Yamaha Fz6 N Service Manual
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ENGINE 3-8 11. Install: Fuel tank Refer to FUEL TANK on page 7-1. Seat Refer to GENERAL CHASSIS on page 4- 1. EAS4S81012 ADJUSTING THE EXHAUST GAS VOLUME (FZ6-N/FZ6-NA/FZ6-S/FZ6-SA) NOTE: Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume. 1. Turn the main switch to “OFF” and set the engine stop switch to “ON”. 2. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: “dIAG” appear on the odometer LCD. 3. Press the “SELECT” button to select the CO adjustment mode “Co” “1” or the diag- nostic mode “dI”. 4. After selecting “Co”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection. NOTE: The selected cylinder number appears on the clock LCD. To decrease the selected cylinder number, press the “RESET” button. To increase the selected cylinder number, press the “SELECT” button. 5. After selecting the cylinder, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selec- tion. 6. Change the CO adjustment volume by pressing the “SELECT” and “RESET” but- tons. NOTE: The CO adjustment volume appears on the tripmeter LCD. To decrease the CO adjustment volume, press the “RESET” button. To increase the CO adjustment volume, press the “SELECT” button. 7. Release the switch to execute the selec- tion. 8. Simultaneously press the “SELECT” and “RESET” buttons to return to the cylinder selection (step 5). 9. Turn the main switch to “OFF” to cancel the mode. EAS4S81002 ADJUSTING THE EXHAUST GAS VOLUME (FZ6-NHG(W)/FZ6-NAHG/FZ6-SHG(W)/FZ6- SAHG) NOTE: Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume. 1. Turn the main switch to “OFF” and set the engine stop switch to “ON”. Throttle cable free play3.0–5.0 mm (0.12–0.20 in)
ENGINE 3-9 2. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: “dI” appears on the clock LCD. 3. Press the “SELECT” button to select the CO adjustment mode “Co” “1” or the diag- nostic mode “dI”. 4. After selecting “Co”, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selection. NOTE: The selected cylinder number appears on the clock LCD. To decrease the selected cylinder number, press the “RESET” button. To increase the selected cylinder number, press the “SELECT” button. 5. After selecting the cylinder, simultaneously press the “SELECT” and “RESET” buttons for 2 seconds or more to execute the selec- tion. 6. Change the CO adjustment volume by pressing the “SELECT” and “RESET” but- tons. NOTE: The CO adjustment volume appears on the tripmeter LCD. To decrease the CO adjustment volume, press the “RESET” button. To increase the CO adjustment volume, press the “SELECT” button. 7. Release the switch to execute the selec- tion. 8. Simultaneously press the “SELECT” and “RESET” buttons to return to the cylinder selection (step 5). 9. Turn the main switch to “OFF” to cancel the mode. EAS20610 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have ade- quate compression. 1. Start the engine and let it warm up for sev-eral minutes. 2. Check: Engine idling speed Out of specification → Adjust. 3. Adjust: Engine idling speed Engine idling speed 1250–1350 r/min
ENGINE 3-10 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the idle adjusting screw “1” in direction “a” or “b” until the specified engine idling speed is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Adjust: Throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-10. EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchronization should be adjusted properly. 1. Check: Throttle cable free play “a” Out of specification → Adjust. 2. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-114. 3. Adjust: Throttle cable free play NOTE: When the throttle is opened, the accelerator cable “1” is pulled. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle body side a. Loosen the locknut “2” on the decelerator cable. b. Turn the adjusting nut “3” in direction “a” or “b” to take up any slack on the decelerator cable. c. Tighten the locknuts NOTE: If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Loosen the locknut “1”. Direction “a” Engine idling speed is increased. Direction “b” Engine idling speed is decreased. Throttle cable free play3.0–5.0 mm (0.12–0.20 in) Throttle cable free play3.0–5.0 mm (0.12–0.20 in) Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased.
