    B. Rear brake 
    						
    							
    CHASSIS
    3-25
    EAS21260
    CHECKING THE REAR BRAKE PADS
    The following procedure applies to all of the 
    brake pads.
    1. Operate the brake.
    2. Check: Rear brake pad
    Wear indicators “b” almost touch the brake 
    disc  → Replace the brake pads as a set.
    Refer to REAR BRAKE on page 4-41.
    EAS21280
    CHECKING THE FRONT BRAKE HOSES
    The following procedure applies to all of the 
    brake hoses and brake hose clamps.
    1. Check:  Brake hose
    Cracks/damage/wear  → Replace.
    2. Check:  Brake hose clamp Loose  → Tighten the clamp bolt.
    3. Hold the vehicle upright and apply the 
    brake several times.
    4. Check:  Brake hose
    Brake fluid leakage  → Replace the dam-
    aged hose.
    Refer to FRONT BRAKE on page 4-23.
    EAS21290
    CHECKING THE REAR BRAKE HOSE
    1. Check:  Brake hose
    Cracks/damage/wear  → Replace.
    2. Check:  Brake hose clamp Loose Connection  → Tighten the clamp 
    bolt.
    3. Hold the vehicle upright and apply the rear  brake several times.
    4. Check:
     Brake hose Brake fluid leakage  → Replace the dam-
    aged hose.
    Refer to REAR BRAKE on page 4-41.
    EAS21330
    ADJUSTING THE REAR BRAKE LIGHT 
    SWITCH
    NOTE:
    The rear brake light switch is operated by 
    movement of the brake pedal. The rear brake 
    light switch is properly adjusted when the 
    brake light comes on just before the braking 
    effect starts.
    1. Check:
     Rear brake light operation timing Incorrect  → Adjust.
    2. Adjust:
     Rear brake light operation timing
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Hold the main body “1” of the rear brake  light switch so that it does not rotate and 
    turn the adjusting nut “2” in direction “a” or 
    “b” until the rear brake light comes on at the 
    proper time.
    Direction “a”
    Brake light comes on sooner.
    Direction “b” Brake light comes on later. 
    						
    							
    CHASSIS
    3-26
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    EAS21340
    BLEEDING THE HYDRAULIC BRAKE SYS-
    TEM
    WARNING
    EWA13100
    Bleed the hydraulic brake system when-
    ever:
     the system is disassembled.
     a brake hose is loosened, disconnected or replaced.
     the brake fluid level is very low.
     brake operation is faulty.
    NOTE:
     Be careful not to spill any brake fluid or allow  the brake master cylinder reservoir or brake 
    fluid reservoir to overflow.
     When bleeding the hydraulic brake system,  make sure there is always enough brake fluid 
    before applying the brake. Ignoring this pre-
    caution could allow air to enter the hydraulic 
    brake system, consider ably lengthening the 
    bleeding procedure.
     If bleeding is difficult, it may be necessary to  let the brake fluid settle for a few hours. 
    Repeat the bleeding procedure when the tiny 
    bubbles in the hose have disappeared.
    1. Bleed:  Hydraulic brake system
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Fill the brake fluid reservoir to the proper  level with the recommended brake fluid.
    b. Install the diaphragm (brake master cylin-
    der reservoir or brake fluid reservoir).
    c. Connect a clear plastic hose “1” tightly to  the bleed screw “2”. d. Place the other end of the hose into a con-
    tainer.
    e. Slowly apply the brake lever several times.
    f. Fully pull the brake lever or fully press  down the brake pedal and hold it in posi-
    tion.
    g. Loosen the bleed screw.
    NOTE:
    Loosening the bleed screw will release the 
    pressure and cause the brake lever to contact 
    the throttle grip or the brake pedal to fully 
    extend.
    h. Tighten the bleed screw and then release 
    the brake lever or brake pedal.
    i. Repeat steps (e) to (h) until all of the air  bubbles have disappeared from the brake 
    fluid in the plastic hose.
    j. Tighten the bleed screw to specification.
    k. Fill the brake fluid reservoir to the proper  level with the recommended brake fluid.
    Refer to CHECKING THE BRAKE FLUID 
    LEVEL on page 3-24.
    A. Front
    B. Rear
    Bleed screw6 Nm (0.6 m·kg, 4.3 ft·lb) 
    						
    							
    CHASSIS
    3-27
    WARNING
    EWA13110
    After bleeding the hydraulic brake system, 
    check the brake operation.
    ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
    Bleeding the ABS brake
    WARNING
    EWA14010
    Bleed the ABS whenever:
     the system is disassembled.
     a brake hose is loosened, disconnected or replaced.
     the brake fluid lever is very low.
     brake operation is faulty.
    NOTE:
     Be careful not to spill any brake fluid or allow  the brake master cylinder reservoir or brake 
    fluid reservoir to overflow.
     When bleeding the ABS, make sure there is 
    always enough brake fluid before applying 
    the brake. Ignoring this precaution could 
    allow air to enter the ABS, considerably 
    lengthening the bleeding procedure.
     If bleeding is difficult, it may be necessary to  let the brake fluid settle for a few hours.
     Repeat the bleeding procedure when the tiny 
    bubbles in the hose have disappeared.
    1. Bleed:  ABS
    ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
    a. Fill the brake fluid reservoir to the proper  level with the recommended brake fluid.
    b. Install the diaphragm (brake master cylin-
    der reservoir or brake fluid reservoir).
    c. Connect a clear plastic hose “1” tightly to  the bleed screw “2”. d. Place the other end of the hose into a con-
    tainer.
    e. Slowly apply the brake several times.
    f. Fully squeeze the brake lever or fully  depress the brake pedal and hold it in posi-
    tion.
    g. Loosen the bleed screw.
    NOTE:
    Loosening the bleed screw will release the 
    pressure and cause the brake lever to contact 
    the throttle grip or the brake pedal to fully 
    extend.
    h. Tighten the bleed screw, and then release  the brake lever or brake pedal.
    i. Repeat steps (e) to (h) until all of the air  bubbles have disappeared from the brake 
    fluid in the plastic hose.
    j. Check the operation of the hydraulic unit. Refer to HYDRAULIC UNIT OPERATION 
    TEST on page 4-56.
    CAUTION:
    ECA14780
    Make sure that the main switch is set to 
    “OFF” before checking the operation of the 
    hydraulic unit.
    k. After operating the ABS, repeat steps (e) to (i), and then fill the primary circuit with the 
    recommended brake fluid.
    l. Tighten the bleed screw to the specified 
    torque.
    m. Fill the brake master cylinder reservoir or  brake fluid reservoir to the proper level with 
    the recommended brake fluid.
    Refer to CHECKING THE BRAKE FLUID 
    LEVEL on page 3-24.
    A. Front
    B. Rear
    Brake caliper bleed screw6 Nm (0.6 m·kg, 4.3 ft·lb) 
    						
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