Yamaha Fz6 N Service Manual
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CHASSIS 3-28 WARNING EWA14020 After bleeding the ABS, check the brake operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21370 ADJUSTING THE SHIFT PEDAL 1. Check: Shift pedal position Align the center of shift pedal “1” and cen- ter of footrest bracket bolt “2” in a straight line. Incorrect → Adjust. 2. Adjust: Shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts “1”. b. Turn the shift rod “2” in direction “a” or “b” to obtain the correct shift pedal position. c. Tighten both locknuts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21390 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: ECA13550 A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci- fied limits. 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Spin the rear wheel several times and find the tightest position of drive chain. 3. Check: Drive chain slack “a” Out of specification → Adjust. 4. Adjust: Drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut “1”. b. Loosen both locknuts “2”. c. Turn both adjusting nuts “3” in direction “a” or “b” until the specified drive chain slack is obtained. Direction “a” Shift pedal is raised. Direction “b” Shift pedal is lowered. Drive chain slack45.0–55.0 mm (1.77–2.17 in)
CHASSIS 3-29 NOTE: To maintain the proper wheel alignment, adjust both sides evenly. d. Tighten both locknuts to specification. e. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rub- ber O-rings between each side plate. Steam cleaning, high-pressure washing, certain sol- vents, and the use of a coarse brush can dam- age these O-rings. Therefore, use only kerosene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain sol- vents that could damage the O-rings. EAS21500 CHECKING AND ADJUSTING THE STEER- ING HEAD 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Check: Steering head Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. 3. Remove: Upper bracket Refer to STEERING HEAD on page 4-72. 4. Adjust: Steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. b. Tighten the lower ring nut “4” with a steer- ing nut wrench “5”. NOTE: Set the torque wrench at a right angle to the steering nut wrench. Direction “a” Drive chain is tightened. Direction “b” Drive chain is loosened. Locknut16 Nm (1.6 m·kg, 12 ft·lb) Wheel axle nut120 Nm (12 m·kg, 87 ft·lb) Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains Steering nut wrench90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque)52 Nm (5.2 m·kg, 38 ft·lb)
CHASSIS 3-30 c. Loosen the lower ring nut “4” completely and then tighten it to specification with a steering nut wrench. WARNING EWA13140 Do not overtighten the lower ring nut. d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD on page 4-72. e. Install the rubber washer “2”. f. Install the upper ring nut “3”. g. Finger tighten the upper ring nut “3”, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer “1”. NOTE: Make sure the lock washer tabs “a” sit correctly in the ring nut slots “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: Upper bracket Refer to STEERING HEAD on page 4-72. 6. Measure: Steering head tension ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Make sure all of the cables and wires are prop- erly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie “1” loosely around the end of the handlebar as shown. c. Hook a spring gauge “2” onto the plastic locking tie. d. Hold the spring gauge at a 90 ° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run. e. Repeat the above procedure on the oppo- site handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. Lower ring nut (final tightening torque) 18 Nm (1.8 m·kg, 13 ft·lb) Steering head tension 200–500g
CHASSIS 3-31 WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube “1” Damage/scratches → Replace. Oil seal “2” Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to FRONT FORK on page 4-64. EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. b. Turn the adjusting ring “1” in direction “a” or “b”. c. Align the desired position on the adjusting ring with the stopper “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: Tire pressure Out of specification → Regulate. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). Spring preload adjusting posi- tions Minimum1 Standard 3 Maximum 7
CHASSIS 3-32 WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. WARNING EWA13190 It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: Tire surfaces Damage/wear → Replace the tire. Tire air pressure (measured on cold tires) Loading condition* 0–90 kg (0–198 lb) Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Loading condition* 90–185 kg (198–408 lb) (FZ6- SA, FZ6-SHGW, FZ6-SAHG) 90–190 kg (198–419 lb) (FZ6-S, FZ6-SHG) 90–191 kg (198–421 lb) (FZ6- NA, FZ6-NAHG) 90–196 kg (198–432 lb) (FZ6-N, FZ6-NHG, FZ6-NHGW) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) High-speed riding Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Maximum load* 185 kg (408 lb) (FZ6-SA, FZ6- SHGW, FZ6-SAHG) 190 kg (419 lb) (FZ6-S, FZ6- SHG) 191 kg (421 lb) (FZ6-NA, FZ6- NAHG) 196 kg (432 lb) (FZ6-N, FZ6- NHG, FZ6-NHGW) * Total weight of rider, passenger, cargo and accessories
CHASSIS 3-33 WARNING EWA14080 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. WARNING EWA14090 After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark “1”: Install the tire with the mark pointing in the direction of wheel rotation. Align the mark “2” with the valve installation point. 1. Tire tread depth 2. Side wall 3. Wear indicator Wear limit (front) 0.8 mm (0.03 in) Wear limit (rear) 0.8 mm (0.03 in) A. Tire B. Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Front tire Size120/70 ZR17M/C (58W) Manufacturer/model BRIDGESTONE/BT020F GG Manufacturer/model DUNLOP/D252F Rear tireSize 180/55 ZR17M/C (73W) Manufacturer/model BRIDGESTONE/BT020R GG Manufacturer/model DUNLOP/D252
CHASSIS 3-34 EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round → Replace. WARNING EWA13260 Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: Outer cable Damage → Replace. 2. Check: Cable operation Rough movement → Lubricate. NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Engine oil or a suitable cable lubricant Recommended lubricantLithium-soap-based grease Recommended lubricantLithium-soap-based grease Recommended lubricantLithium-soap-based grease Recommended lubricantLithium-soap-based grease Recommended lubricantMolybdenum disulfide grease
ELECTRICAL SYSTEM 3-35 EAS21750 ELECTRICAL SYSTEM EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: Headlight coupler “1” 2. Remove: Headlight bulb cover “2” 3. Remove: Headlight bulb holder “1” 4. Remove: Headlight bulb “2” WARNING EWA13320 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: Headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: ECA13690 Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install: Headlight bulb holder 7. Install: Headlight bulb cover 8. Connect: Headlight coupler EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/ FZ6-NA/FZ6-NAHG A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. New
ELECTRICAL SYSTEM 3-36 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/ FZ6-NA/FZ6-NAHG Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. A. FZ6-S/FZ6-SHG(W)/FZ6-SA/FZ6-SAHG B. FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG