Yamaha Fz6 N Service Manual
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FRONT FORK 4-68 EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING EWA13660 Make sure the oil levels in both front fork legs are equal. Uneven oil levels can result in poor han- dling and a loss of stability. NOTE: When assembling the front fork leg, be sure to replace the following parts: - Inner tube bushing - Outer tube bushing -Oil seal - Dust seal Before assembling the front fork leg, make sure all of the components are clean. 1. Install: Inner tube bushing Outer tube bushing Oil flow stopper Damper rod assembly “1” Copper washer CAUTION: ECA14210 Allow the damper rod assembly to slide slowly down the inner tube until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: Inner tube’s outer surface 3. Tighten: Damper rod assembly bolt “1” NOTE: While holding the damper rod assembly with the damper rod holder “2” and T-handle “3”, tighten the damper rod assembly bolt. 4. Install: Outer tube bushing “1” (with the fork seal driver “2” and fork seal attachment “3”) New Recommended lubricantSuspension oil 01 or equiva- lent Damper rod assembly bolt23 Nm (2.3 m·kg, 17 ft·lb) LOCTITE® Damper rod holder90890-01294 Damping rod holder set YM-01300 T-handle 90890-01326 YM-01326 Fork seal driver weight90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 90890-01374 Replacement 43 mm YM-A5142-3
FRONT FORK 4-69 5. Install: Washer Oil seal “1” (with the fork seal driver and adapter) CAUTION: ECA14220 Make sure the numbered side of the oil seal faces up. NOTE: Before installing the oil seal, lubricate its lips with lithium soap base grease. Lubricate the outer surface of the inner tube with fork oil. Before installing the oil seal, cover the top of the front fork leg with a plastic bag “2” to pro- tect the oil seal during installation. 6. Install: Oil seal clip “1” NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 7. Install: Dust seal “1” (with the fork seal driver weight) 8. Fill: Front fork leg (with the specified amount of the recom- mended fork oil) CAUTION: ECA4S81015 Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Quantity467.0 cm³ (15.79 US oz) (16.47 Imp.oz) Recommended oil Suspension oil 01 or equiva- lent
FRONT FORK 4-70 9. Measure: Front fork leg oil level “a” Out of specification → Correct. NOTE: While filling the front fork leg, keep it upright. After filling, slowly pump the front fork leg up and down to distribute the fork oil. 10. Install: Spring “1” Spring seat “2” Spacer “3” Cap bolt NOTE: Install the spring with the smaller pitch “a” facing down. Before installing the cap bolt, lubricate its O- ring with grease. Temporarily tighten the cap bolt. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: Lower bracket pinch bolt “1” Cap bolt “2” Upper bracket pinch bolt “3” WARNING EWA13680 Make sure the brake hoses are routed prop- erly. Level 134.0 mm (5.28 in) b. Lager pitch Lower bracket pinch bolt30 Nm (3.0 m·kg, 22 ft·lb) Cap bolt24 Nm (2.4 m·kg, 17 ft·lb) Upper bracket pinch bolt 30 Nm (3.0 m·kg, 22 ft·lb)
STEERING HEAD 4-72 EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page 4-7. Front fender Refer to FRONT FORK on page 4-64. Front fork Refer to FRONT FORK on page 4-64. Handlebar Refer to HANDLEBAR on page 4-60. Front cowling inner panel (left side) Refer to GENERAL CHASSIS on page 4-1. Front cowling inner panel (right side) Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. 1 Main switch coupler 2 Disconnect. 2 Immobilizer coupler 1 Disconnect. 3 Steering stem nut 1 4 Washer 1 5 Upper bracket 1 6 Horn stay 1 7 Lock washer 1 8 Upper ring nut 1 9 Rubber washer 1 10 Lower ring nut 1 11 Lower bracket 1 12 Bearing cover 1
STEERING HEAD 4-73 13 Bearing inner race 2 14 Upper bearing 1 15 Lower bearing 1 16 Dust seal 1 17 Bearing outer race 2For installation, reverse the removal proce- dure. Removing the lower bracket Order Job/Parts to remove Q’ty Remarks
STEERING HEAD 4-74 EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Remove: Steering stem nut Washer Upper ring nut Lock washer Rubber washer Lower ring nut “1” (with the steering nut wrench “2”) Lower bracket NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, and then remove the upper ring nut with the ring nut wrench. WARNING EWA13730 Securely support the lower bracket so that there is no danger of it falling. EAS23130 CHECKING THE STEERING HEAD 1. Wash: Bearing balls Bearing races 2. Check: Bearing balls “1” Bearing races “2” Damage/pitting → Replace. 3. Replace: Bearing balls Bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races “1” from the steering head pipe with a long rod “2” and hammer. b. Remove the bearing race “3” from the lower bracket with a floor chisel “4” and hammer. c. Install a new dust seal and new bearing races. CAUTION: ECA14270 If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the bearings and bearing races as a set. Whenever the steering head is disassem- bled, replace the rubber seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: Steering nut wrench 90890-01403 Spanner wrench YU-33975 Recommended cleaning solvent Kerosene
STEERING HEAD 4-75 Upper bracket Lower bracket(along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: Upper bearing Lower bearing Bearing races 2. Install: Lower bracket Lower ring nut “1” Rubber washer “2” Upper ring nut “3” Lock washer “4” Refer to CHECKING THE STEERING HEAD on page 4-74. 3. Install: Upper bracket Washer Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4-70. NOTE: Temporarily tighten the upper and lower bracket pinch bolts. Recommended lubricantLithium-soap-based grease
REAR SHOCK ABSORBER ASSEMBLY 4-76 EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1. Side cover Refer to GENERAL CHASSIS on page 4-1. Rear brake caliper Refer to REAR BRAKE on page 4-41. Rear wheel Refer to REAR WHEEL on page 4-15. 1 Self-locking nut/collar/bolt 1/1/1 2 Self-locking nut/washer/bolt 1/1/1 3 Rear shock absorber assembly 1 4 Oil seal/bearing 2/1 For installation, reverse the removal proce- dure.
REAR SHOCK ABSORBER ASSEMBLY 4-77 EAS23180 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. Rear shock absorber damage will result in poor damping per- formance. EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release the gas pressure, drill a 2–3-mm hole through the rear shock absorber at a point 15–20 mm from its end as shown. WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips. EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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. Remove: Seat Side cover Refer to GENERAL CHASSIS on page 4- 1. Rear wheel Refer to REAR WHEEL on page 4-15. 3. Remove: Rear shock absorber assembly lower bolt “1” NOTE: While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 4. Remove: Rear shock absorber assembly upper bolt “2” Rear shock absorber assembly EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: Rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. Spring Damage/wear → Replace the rear shock absorber assembly.