Yamaha Fz6 N Service Manual

REAR BRAKE
4-48
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a. Blow compressed air into the brake hose joint opening “a” to force out the piston from 
the brake caliper.
WARNING
EWA13550
 Cover the brake caliper piston with a rag. Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
 Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston seals.
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EAS22640
CHECKING THE REAR BRAKE CALIPER
1. Check:  Brake caliper pistons “1”...

REAR BRAKE
4-49
1. Install: Brake caliper seals 
 Brake caliper piston
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install: Brake caliper “1” (temporarily)
 Copper washers 
 Brake hose “2”
 Union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-47.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.
2....

REAR BRAKE
4-50
7. Check: Brake pedal operation Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
EAS22700
REMOVING THE REAR BRAKE MASTER 
CYLINDER
1. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
2. Disconnect:
 Brake fluid reservoir hose
3. Remove:
 Pin (from the brake pedal link)
4. Remove:  Rear...

REAR BRAKE
4-51
EAS22730
ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER
WARNING
EWA13520
 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.
1. Install:  Master cylinder kit
 Circlip 
EAS22740
INSTALLING THE REAR BRAKE MASTER 
CYLINDER
1. Install:
 Copper washers 
 Brake hoses
 Union bolt
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer...

REAR BRAKE
4-52
6. Adjust: Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-25.
Brake pedal position
25.8 mm (1.02 in) 

ABS (ANTI-LOCK BRAKE SYSTEM)
4-53
EAS22760
ABS (ANTI-LOCK BRAKE SYSTEM)
Removing the hydraulic unit
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
ABS ECU Refer to ABS ECU AND ABS MOTOR 
RELAY on page 8-77.
Hydraulic unit solenoid coupler Refer to ABS ECU AND ABS MOTOR 
RELAY on page 8-77.
Brake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
1 Rectifier/regulator 1
2ECU 1
3Cover 1
4 Sub-complete bracket...

ABS (ANTI-LOCK BRAKE SYSTEM)
4-54
10Brake hose (hydraulic unit to front brake cali-
pers) 1
11 Union bolt 1
12 Copper washer 2
13 Brake hose (rear brake master cylinder to 
hydraulic unit)
1
14 Union bolt 1
15 Copper washer 2
16 Brake hose (hydraulic unit to rear brake caliper) 1
17 Hydraulic unit 1
18 Hydraulic unit bracket 1 1
19 Hydraulic unit bracket 2 1 For installation, reverse the removal proce-
dure.
Removing the hydraulic unit
Order Job/Parts to remove Q’ty Remarks 

ABS (ANTI-LOCK BRAKE SYSTEM)
4-55
EAS22770
[D-5] MAINTENANCE OF THE HYDRAULIC 
UNIT
CAUTION:
ECA15060
Do not turn the crankshaft when installing 
the camshaft sprockets to avoid damage or 
improper valve.
WARNING
EWA13930
Refill with the same type of brake fluid that 
is already in the system. Mixing fluids may 
result in a harmful chemical reaction, lead-
ing to poor braking performance.
CAUTION:
ECA14520
 Handle the ABS components with care since they have been accurately adjusted. 
Keep them away...

ABS (ANTI-LOCK BRAKE SYSTEM)
4-56
Installing the hydraulic unit
Proceed in the reverse order of disassembly. 
Pay attention to the following items.
1. Install: Hydraulic unit bracket
NOTE:
Tighten the nuts in the proper sequence.
2. Install:
 Hydraulic unit
NOTE:
Do not allow any foreign materials to enter the 
hydraulic unit or the brake hoses when install-
ing the hydraulic unit.
CAUTION:
ECA14740
When installing the fuel hose, make sure 
that it is securely connected, and that the 
fuel hose...

ABS (ANTI-LOCK BRAKE SYSTEM)
4-57
 Hydraulic unit operation test 1: this test gen-erates the same reaction-force pulsating 
action that is generated in the brake lever 
and brake pedal when the ABS is activated.
 Hydraulic unit operation test 2: this test 
checks the function of the ABS after the sys-
tem was disassembled, adjusted, or ser-
viced.
Hydraulic unit operation test 1
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
1. Place the vehicle on the...