Yamaha Fz6 N Service Manual
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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)