ENGINE 3-11 b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. c. Tighten the locknut ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-114. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Seat Refer to GENERAL CHASSIS on page 4- 1. WARNING EWA4S81001 After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: Radiator lower bolt “1” Radiator lower hose bracket bolt “2” Refer to RADIATOR on page 6-1. 2. Disconnect: Spark plug caps 3. Remove: Spark plugs CAUTION: ECA13320 Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: Spark plug type Incorrect → Change. 5. Check: Electrode “1” Damage/wear → Replace the spark plug. Insulator “2” Abnormal color → Replace the spark plug. Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. A. Right side #1, #2 and #3 B. Left side #4 Manufacturer/modelNGK/CR9EK
ENGINE 3-12 Normal color is medium-to-light tan. 6. Clean: Spark plug (with a spark plug cleaner or wire brush) 7. Measure: Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. 8. Install: Spark plugs NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: Spark plug caps 10. Install: Radiator lower hose bracket bolt Radiator lower bolt Refer to RADIATOR on page 6-1. EAS20710 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pr essure will result in a loss of performance. 1. Measure: Valve clearance Out of specification → Adjust. Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-114. Battery box Battery box bracket Refer to GENERAL CHASSIS on page 4- 1. Heat protector plate Cover Ignition coils 4. Disconnect: Spark plug caps 5. Remove: Spark plugs CAUTION: ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 6. Install: Compression gauge “1” 7. Measure: Compression pressure Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Spark plug18 Nm (1.8 m·kg, 13 ft·lb) Compression gauge 90890-03081 Engine compression tester YU-33223
ENGINE 3-13 Out of specification → Refer to steps (c) and (d). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes. WARNING EWA4S81003 To prevent sparking, ground all spark plug leads before cranking the engine. CAUTION: ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm², 14 psi). c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. Install: Spark plugs 9. Connect: Spark plug caps 10. Install: Ignition coils Cover Heat protector plate Battery box bracket Battery box Refer to GENERAL CHASSIS on page 4- 1. Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-114. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Seat Refer to GENERAL CHASSIS on page 4- 1. EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended engine oil to the proper level. Standard compression pres- sure (at sea level) 1550 kPa/400 r/min (220.5 psi/ 400 r/min) (15.5 kgf/cm²/400 r/ min) Minimum–maximum 1350–1736 kPa (192.0–246.9 psi) (13.5–17.4 kgf/cm²) Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston ring(s) wear or damage → Repair. Same as without oil Piston, valves, cylin- der head gasket or piston possibly defec- tive → Repair. Spark plug 18 Nm (1.8 m·kg, 13 ft·lb)
ENGINE 3-14 CAUTION: ECA4S81007 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD “a” or higher and do not use oils labeled “ENERGY CON- SERVING II” “b” or higher. Do not allow foreign materials to enter the crankcase. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20790 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: Engine oil filler cap “1” Engine oil drain bolt “2” (along with the gasket) 4. Drain: Engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. Ty p eSAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher, JASO standard MA
ENGINE 3-15 b. Lubricate the O-ring “3” of the new oil filter cartridge with a thin coat of engine oil. CAUTION: ECA13390 Make sure the O-ring “3” is positioned cor- rectly in the groove of the oil filter car- tridge. c. Tighten the new oil filter cartridge to speci-fication with an oil filter wrench. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: Engine oil drain bolt gasket 7. Install: Engine oil drain bolt (along with the new gasket) 8. Fill: Crankcase (with the specified amount of the recom- mended engine oil) 9. Install: Engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: Engine (for engine oil leaks) 12. Check: Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3-13. EAS20820 MEASURING THE ENGINE OIL PRESSURE 1. Check: Engine oil level Below the minimum level mark → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. CAUTION: ECA13410 When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3. Remove: Oil gallery bolt “1” WARNING EWA12980 The engine, muffler and engine oil are extremely hot. Oil filter wrench 90890-01426 YU-38411 Oil filter cartridge17 Nm (1.7 m·kg, 12 ft·lb) Engine oil drain bolt43 Nm (4.3 m·kg, 31 ft·lb) New Engine oil quantityTotal amount3.40 L (3.59 US qt) (2.99 Imp.qt) Without oil filter cartridge replacement 2.50 L (2.64 US qt) (2.20 Imp.qt) With oil filter cartridge replace- ment 2.80 L (2.96 US qt) (2.46 Imp.qt)
ENGINE 3-16 4. Install: Oil pressure gauge “1” Adapter “2” 5. Measure: Engine oil pressure (at the following conditions) Out of specification → Adjust. 6. Install: Main gallery bolt “1” EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: Clutch cable free play “a” Out of specification → Adjust. 2. Adjust: Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting bolt “1” in direction “a” or “b” until the specified clutch cable free play is obtained. Pressure gauge90890-03153 YU-03153 Oil pressure adapter H 90890-03139 Engine oil pressure 240 kPa (34.1 psi) (2.4 kg/cm 2) Engine speed Approx 6,600 r/min Oil temperature 75.0–85.0 °C (167.00–185.00 ° F) Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil passage Faulty oil filter Oil viscosity too high Main gallery bolt8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch lever free play10.0–15.0 mm (0.39–0.59 in) Engine oil pressure Possible causes
ENGINE 3-17 NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Engine side a. Loosen the locknuts “1”. b. Turn the adjusting nut “2” in direction “a” or “b” until the specified clutch cable free play is obtained. c. Tighten the locknuts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20950 CLEANING THE AIR FILTER ELEMENT 1. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. 2. Remove: Air filter case cover “1” Air filter element “2” 3. Clean: Air filter element (with solvent) 4. Check: Air filter element Damage → Replace. 5. Install: Air filter element Air filter case cover CAUTION: ECA4S81008 Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle bodies synchronization, leading to poor engine performance and possible overheating. 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 on page 7-1. Seat Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased.