Yamaha Fz6 N Service Manual

FRONT BRAKE
4-28
* FZ6-NAHG/FZ6-SAHG
Removing the front brake calipers (FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-SAHG)
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
1 Union bolt 2
2 Copper washer 5
3 Brake hose 2
4 Brake caliper 1
5Clamp 1
6 Brake hose holder 2 For installation, reverse the removal proce-
dure. 

FRONT BRAKE
4-29
Disassembling the front brake calipers (FZ6-N/FZ6-NA/FZ6-S/FZ6-SA)
Order Job/Parts to remove Q’ty Remarks1 Brake pad 2
2 Brake caliper piston 2
3 Brake caliper piston seal 4
4 Brake pad spring 1
5 Bleed screw 1 For assembly, reverse the disassembly pro-
cedure. 

FRONT BRAKE
4-30
Disassembling the front brake calipers (FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-SAHG)
Order Job/Parts to remove Q’ty Remarks
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston seal 8
7 Bleed screw 1 For assembly, reverse the disassembly pro-
cedure. 

FRONT BRAKE
4-31
EAS22220
INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require dis-
assembly. Therefore, always follow these 
preventive measures:
 Never disassemble brake components unless absolutely necessary.
 If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after 
reassembly.
 Never use solvents on internal brake  components.
 Use only clean or new brake fluid for  cleaning...

FRONT BRAKE
4-32
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust-ment steps until the brake disc deflection is 
within specification.
f. If the brake disc deflection cannot be  brought within specification, replace the 
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake 
calipers.
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the...

FRONT BRAKE
4-33
5. Check: Brake lever operation
Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-
SAHG
1. Measure:  Brake pad wear limit “a”
Out of specification  → Replace the brake 
pads as a set.
2. Install:  Brake pads
 Brake pad spring
NOTE:
Always install new brake pads and a brake pad 
spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to 
the bleed screw...

FRONT BRAKE
4-34
5. Check: Brake lever operation Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
NOTE:
Before removing the brake caliper, drain the 
brake fluid from the entire brake system.
1. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hose “3”
 Brake caliper
NOTE:
Put the end of the brake hose into a container 
and pump...

FRONT BRAKE
4-35
FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-
SAHG
1. Remove: Brake caliper pistons “1”
 Brake caliper piston seals “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the brake caliper pistons with a  piece of wood “a”.
b. Blow compressed air into the brake hose  joint opening “b” to force out the left side 
pistons from the brake caliper.
WARNING
EWA4S81016
 Cover the brake caliper piston with a lag.
Be careful not the get injured when the 
pistons are expelled from the brake cali-
per.
 Never try...

FRONT BRAKE
4-36
EAS22410
ASSEMBLING THE FRONT BRAKE CALI-
PERS
WARNING
EWA13620
 Before installation, all internal brake com-ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake  components as they will cause the piston 
seals to swell and distort.
 Whenever a brake caliper is disassem- bled, replace the brake caliper piston 
seals.
1. Install:  Brake caliper seals 
 Brake caliper pistons
EAS22440
INSTALLING THE FRONT BRAKE CALI-
PERS
The...

FRONT BRAKE
4-37
 Brake systemRefer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
4. Check:  Brake fluid level
Below the minimum level mark “c”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-24.
5. Check:  Brake lever operation Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6-
SAHG
1. Install:  Brake caliper “1” (temporarily)
 Copper...