Yamaha Fz6n Manual

							4-5
FRONT WHEEL AND BRAKE DISCSCHAS
CAUTION:
c. Remove the wheel bearings 3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race 
3.
Use a socket 
4 that matches the diameter of
the wheel bearing outer race and oil seal.
EAS00531
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling 
 Replace.
2. Measure:

brake disc deflection
Out of specification 
 Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front: 0.1 mm (0.004 in)
Rear: 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 2 
 3 mm (0.08 

0.12 in) below the edge of the brake disc. 
						

							4-6
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification 
 Replace.
Brake disc thickness limit
(minimum)
Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
Brake disc bolt
18 Nm (1.8 m
kg, 13 ft
lb)
LOCTITE

d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs. 
						

							4-7
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
72 Nm (7.2 m
kg, 52 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
CAUTION:
40 Nm (4.0 m
kg, 29 ft
lb)
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
WARNING
NOTE:
NOTE: 3. Insert the wheel axle.
Install the tire and wheel with the mark 
1 point-
ing in the direction of wheel rotation.
4. Lower the front wheel so that it is on the
ground.
5. Tighten:

wheel axle

wheel axle pinch bolt
Before tightening the wheel axle pinch bolt,
push down hard in the handlebar several
times and check if the front fork rebounds
smoothly.
6. Install:

brake calipers (left and right)
Make sure that there is enough space between
the brake pads before installing the brake cali-
pers onto the brake discs.
7. Install:

brake hose holder
Make sure the brake hose is routed properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC
BALANCE

After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.

Adjust the front wheel static balance with the
brake discs installed.
1. Remove:

balancing weight(s)
2. Find:

front wheel’s heavy spot
Place the front wheel on a suitable balancing
stand. 
						

							4-8
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
a. Spin the front wheel.
b. When the front wheel stops, put an “X
1” mark
at the bottom of the wheel.
c. Turn the front wheel 90 so that the “X
1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X
2” mark at
the bottom of the wheel.
f. Repeat steps (d) through (f) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
3. Adjust:

front wheel static balance
a. Install a balancing weight 
1 onto the rim ex-
actly opposite the heavy spot “X”.
Start with the lightest weight.
b. Turn the front wheel 90 so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:

front wheel static balance
a. Turn the front wheel and make sure it stays at
each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it. 
						

							4-9
REAR WHEEL AND BRAKE DISCCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear wheel
Brake caliper
Lock nut (left and right)
Adjusting nut (left and right)
Wheel axle nut
Washer
Rear wheel axle
Washer
Drive chain puller (left and right)
Rear wheel
Rear brake caliper bracket1
2
2
1
1
1
1
2
1
1Remove the parts in the order listed.
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
Loosen.
Loosen.
For installation, reverse the removal 
procedure.
NOTE:
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
120 Nm (12 m
kg, 87 ft
lb)
EAS00551
REAR WHEEL AND BRAKE DISC
REAR WHEEL 
						

							4-10
REAR WHEEL AND BRAKE DISCCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the rear brake disc and
rear wheel sprocket
Rear brake disc
Rear wheel sprocket
Collar
Oil seal
Bearing
Rear wheel drive hub
Rear wheel drive hub damper
Rear wheel1
1
2
2
2
1
6
1Remove the parts in the order listed.
For installation, reverse the removal 
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)
100 Nm (10 m
kg, 72 ft
lb)
EAS00556
REAR BRAKE DISC AND REAR WHEEL SPROCKET 
						

							4-11
REAR WHEEL AND BRAKE DISCCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear wheel
Collar
Bearing
Spacer
Oil seal
Circlip
Bearing1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
3
2
4
5
6
EAS00560 
						

							4-12
REAR WHEEL AND BRAKE DISCCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00561
REMOVING THE REAR WHEEL
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

brake caliper 
1
Do not depress the brake pedal when removing
the brake caliper.
3. Loosen:

locknut 
1

adjusting nut 2
4. Remove:

wheel axle nut 
3

wheel axle 4

washer

rear wheel
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:

left collar 
1

rear wheel drive hub 2

rear wheel drive hub damper

right collar 
						

							4-13
REAR WHEEL AND BRAKE DISCCHAS
EAS00565
CHECKING THE REAR WHEEL
1. Check:

wheel axle

rear wheel

wheel bearings

oil seals
Refer to “CHECKING THE FRONT
WHEEL”.
2. Check:

tire

rear wheel
Damage / wear 
 Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Measure:

radial wheel runout

lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:

rear wheel drive hub 
1
Cracks / damage 
 Replace.

rear wheel drive hub dampers 
2
Damage / wear 
 Replace.
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:

rear wheel sprocket
More than 1 / 4 tooth 
a wear 
 Replace the
rear wheel sprocket.
Bent teeth 
 Replace the rear wheel sprock-
et.
bCorrect
1Drive chain roller
2Rear wheel sprocket 
						

							4-14
REAR WHEEL AND BRAKE DISCCHAS
NOTE:
120 Nm (12 m
kg, 87 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
2. Replace:

rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking 
nut
100 Nm (10 m
kg, 72 ft
lb)
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:

wheel axle

wheel bearings

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Install:

collars

rear brake caliper bracket

rear wheel

washer

rear wheel axle
3. Adjust:

drive chain slack
Drive drain slack
45 
 55 mm (1.77 
 2.17 in)
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
4. Tighten:

wheel axle nut

brake caliper bolts (front)

brake caliper bolts (rear)