Yamaha Fz6 N Service Manual

							
FRONT BRAKE
4-38
5. Check: Brake lever operation Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
EAS22490
REMOVING THE FRONT BRAKE MASTER 
CYLINDER
NOTE:
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake 
system.
1. Disconnect:  Brake switch coupler
(from the brake switch)
2. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hoses “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
3. Remove:
Brake lever
 Brake master cylinder holder
 Brake master cylinder
EAS22500
CHECKING THE FRONT BRAKE MASTER 
CYLINDER
1. Check: Brake master cylinder “1” Damage/scratches/wear  → Replace.
 Brake fluid delivery passages
(brake master cylinder body)
Obstruction  → Blow out with compressed 
air.
2. Check:  Brake master cylinder kit “1”
Damage/scratches/wear  → Replace.
3. Check:  Brake master cylinder reservoir “1”
Cracks/damage  → Replace.
 Brake master cylinder reservoir diaphragm  “2”
Damage/wear  → Replace.
4. Check:  Brake hoses Cracks/damage/wear  → Replace. 
						

							
FRONT BRAKE
4-39
EAS22520
ASSEMBLING THE FRONT BRAKE MAS-
TER 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 
EAS22530
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1. Install: Brake master cylinder “1”
NOTE:
 Install the brake master cylinder holder with the “UP” mark facing up.
 Align the end of the brake master cylinder  holder with the punch mark “a” on the han-
dlebar.
 First, tighten the upper bolt, then the lower 
bolt.
2. Install:  Copper washers “1” 
 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:
ECA4S81013
When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection “b” on 
the brake master cylinder.
NOTE:
 While holding the brake hose, tighten the union bolt as shown.
 Turn the handlebar to the left and right to 
make sure the brake hose does not touch 
other parts (e.g., wire harness, cables, 
leads). Correct if necessary.
3. Fill:  Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13540
 Use only the designated brake fluid. Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid  that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does 
not enter the brake master cylinder reser-
voir. Water will significantly lower the 
Recommended fluid DOT 4
Brake master cylinder holder 
bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
Brake hose union bolt30 Nm (3.0 m·kg, 22 ft·lb)
New
New
Recommended fluidDOT 4 
						

							
FRONT BRAKE
4-40
boiling point of the brake fluid and could 
cause vapor lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
4. Bleed: Brake system Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
5. 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.
6. Check:  Brake lever operation Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26. 
						

							
REAR BRAKE
4-41
EAS22550
REAR BRAKE
Removing the rear brake pads 
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Rear brake caliper 1
4 Brake pad shim 4
5 Brake pad 2
6 Brake screw 1
7 Brake pad spring 1
For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-42
Removing the rear brake master cylinder
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
1 Brake fluid reservoir cap 1
2 Rear brake fluid reservoir diaphragm holder 1
3 Rear brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir hose 1
6 Union bolt 1
7 Copper washer 1
8 Brake hose 1
9 Rear brake master cylinder 1 For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-43
Disassembling the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4Spring 1
5 Brake master cylinder body 1 For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-44
Removing the rear brake caliper
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Rear brake caliper 1 For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-45
Disassembling the rear brake caliper
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Brake pad 2
4 Brake pad shim 4
5 Brake pad spring 1
6 Brake caliper piston 1
7 Brake caliper piston seal 2
8 Bleed screw 1 For assembly, reverse the disassembly pro-
cedure. 
						

							
REAR BRAKE
4-46
EAS22560
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 brake components.
 Brake fluid may damage painted surfaces  and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
 Avoid brake fluid coming into contact  with the eyes as it can cause serious 
injury.
 FIRST AID FOR BRAKE FLUID ENTERING  THE EYES:
 Flush with water for 15 minutes and get 
immediate medical attention.
EAS22570
CHECKING THE REAR BRAKE DISC
1. Check: Brake disc Damage/galling  → Replace.
2. Measure:  Brake disc deflection Out of specification  → Correct the brake 
disc deflection or replace the brake disc.
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-31.
3. Measure:  Brake disc thickness Measure the brake disc thickness at a few 
different locations.
Out of specification  → Replace.
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-31. 4. Adjust:
 Brake disc deflection
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-31.
EAS22580
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Measure: Brake pad wear limit “a” Out of specification  → Replace the brake 
pads as a set.
2. Install:  Brake pad spring
 Brake pad shims (onto the brake pads)
 Brake pads
NOTE:
Always install new brake pads, brake pad 
shims, and a brake pad spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to  the bleed screw “2”. Put the other end of 
the hose into an open container.
Brake disc deflection limit0.15 mm (0.0059 in)
Brake disc thickness limit4.5 mm (0.18 in)
Brake disc bolt30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE®
Brake pad lining thickness
(inner)
6.0 mm (0.24 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness
(outer) 6.0 mm (0.24 in)
Limit 1.0 mm (0.04 in) 
						

							
REAR BRAKE
4-47
b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper 
with your finger.
c. Tighten the bleed screw.
d. Install a new brake pad shim “3” onto each  new brake pad “4”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
 Brake caliper
 Brake pad pin
 Screw plug
4. Check:  Brake fluid level Below the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-24. 5. Check:
 Brake pedal operation Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
EAS22590
REMOVING THE REAR BRAKE CALIPER
NOTE:
Before disassembling 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 “4”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22600
DISASSEMBLING THE REAR BRAKE CALI-
PER
1. Remove: Brake caliper piston “1”
 Brake caliper piston seals “2”
Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
Brake caliper bolt (front side)27 Nm (2.7 m·kg, 20 ft·lb)
Brake caliper bolt (rear side) 22 Nm (2.2 m·kg, 16 ft·lb)
Brake pad pin 17 Nm (1.7 m·kg, 12 ft·lb)
Screw plug
3 Nm (0.3 m·kg, 22 ft·lb)