Yamaha Fz6 N Service Manual
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ABS (ANTI-LOCK BRAKE SYSTEM) 4-58 CAUTION: ECA14810 Check that the brake lever returns to its home position before the brake pedal returns to its home position. If the brake pedal returns to its home position before the brake lever does, check that the brake hoses are connected correctly to the hydraulic unit. If either the brake lever or brake pedal returns its home position slowly, check that the brake hoses are connected cor- rectly to the hydraulic unit. If the operation of the hydraulic unit is nor- mal, delete all of the malfunction codes. Hydraulic unit operation test 2 WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 1. Place the vehicle on the centerstand. 2. Set the main switch to “OFF”. 3. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. 4. Check: Battery voltage Lower than 12.8 V → Charge or replace the battery. NOTE: If the battery voltage is lower than 12.8 V, charge the battery and perform hydraulic unit operation test 1. If the battery voltage is lower than 10 V, the ABS warning light comes on and the ABS does not operate. 5. Connect the test coupler adaptor “1” to the test coupler “2”. 6. Set the engine stop switch to “ ”. 7. Set the main switch to “ON”. a. ABS warning light b. Main switch “ON” c. Comes on d. Goes off e. Flashes f. 2.0 seconds g. 3.0 second h. 0.5 second Battery voltage Higher than 12.8 V Test coupler adapter 90890-03149
ABS (ANTI-LOCK BRAKE SYSTEM) 4-59 NOTE: After setting the main switch to “ON”, wait (approximately 2 seconds) until the ABS warn- ing light goes off. 8. Push the start switch for at least 4 seconds. CAUTION: ECA14790 Do not operate the brake lever or the brake pedal. 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. NOTE: A reaction-force pulsating action is gener- ated in the brake lever “1” 0.5 second after the brake lever and the brake pedal are oper- ated simultaneously and continues for approximately 1 second. Be sure to continue to operate the brake lever and brake pedal even after the pulsat- ing action has stopped. 10. After the pulsating action has stopped in the brake lever, it is generated in the brake pedal “2” 0.5 second after and continues for approximately 1 second. NOTE: Be sure to continue to operate the brake lever and brake pedal even after the pulsating action has stopped. 11. After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second after and continues for approximately 1 second. CAUTION: ECA14800 Check that the pulsating action is felt in the brake lever, brake pedal, and again in the brake lever, respectively. If the pulsating action is felt in the brake pedal before it is felt in the brake lever, check that the brake hoses are connected correctly to the hydraulic unit. If the pulsating action is hardly felt in either the brake lever or brake pedal, check that the brake hoses are connected correctly to the hydraulic unit. 12. Set the main switch to “OFF”. 13. Remove the test coupler adaptor from the test coupler. 14. Set the main switch to “ON”. 15. Set the engine stop switch to “ ”. EAS22820 [D-6-5] TRIAL RUN After all checks and services are completed, always ensure the scooter has no problems by performing the trial running at a speed of faster than 10 km/h.
HANDLEBAR 4-60 EAS22840 HANDLEBAR * FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-SAHG Removing the handlebar Order Job/Parts to remove Q’ty Remarks1 Grip end 2 2 Handlebar grip 1 3 Clutch switch connector 1 Disconnect. 4 Left handlebar switch 1 5Clutch cable 1 6 Clutch lever 1 7 Right handlebar switch 1 8 Throttle grip 1 9 Throttle cable 2 10 Front brake light switch connector 1 Disconnect. 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 13 Upper handlebar holder 2 14 Upper handlebar holder 1 15 Handlebar 1 For installation, reverse the removal proce- dure.
HANDLEBAR 4-61 EAS22860 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Handlebar grip “1” NOTE: Blow compressed air between the left handle- bar and the handlebar grip, and gradually push the grip off the handlebar. 3. Disconnect: Clutch switch connector 4. Remove: Left handlebar switch “1” Clutch cable “2” Clutch lever holder “3” 5. Remove: Right handlebar switch “1” Throttle grip “2” Throttle cable 6. Disconnect: Front brake light switch connector 7. Remove: Front brake master cylinder holder “3” Front brake master cylinder Upper handlebar holder Handlebar EAS22880 CHECKING THE HANDLEBAR 1. Check: Handlebar “1” Bends/cracks/damage → Replace. WARNING EWA13690 Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. 2. Install: Handlebar grip ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS22930 INSTALLING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over.
