Yamaha Fz6n Manual

							2-44
CABLE ROUTINGSPEC
A Either right or left side arrangement for the left han-
dlebar switch lead coupler and radiator fan motor
coupler can be accepted.
B Point the L-shape terminal to the front side of the ve-
hicle.
C Hook the starter motor lead to the alternate pawls
on the battery cover.
D Route the crank shaft position sensor lead above
the starter motor leads.
E To the crankshaft position sensor.
F Clamp the starter motor lead and crank shaft posi-
tion sensor lead. Point the projected part of the tip to
the inner side of the vehicle.
G Pass the radiator hose, coolant reservoir hose, wire
harness and starter motor lead in order through the
lower side of the vehicle.H Set the 4-pin coupler in the connector cover after
wiring it.
I To the sidestand switch.
J To the speed sensor.
K To the A.C. magneto.
L To the oil level gauge.
M To the rear brake/light switch.
N To the neutral switch.
O Push the wire harness in the groove of the mud
guard.
P Point the opening section of the clamp upward.
Q To the rear turn signal (right)
R To the rear turn signal (left) 
						

							2-45
AD Press the battery negative lead into the space be-
tween the ribs of the frame.
AE Pass the spark plug leads #1 and #4 through the
slit of the cover 2.
AF Pass the spark plug lead #2 through the inner
hole of the cover 2.
AG Pass the spark plug lead #3 through the outer
hole of the cover 2.
AH Route the spark plug lead #4 behind the air cut-off
valve hose.
AI Point the spark plug caps of #1 to #4 to the direc-
tion as shown in the illustration.
AJ Route the spark plug lead #3 under the air cut-off
valve hose.
AK Route the spark plug lead #2 behind the air cut-off
valve hose.
CABLE ROUTINGSPEC
S To the license plate light.
T To the tail/brake light.
U Insert the enwinding clamp of the wire harness into
the hole of the rear frame.
V Attach the rectifier regulator lead to the clamp of the
rectifier bracket.
W To the engine ground.
X To the fuel injection.
Y To the fuel pump.
Z Route the clutch cable under the fuel injection lead.
AA Pass the clutch cables through the clamp, and
then install the clamp to the cover. Position of the
clamp is forward of the cable stopper.
AB To the main switch.
AC Route the starter relay lead outside of the main
switch. 
						

							2-46
CABLE ROUTINGSPEC
AL Route the spark plug lead #4 by the front side of
the spark plug leads #2 and #3.
AM Route the spark plug leads #2 and #3 behind the
air cut-off valve hose. 
						

							2-47
CABLE ROUTINGSPEC
a Fuel piping connector attachment directions. (fuel
pump side)
1. It is inserted until it makes a click sound the connec-
tor, and it checks that a connector does not fail out. It
takes care that a foreign substance does not enter
into a seal portion. (Working gloves should not be
used at the time of work.)
E It prevents that this portion falls out.
2. The clamp is attached from the bottom after the
work of “1”.
It checks being completely equipped with   ,    and
 section.
AB
C
1Fuel pump assembly
2Fuel tank breather hose (except for CAL)
3Fuel tank drain hose
4Fuel hose
5Clip
6Clamp
7Charge hose (for CAL)
8Roll over valve (for CAL)
A Air opening.
B Install the O-ring with its lip pointed upward.
C Fuel tank breather hose has a white point mark.
D Point the knob of clip front side. 
						

							2-48
A Front side.
B Pass the coolant reservoir tank hose hangs down
downward from back of the bolt.
C Insert this portion securely.
D Spittle is turned back.
E Insert the clamp certainly.
F It may open and close to direction of which. All
notches gear at the time of attachment.
G Pass the coolant reservoir tank hose inside of the
clamp.
H Insert in certainly.
I To the fuel tank drain tube.
J Air opening.
K There should be no slacking of the hose when it is
routed.except for CAL
1Coolant breather hose
2Coolant reservoir tank
3Coolant reservoir tank hose
4Clamp
5Fuel tank drain hose
CABLE ROUTINGSPEC 
						

							2-49
CABLE ROUTINGSPEC
A Front side.
B Point the paint marking upward.
C Pass the canister hose and balance hose behind
the bolt.
D Pass the canister hose outside, pass the balance
hose inside.
E Pass the coolant reservoir tank hose hangs dowm
downward from back of the bolt.
F Point the knob of the clip upward. The application of
water is possible at the time of attachment.
G Pass the balance hose under the canister hose.
H Insert this portion securely.
I Spittle is turned back.
J Insert to the back, but the tip of the nipple should not
come out from the hose.for CAL
1Clip
2Roll over valve
3Canister hoes
4Balance hose
5Coolant reservoir tank
6Coolant reservoir tank hose
7Coolant breather hose
8Roll over valve hose
9Canister
10Hose
11Fuel tank drain hose
12Clamp 
						

							2-50
K Insert the clamp certainly.
L It may open and close to direction of which. All
notches gear at the time of attachment.
M Pass the coolant reservoir tank hose and the fuel
tank drain hose inside of the clamp.
N Point the knob of clamp downward.
O Point the knob of clamp upward.
P Insert in certainly.
Q To the fuel tank drain tube.
R Point the paint marking (both white) front side. The
application of water is possible at the time of attach-
ment.
S Clamp the fuel tank drain hose, then the paint mark
of the central part is united.
T Air opening.
CABLE ROUTINGSPEC 
						

							3-1
INTRODUCTION /PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND
LUBRICATION CHARTCHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIALODOMETER READINGS
NO.ITEMREMARKS600 mi
(1,000 km)
or
1 month4,000 mi
(7,000 km)
or
6 months8,000 mi
(13,000 km)
or
12 months12,000 mi
(19,000 km)
or
18 months16,000 mi
(25,000 km)
or
24 months20,000 mi
(31,000 km)
or
30 months
1*Fuel line
(See page 3-35)
Check fuel and vacuum hoses for cracks or
damage.

