Yamaha Fz6 N Service Manual

							
4
CHASSIS
GENERAL CHASSIS.................................................................................... 4-1
FRONT WHEEL ............................................................................................ 4-7
REMOVING THE FRONT WHEEL ....................................................... 4-10
CHECKING THE FRONT WHEEL........................................................ 4-10
[D-3] MAINTENANCE OF THE FRONT WHEEL SENSOR AND 
SENSOR ROTOR ................................................................................. 4-11
ADJUSTING THE FRONT WHEEL STATIC BALANCE ....................... 4-13
INSTALLING THE FRONT WHEEL ...................................................... 4-14
REAR WHEEL ............................................................................................ 4-15
REMOVING THE REAR WHEEL ......................................................... 4-19
CHECKING THE REAR WHEEL .......................................................... 4-19
CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-19
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ....... 4-20
[D-4] MAINTENANCE OF THE REAR WHEEL SENSOR AND 
SENSOR ROTOR ................................................................................. 4-20
ADJUSTING THE REAR WHEEL STATIC BALANCE .......................... 4-22
INSTALLING THE REAR WHEEL ........................................................ 4-22
FRONT BRAKE .......................................................................................... 4-23
INTRODUCTION ........................... ....................................................... 4-31
CHECKING THE FRONT BRAKE DISCS ............................................ 4-31
REPLACING THE FRONT BR AKE PADS ............................................ 4-32
REMOVING THE FRONT BRAKE  CALIPERS ..................................... 4-34
DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-34
CHECKING THE FRONT BRAKE CALIPERS ..................................... 4-35
ASSEMBLING THE FRONT BRAKE CALIPERS ................................. 4-36
INSTALLING THE FRONT BRAKE CALIPERS .................................... 4-36
REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-38
CHECKING THE FRONT BRAKE MASTER CYLINDER ..................... 4-38
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER................. 4-39
INSTALLING THE FRONT BRAKE MASTER CYLINDER ................... 4-39
REAR BRAKE ............................................................................................ 4-41
INTRODUCTION ........................... ....................................................... 4-46
CHECKING THE REAR BRAKE DISC ................................................. 4-46
REPLACING THE REAR BRAKE PADS .............................................. 4-46
REMOVING THE REAR BR AKE CALIPER .......................................... 4-47
DISASSEMBLING THE REAR BRAKE CALIPER ................................ 4-47
CHECKING THE REAR BRAKE CALIPER .......................................... 4-48
ASSEMBLING THE REAR BRAK E CALIPER ...................................... 4-48
INSTALLING THE REAR BRAKE CALIPER......................................... 4-49
REMOVING THE REAR BRAKE MASTER CYLINDER ....................... 4-50
CHECKING THE REAR BRAKE MASTER CYLINDER ....................... 4-50
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ................... 4-51
INSTALLING THE REAR BRAKE MASTER CYLINDER ...................... 4-51 
						