HANDLEBAR 4-62 2. Install: Handlebar “1” Upper handlebar holders “2” Upper handlebar holder caps “3” (Stan- dard) CAUTION: ECA14250 First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. NOTE: Align the match marks “a” on the handlebar with the upper surface of the lower handlebar holders. 3. Install: Throttle cables Right handlebar switch “1” Throttle grip “2” NOTE: Align the projections “a” on the handlebar switch with the holes “b” in the handlebar. 4. Install: Brake master cylinder “1” Brake master cylinder holder “2” Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER on page 4- 39. NOTE: Align the mating surfaces of the brake master cylinder bracket with the punch mark (right handlebar switch side) “a” on the handlebar. 5. Install: Clutch lever holder “1” Upper handlebar holder bolt 23 Nm (2.3 m·kg, 17 ft·lb) A. FZ6-N/FZ6-NA/FZ6-S/FZ6-SA B. FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/ FZ6-SAHG
HANDLEBAR 4-63 Clutch cable NOTE: Align the slit on the clutch lever holder with the punch mark “a” on the handlebar. 6. Install: Left handlebar switch NOTE: Align the projection “a” on the left handlebar switch with the hole “b” on the handlebar. 7. Install: Handlebar grip Grip end ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. Adjust: Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-10. 9. Adjust: Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3-16. Grip end26 Nm (2.6 m·kg, 19 ft·lb) Throttle cable free play3.0–5.0 mm (0.12–0.20 in)
FRONT FORK 4-64 EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page 4-7. Front brake calipers Refer to FRONT BRAKE on page 4-23. 1 Front fender 1 2 Cap bolt 1 Loosen. 3 Upper bracket pinch bolt 1 Loosen. 4 Under bracket pinch bolt 1 Loosen. 5Front fork leg 1 For installation, reverse the removal proce- dure.
FRONT FORK 4-65 Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks1 Cap bolt 1 2O-ring 1 3Spacer 1 4 Washer 1 5 Front fork spring 1 6 Dust seal 1 7 Oil seal clip 1 8 Damper rod assembly bolt 1 9 Copper washer 1 10 Damper rod assembly 1 11 Oil seal 1 12 Washer 1 13 Inner tube 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Oil flow stopper 1 17 Outer tube 1 For assembly, reverse the disassembly pro- cedure.
FRONT FORK 4-66 EAS22970 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Loosen: Upper bracket pinch bolts “1” Cap bolt “2” Lower bracket pinch bolts “3” WARNING EWA13640 Before loosening the upper and lower bracket pinch bolts, support the front fork leg. 3. Remove: Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: Cap bolt Washer Spacer Fork spring 2. Drain: Fork oil NOTE: Stroke the inner tube several times while drain- ing the fork oil. 3. Remove: Dust seal “1” Oil seal clip “2” (with a flat-head screwdriver) CAUTION: ECA14180 Do not scratch the inner tube. 4. Remove: Damper rod assembly bolt Damper rod assembly NOTE: While holding the damper rod with the damper rod holder “1” and T-handle “2”, loosen the damper rod assembly bolt. 5. Remove: Inner tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but care- fully. Damper rod holder90890-01294 Damping rod holder set YM-01300 T-handle 90890-01326 YM-01326
FRONT FORK 4-67 CAUTION: ECA14190 Excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23010 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: Inner tube “1” Outer tube “2” Bends/damage/scratches → Replace. WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: Spring free length “a” Out of specification → Replace. 3. Check: Damper rod “1” Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. Oil flow stopper “2” Damage → Replace. CAUTION: ECA14200 The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material. When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check: Cap bolt O-ring Damage/wear → Replace. Fork spring free length 354.0 mm (13.94 in) Limit 347.0 mm (13.66 in)