Replace if necessary.





2*Spark plugs
(See page 3-23)
Check Condition.

Adjust gap and clean.

Replace every 8000 mi (13000 km) or 12
months.
Replace.
Replace.

3*Valve clearance
(See page 3-11)
Check and adjust valve clearance when en-
gine is cold.Every 26,600 mi (42,000 km)
4*Crankcase breather
system
(See page 3-35)
Check breather hose for cracks or damage.

Replace if necessary.





5*Electronic fuel injection
(See page 3-17, 19)
Check and adjust engine idle speed and syn-
chronization.






6*Exhaust system
(See page 3-36)
Check for leakage.

Tighten if necessary.

Replace gasket(s) if necessary.






7*Evaporative emission
control system
(For California only)
Check control system for damage.

Replace if necessary.


8*Air induction system 
(See page 7-32)
Check the air cut-off valve, reed valve, and
hose for damage.

Replace any damaged parts if necessary.


* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIALODOMETER READINGS
NO.ITEMREMARKS600 mi
(1,000 km)
or
1 month4,000 mi
(7,000 km)
or
6 months8,000 mi
(13,000 km)
or
12 months12,000 mi
(19,000 km)
or
18 months16,000 mi
(25,000 km)
or
24 months20,000 mi
(31,000 km)
or
30 months
1*Air filter element
Check condition and damage.

1*Air filter element(See page 3-33)
Replace if necessary.

2*Clutch
(See page 3-32)
Check operation.
Adjust or replace cable.






3*Front brake
(See page 3-42, 44, 46)
Check operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.






4*Rear brake
(See page 3-43, 44, 46)
Check operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.






5*Brake hoses
Check for cracks or damage.




5*Brake hoses(See page 3-46)
Replace.Every 4 years
6*Wheels
(See page 4-3)
Check runout and for damage.
Replace if necessary.





7*Tires
(See page 3-54)
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.






8*Wheel bearings
(See page 4-3)
Check bearings for smooth operation.
Replace if necessary.





* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service. 
						

							3-2
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
3
NOTE:
NOTE:
INITIALODOMETER READINGS
NO.ITEMREMARKS600 mi
(1,000 km)
or
1 month4,000 mi
(7,000 km)
or
6 months8,000 mi
(13,000 km)
or
12 months12,000 mi
(19,000 km)
or
18 months16,000 mi
(25,000 km)
or
24 months20,000 mi
(31,000 km)
or
30 months
9*Swingarm pivot
bearings
(See page 4-70)
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease.
Repack.
10Drive chain
(See page 3-49, 50)
Check chain slack/alignment and condition.
Adjust and lubricate chain with a special O-
ring chain lubricant thoroughlyEvery 600 mi (1000 km) and after washing the motorcycle or riding in the rain
11*Steering bearings
(See page 3-51)
Check bearing assembly for looseness.
Moderately repack with lithium-soap-based
grease every 16000 mi (25000 km) or 24
months.



Repack.

12*Chassis fasteners
(See page 2-21)
Check all chassis fitting and fasteners.
Correct if necessary.





13Brake and clutch
lever pivot shafts
(See page 3-58)
Apply lithium-soap-based grease (all-purpose
grease) lightly.





14Brake and shift
pedal pivot shafts
(See page 3-58)
Apply lithium-soap-based grease (all-purpose
grease) lightly.





15*Centerstand and
sidestand pivots
(See page 3-58)
Check operation.
Apply lithium-soap-based grease (all-purpose
grease) lightly.





16*Sidestand switch
(See page 3-58, 8-4)
Check operation and replace if necessary.






17*Front fork
(See page 3-53)
Check operation and for oil leakage.
Replace if necessary.





18*Shock absorber
assembly
(See page 3-54, 4-65)
Check operation and for oil leakage.
Replace if necessary.





19*Rear suspension
link pivots
(See page 4-70)
Check operation.
Correct if necessary.


20Engine oil
(See page 3-27, 28)
Change (warm engine before draining.)






21*Engine oil filter
cartridge
(See page 3-28)
Replace.



22*Cooling system

Check hoses for cracks or damage.
Replace if necessary.





22*Cooling system(See page 3-37, 38)
Change with ethylene glycol antifreeze cool-
ant every 24 months.Change.
23*Control cables
(See page 3-58)
Apply Yamaha chain and cable lube or en-
gine oil SAE 10W-30 thoroughly.






24*Throttle grip housing
and cable
(See page 3-20)
Check operation and free play.
Adjust the throttle cable free play if neces-
sary.

Lubricate the throttle grip housing and cable.






* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged. 
						

							3-3
SEAT
CHK
ADJ
Order Job / Part Q’ty Remarks
1Removing the seat
Seat 1Remove the parts in the order listed.
For installation, reverse the removal
procedure.
EAS00038
SEAT