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” Rust/scratches/wear  → Replace the brake 
caliper pistons.
 Brake caliper cylinders “2” Scratches/wear 
→ Replace the brake cali-
per assembly.
 Brake caliper body “3” Cracks/damage  → Replace the brake cali-
per assembly.
 Brake fluid delivery passages (brake caliper body)
Obstruction  → Blow out with compressed 
air.
WARNING
EWA13610
Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals.
2. Check:  Rear brake caliper bracket “1” Cracks/damage  → Replace.
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER
WARNING
EWA13620
 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 as they will cause the piston 
seals to swell and distort.
 Whenever a brake caliper is disassem- bled, replace the brake caliper piston 
seals.
Recommended brake component
replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Brake fluid
Every two years and 
whenever the brake is 
disassembled
Recommended fluid
DOT 4 
						

							
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. Remove:  Brake caliper
3. Install:
 Brake pad spring  Brake pad shims (on to the brake pads)
 Brake pads
 Brake caliper
4. Fill:  Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13090
 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 fluid reservoir. Water 
will significantly lower the 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.
5. Bleed: Brake system Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
6. 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.
Brake hose union bolt 30 Nm (3.0 m·kg, 22 ft·lb)
New
New
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 pas pin 17 Nm (1.7 m·kg, 12 ft·lb)
Screw plug 3 Nm (0.3 m·kg, 2.2 ft·lb)
Recommended fluidDOT 4 
						

							
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 brake master cylinder
5. Remove:  Circlip (from the rear brake master cylinder)
 Master cylinder kit
EAS22720
CHECKING THE REAR 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 fluid reservoir “1”
Cracks/damage  → Replace.
 Brake fluid reservoir diaphragm “2” Cracks/damage  → Replace.
4. Check:  Brake hoses
Cracks/damage/wear  → Replace. 
						

							
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 to 
CABLE ROUTING on page 2-47.
CAUTION:
ECA14160
When installing the brake hose onto the 
brake master cylinder, make sure the brake 
pipe touches the projection “a” as shown.
2. Fill: Brake fluid reservoir (to the maximum level mark “a”)
WARNING
EWA13090
 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 fluid reservoir. Water 
will significantly lower the 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.
3. Bleed:
 Brake system Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-26.
4. Check:  Brake fluid level Below the minimum level mark “b”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-24.
5. Adjust:  Brake pedal position “c” Refer to ADJUSTING THE REAR DISC 
BRAKE on page 3-23.
Recommended fluidDOT 4
Brake hose union bolt30 Nm (3.0 m·kg, 22 ft·lb)
New
New
Recommended fluidDOT 4 
						

							
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 1 1
5 Union bolt 1
6 Copper washer 2
7 Brake hose (front brake master cylinder to 
hydraulic unit) 1
8 Union bolt 1
9 Copper washer 2 
						

							
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 from dirt and do not sub-
ject them to shocks.
 The ABS wheel sensor cannot be disas- sembled. Do not attempt to disassemble 
it. If faulty, replace with a new one.
 Do not turn the main switch to “ON” when  removing the hydraulic unit.
 Do not clean with compressed air.
 Do not use reuse the brake fluid.
 Brake fluid may damage painted surfaces  and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
 Do not allow any brake fluid to contact the 
couplers. Brake fluid may damage the 
couplers and cause bad contacts.
 If the union bolts for the hydraulic unit 
have been removed, be sure to tighten 
them to the specified torque and bleed 
the brake system.
Removing the hydraulic unit
1. Remove:  Brake hose “1” (from the front brake master  cylinder)
 Brake hose “2” (to the front brake caliper)  Brake hose “3” (from the rear brake master 
cylinder)
 Brake hose “4” (to the rear brake caliper)
NOTE:
Do not operate the brake lever and brake pedal 
while removing the brake hoses.
CAUTION:
ECA14530
When removing the brake hoses, cover the 
area around the hydraulic unit to catch any 
spilt brake fluid. Do not allow the brake 
fluid to contact other parts.
2. Remove:  Hydraulic unit bracket
NOTE:
Loosen the bolt in the proper sequence.
3. Remove:
 Hydraulic unit “1”
NOTE:
To avoid brake fluid leakage and to prevent for-
eign materials from entering the hydraulic unit, 
insert a rubber plug “a” or a bolt (M10  × 1.25) 
into each union bolt hole.
Checking the hydraulic unit
1. Check:
 Hydraulic unit “1” Cracks/damage  → Replace the hydraulic 
unit. 
						

