Home > Yamaha > Motorcycle > Yamaha Fz6 N Service Manual

Yamaha Fz6 N Service Manual

    Download as PDF Print this page Share this page

    Have a look at the manual Yamaha Fz6 N Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.

    Page
    of 538
    							
    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) 
    						
    All Yamaha manuals Comments (0)

    Related Manuals for Yamaha Fz6 N Service Manual