Yamaha Fz6n Manual
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3-34 CLEANING THE AIR FILTER ELEMENT / CHECKING THE THROTTLE BODY JOINTSCHK ADJ NOTE: When installing the air filter element into the air filter case cover, make sure their sealing sur- faces are aligned to prevent any air leaks. 6. Install: fuel tank Refer to “FUEL TANK”. front cowling inner panel (left and right) Refer to “COWLINGS”. rider seat Refer to “SEAT”. EAS00095 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” in chapter 7. 2. Check: throttle body joints 1 Cracks / damage Replace. 3. Install: throttle bodies Refer to “THROTTLE BODIES” in chapter 7.
3-35 CHECKING THE FUEL AND BREATHER HOSES / CHECKING THE CRANKCASE BREATHER HOSECHK ADJ NOTE: CAUTION: EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remove: rider seat Refer to “SEAT”. front cowling inner panel (left and right) Refer to “COWLINGS” fuel tank Refer to “FUEL TANK”. 2. Check: breather hose 1 fuel hose 2 Cracks / damage Replace. Loose connection Connect properly. Before removing the fuel hose, place a few rags in the area under where it will be re- moved. There is a white mark on the fuel tank breather hose. Refer to “CABLE ROUTING” in chapter 2. 3. Install: fuel tank Refer to “FUEL TANK”. front cowling inner panel (left and right) Refer to “COWLINGS”. rider seat Refer to “SEAT”. EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: rider seat Refer to “SEAT”. front cowling inner panel (left and right) Refer to “COWLINGS”. fuel tank Refer to “FUEL TANK”. 2. Check: crankcase breather hose 1 Cracks / damage Replace. Loose connection Connect properly. Make sure the crankcase breather hose is routed correctly.
3-36 CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEMCHK ADJ 3. Install: fuel tank Refer to “FUEL TANK”. front cowling inner panel (left and right) Refer to “COWLINGS”. rider seat Refer to “SEAT”. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. 1. Remove: radiator Refer to “RADIATOR” in chapter 6. 2. Check: exhaust pipe 1 catalyst pipe 2 muffler 3 Cracks / damage Replace. gasket 4 Exhaust gas leaks Replace. 3. Check: tightening torque Exhaust pipe nut 5 20 Nm (2.0 mkg, 15 ftlb) Catalyst joint bolt 6 20 Nm (2.0 mkg, 15 ftlb) Muffler joint bolt 7 Muffler and muffler stay 8 20 Nm (2.0 mkg, 15 ftlb) Exhaust pipe and exhaust pipe stay 9 20 Nm (2.0 mkg, 15 ftlb) Catalyst pipe and catalyst pipe stay 10 20 Nm (2.0 mkg, 15 ftlb) 4. Install: radiator Refer to “RADIATOR” in chapter 6.
3-37 CHECKING THE COOLANT LEVEL CHK ADJ NOTE: CAUTION: NOTE: EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure the motorcycle 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. Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. Use only distilled water. However, if dis- tilled water is not available, soft water may be used. 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: coolant level Before checking the coolant level, wait a few minutes until it settles.
3-38 CHECKING THE COOLING SYSTEM / CHANGING THE COOLANTCHK ADJ EAS00104 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 outlet joint 7 water jacket hose 8 water pump outlet pipe 9 water pump outlet hose 10 Cracks / damage Replace. Refer to “COOLING SYSTEM” in chapter 6. EAS00105 CHANGING THE COOLANT 1. Remove: seat Refer to “SEAT”. front cowling inner panel (left and right) Refer to “COWLINGS”. fuel tank Refer to “FUEL TANK”. 2. Remove: coolant reservoir tank
3-39 CHANGING THE COOLANT CHK ADJ CAUTION: 10 Nm (1.0 mkg, 7.2 ftlb) 3. Disconnect: coolant reservoir cap 1 4. Drain: coolant (from the coolant reservoir tank) 5. Remove: radiator cap lock bolt 1 radiator cap 2 A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun- terclockwise toward the detent to allow any residual pressure to escape. When the his- sing 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. 6. Remove: coolant drain bolt (water pump) 1 (along with the copper washer) 7. Drain: coolant (from the engine and radiator) 8. Check: copper washer 1 New (coolant drain bolt-water pump 2) 9. Install: coolant drain bolt (water pump) (with copper washer)
3-40 CHANGING THE COOLANT CHK ADJ WARNING CAUTION: 10. Install: coolant reservoir tank 11. Connect: coolant reservoir hose 12. Fill: cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 2.0 L (1.76 Imp qt, 2.11 US qt) Coolant reservoir capacity 0.27 L (0.24 Imp qt, 0.29 US qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care. If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. If coolant splashes on your clothes, quick- ly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention. Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant.
3-41 CHANGING THE COOLANT CHK ADJ NOTE: Use only distilled water. However, if dis- tilled water is not available, soft water may be used. If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. Do not mix different types of antifreeze. 13. Install: radiator cap 14. Fill: coolant reservoir tank (with the recommended coolant to the maxi- mum level mark a) 15. Install: coolant reservoir cap 16. Start the engine, warm it up for several min- utes, and then stop it. 17. Check: coolant level Refer to “CHECKING THE COOLANT LEV- EL”. Before checking the coolant level, wait a few minutes until the coolant has settled. 18. Install: fuel tank Refer to “FUEL TANK”. front cowling inner panel (left and right) Refer to “COWLINGS”. seat Refer to “SEAT”.
3-42 ADJUSTING THE FRONT BRAKE CHK ADJ NOTE: a a WARNING CAUTION: EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: brake lever position (distance a from the throttle grip to the brake lever) 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 hold- er. Position #1 Distance is the largest. Position #5Distance is the smallest. After adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjust- ing dial. A soft or spongy feeling in the brake lever 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 in loss of control and possi- bly an accident. Therefore, check and if necessary, bleed the brake system. After adjusting the brake lever position, make sure there is no brake drag.
3-43 ADJUSTING THE REAR BRAKE CHK ADJ a b WARNING WARNING CAUTION: EAS00110 ADJUSTING THE REAR BRAKE 1. Check: brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification Adjust. Brake pedal position (below the top of the rider footrest) 25.8 mm (1.02 in) 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 ob- tained. Direction Brake pedal is raised. DirectionBrake pedal is lowered. 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. Locknut 18 Nm (1.8 mkg, 13 ftlb) 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 and could result in loss of control and possibly an accident. Therefore, check and, if neces- sary, bleed the brake system. After adjusting the brake pedal position, make sure there is no brake drag.