							
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 holders are in the correct posi-
tion, otherwise the fuel hose will not be 
properly installed.
3. Remove: Rubber plugs or bolts (M10  × 1.25)
4. Install:
 Copper washer 
 Brake hose “1” (to the rear brake caliper)
 Brake hose “2” (from the rear brake master  cylinder)
 Brake hose “3” (to the front brake caliper)
 Brake hose “4” (from the front brake master  cylinder)
 Union bolt
WARNING
EWA13940
The brake hoses to the front and rear brake 
calipers can be distinguished by the rubber 
at the end of each hose. Be sure to connect 
each brake hose to the correct union bolt 
hole.
CAUTION:
ECA14760
To route the front and rear brake hoses, 
refer to CABLE ROUTING on page 2-47.
5. Fill:  Brake master cylinder reservoir
6. Bleed the brake system.
7. Check the operation of the hydraulic unit  according to the brake lever and the brake 
pedal response. (Refer to HYDRAULIC 
UNIT OPERATION TEST on page 4-56.)
CAUTION:
ECA14770
Always check the operation of the hydrau-
lic unit according to the brake lever and the 
brake pedal response.
8. Delete the malfunction codes. (Refer to [D-6-4] DELETING THE MALFUNCTION 
CODE on page 8-101.)
9. Perform a trial run. (Refer to [D-6-5] TRIAL 
RUN on page 4-59.)
EAS22800
HYDRAULIC UNIT OPERATION TEST
The reaction-force pulsating action generated 
in the brake lever and brake pedal when the 
ABS is activated can be tested when the vehi-
cle is stopped.
The hydraulic unit operation can be tested by 
the following two methods.
Hydraulic unit bracket bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
Brake hose union bolt30 Nm (3.0 m·kg, 22 ft·lb)
New
Recommended brake fluidDOT 4 
						

							
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 centerstand.
2. Set the main switch to “OFF”.
3. Remove: Seat Refer to GENERAL CHASSIS on page 4-
1.
 Fuel tank Refer to FUEL TANK on page 7-1.
 Front cowling inner panel (left side)
Refer to GENERAL CHASSIS on page 4-
1.
4. Check:
 Battery voltage
Lower than 12.8 V  → Charge or replace the 
battery.
NOTE:
 If the battery voltage is lower than 12.8 V,  charge the battery and perform hydraulic unit 
operation test 2.
 If the battery voltage is lower than 10 V, the  ABS warning light co mes on and the ABS 
does not operate.
5. Connect the test coupler adaptor “1” to the  test coupler “2”. 6. Set the main switch to “ON” while operating 
the brake lever and the brake pedal simul-
taneously.
CAUTION:
ECA4S81014
When the main switch is set to “ON”, be 
sure to operate both the brake levers and 
the brake pedal simultaneously. If only the 
brake levers or brake pedal are operated, 
set the main switch to “OFF” and start the 
procedure again.
7. Check:
 Hydraulic unit operation When the main switch is set to “ON”, the 
ABS warning light comes on for 2 seconds, 
goes off for 3 seconds, then starts flashing. 
When the ABS warning light starts flashing, 
the brake lever “1” will return to its home 
position. The brake pedal “2” will then 
return to its home position, then the brake 
lever will return to its home position again.
Battery voltage
Higher than 12.8 V
Test coupler adapter90890-03149