							
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................ 4-53
[D-5] MAINTENANCE OF THE HYDRAULIC UNIT .............................. 4-55
HYDRAULIC UNIT OPERATION TEST ................................................ 4-56
[D-6-5] TRIAL RUN ............................................................................... 4-59
HANDLEBAR .............................................................................................. 4-60
REMOVING THE HANDLEBARS ......................................................... 4-61
CHECKING THE HANDLEBAR ............................................................ 4-61
INSTALLING THE HANDL EBAR ................................... ....................... 4-61
FRONT FORK ............................................................................................. 4-64
REMOVING THE FRONT FORK LEGS ............................................... 4-66
DISASSEMBLING THE FRONT FO RK LEGS ..................................... 4-66
CHECKING THE FRONT FORK LEGS ................................................ 4-67
ASSEMBLING THE FRONT FORK  LEGS ........................................... 4-68
INSTALLING THE FRONT FORK LEGS .............................................. 4-70
STEERING HEAD ....................................................................................... 4-72
REMOVING THE LOWER BRACKET .................................................. 4-74
CHECKING THE STEERING HEAD .................................................... 4-74
INSTALLING THE STEERING HEAD ................................................... 4-75
REAR SHOCK ABSORBER ASSEMBLY .................................................. 4-76
HANDLING THE REAR SHOC K ABSORBER ..................................... 4-77
DISPOSING OF A REAR SHOCK ABSORBER ................................... 4-77
REMOVING THE REAR SHOCK  ABSORBER ASSEMBLY................. 4-77
CHECKING THE REAR SHOCK ABSO RBER ASSEMBLY ................. 4-77
INSTALLING THE REAR SHOCK  ABSORBER ASSEMBLY ............... 4-78
SWINGARM ................................................................................................ 4-79
REMOVING THE SWINGARM ............................................................. 4-81
CHECKING THE SWINGARM ............................................................. 4-81
INSTALLING THE SWINGARM ............................................................ 4-82
CHAIN DRIVE ............................................................................................. 4-83
REMOVING THE DRIVE CHAIN .......................................................... 4-84
CHECKING THE DRIVE CHAIN .......................................................... 4-84
CHECKING THE DRIVE SPROCKET .................................................. 4-85
CHECKING THE REAR WHEEL SPROCKET ..................................... 4-85
CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-85
INSTALLING THE DRIVE CHAIN ......................................................... 4-85 
						

							
GENERAL CHASSIS
4-1
EAS21830
GENERAL CHASSIS
Removing the seat
Order Job/Parts to remove Q’ty Remarks1Seat 1
For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-2
Removing the cowlings (FZ6-N/FZ6-NHG(W)/FZ6-NA/FZ6-NAHG)
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
1 Side cover 2
2 Rear cowling 1
For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-3
Removing the cowlings (FZ6-S/FZ6-SA)
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
1 Left front cowling inner panel (with cowling) 1
2 Right front cowling inner panel (with cowling) 1
3 Front turn signal light coupler 2 Disconnect.
4 Front cowling 1
5 Rear view mirrors  2
6 Windshield 1
7 Side cover  2
8 Rear cowling  1
For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-4
Removing the cowlings (FZ6-SHG(W)/FZ6-SAHG)
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
1 Left front cowling inner panel (with cowling) 1
2 Right front cowling inner panel (with cowling) 1
3 Front turn signal light coupler 2 Disconnect.
4 Front cowling 1
5 Front cowling inner panel (center) 1
6 Rear view mirrors  2
7 Windshield 1
8 Side cover  2
9 Rear cowling  1 For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-5
Removing the air filter case and battery
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel (with cowling) Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel (with cowlin g) Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
ABS motor relay (with ABS) Refer to ABS ECU AND ABS MOTOR 
RELAY on page 8-77.
1 Intake air temperature sensor coupler 1 Disconnect.
2 Throttle body hose 2 Disconnect.
3 Air induction system hose 1 Disconnect.
4 Clamp 4 Loosen.
5 Crankcase breather hose 1 Disconnect.
6 Starter relay 1
7 Battery negative lead 1 Disconnect.
8 Battery positive lead 1 Disconnect.
9Battery cover 1
10 Battery 1
11 Air filter case 1
For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-6
Removing the battery box
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel (with cowling) Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel (with cowlin g) Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Battery Refer to GENERAL CHASSIS on page 4-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
1Battery box 1
2 Battery box bracket 3
3 Ignition coil 2 For installation, reverse the removal proce-
dure. 
						

							
FRONT WHEEL
4-7
EAS21880
FRONT WHEEL
* FZ6-NHG(W)/FZ6-SHG(W)
Removing the front wheel and brake discs (FZ6-N/FZ6-NHG(W)/FZ6-S/FZ6-SHG(W))
Order Job/Parts to remove Q’ty Remarks1 Brake hose holder  2
2 Brake hose holder 1
3 Front brake caliper  2
4 Front wheel axle pinch bolt 1 Loosen.
5 Front wheel axle 1
6 Collar 2
7 Front wheel 1
8 Front brake disc  2 For installation, reverse the removal proce-
dure.