Yamaha Fz6 N Service Manual
Have a look at the manual Yamaha Fz6 N Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
SPECIAL TOOLS 1-32 Steering nut wrench 90890-01403 Spanner wrench YU-339753-29, 4-74 Damper rod holder 90890-01294 Damping rod holder set YM-01300 4-66, 4-68 T-handle 90890-01326 YM-01326 4-66, 4-68 Oil filter wrench 90890-01426 YU-38411 3-15 Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 4-68, 4-69 Fork seal driver attachment (ø43) 90890-01374 Replacement 43 mm YM-A5142-3 4-68 Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456 3-7 Compression gauge 90890-03081 Engine compression tester YU-33223 3-12 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-33 Pocket tester 90890-03112 Analog pocket tester YU-03112-C1-30, 5-38, 8- 111, 8-112, 8- 113, 8-114, 8- 117, 8-118, 8- 119, 8-120, 8- 121, 8-122, 8- 123, 8-124, 8- 125, 8-126, 8- 127, 8-128, 8- 129, 8-130 Pressure gauge 90890-03153 YU-03153 3-16, 7-6 Oil pressure adapter H 90890-03139 3-16 Fuel pressure adapter 90890-03176 YM-03176 7-6 Valve spring compressor 90890-04019 YM-04019 5-21, 5-27 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 5-21, 5-27 Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 6-12 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-34 Mechanical seal installer 90890-04078 Water pump seal installer YM-33221-A6-12 Universal clutch holder 90890-04086 YM-91042 5-49, 5-51 Valve lapper 90890-04101 Valve lapping tool YM-A8998 3-5 Valve guide remover (ø4) 90890-04111 Valve guide remover (4.0 mm) YM-04111 5-23 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 5-23 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 5-23 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 8-122 Yamaha bond No. 1215 (Three bond No.1215®) 90890-85505 5-32, 5-35, 5- 58, 6-12 Tool name/Tool No. Illustration Reference pages
SPECIAL TOOLS 1-35 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A19277-7 Test coupler adapter 90890-03149 1-25, 4-57, 4-58 Thickness gauge 90890-03079 Narrow gauge set YM-34483 4-21 Tool name/Tool No. Illustration Reference pages
2 SPECIFICATIONS GENERAL SPECIFICATIONS...................................................................... 2-1 ENGINE SPECIFICATIONS .......................................................................... 2-2 CHASSIS SPECIFICATIONS ........................................................................ 2-9 ELECTRICAL SPECIFICATIONS ............................................................... 2-12 TIGHTENING TORQUES ............................................................................ 2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS ....................... 2-15 ENGINE TIGHTENING TORQUES ...................................................... 2-16 CHASSIS TIGHTENING TORQUES .................................................... 2-20 LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-23 ENGINE ................................................................................................ 2-23 CHASSIS .............................................................................................. 2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS ................................. 2-25 ENGINE OIL LUBRICATION CHART ................................................... 2-25 LUBRICATION DIAGRAMS .................................................................. 2-27 COOLING SYSTEM DIAGRAMS ............................................................... 2-39 CABLE ROUTING ...................................................................................... 2-47
GENERAL SPECIFICATIONS 2-1 EAS20280 GENERAL SPECIFICATIONS ModelModel 1B3D (Europe) FZ6-N (Standard) 5S31 (Europe) FZ6-NA (ABS) 5S51 (Europe) FZ6-NHG (High-grade) 5S52 (Aus) FZ6-NHGW (High-grade) 5S41 (Europe) FZ6-NAHG (High-grade+ABS) 5VXL (Europe) FZ6-S (Standard) 4P53 (Europe) FZ6-SA (ABS) 4P54 (Europe) FZ6-SA (ABS) 4S81 (Europe) FZ6-SHG (High-grade) 4S85 (Aus) FZ6-SHGW (High-grade) 5S21 (Europe) FZ6-SAHG (High-grade+ABS) Dimensions Overall length 2095 mm (82.5 in) Overall width 750 mm (29.5 in) (FZ6-S/FZ6-SA/FZ6- SHG(W)/FZ6-SAHG) 755 mm (29.7 in) (FZ6-N/FZ6-NA/FZ6- NHG(W)/FZ6-NAHG) Overall height 1085 mm (42.7 in) (FZ6-N/FZ6-NA/FZ6- NHG(W)/FZ6-NAHG) 1210 mm (47.6 in) (FZ6-SHG(W)/FZ6-SAHG) 1215 mm (47.8 in) (FZ6-S/FZ6-SA) Seat height 795 mm (31.3 in) Wheelbase 1440 mm (56.7 in) Ground clearance 145 mm (5.71 in) Minimum turning radius 2800 mm (110.2 in) Weight With oil and fuel 201.0 kg (443 lb) (FZ6-N/FZ6-NHG(W)) 206.0 kg (454 lb) (FZ6-NA/FZ6-NAHG) 207.0 kg (456 lb) (FZ6-S/FZ6-SHG(W)) 212.0 kg (467 lb) (FZ6-SA/FZ6-SAHG) Maximum load 185 kg (408 lb) (FZ6-SA/FZ6-SAHG) 190 kg (419 lb) (FZ6-S/FZ6-SHG(W)) 191 kg (421 lb) (FZ6-NA/FZ6-NAHG) 196 kg (432 lb) (FZ6-N/FZ6-NHG(W))
ENGINE SPECIFICATIONS 2-2 EAS20290 ENGINE SPECIFICATIONS EngineEngine type Liquid cooled 4-stroke, DOHC Displacement 600.0 cm³ Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) Compression ratio 12.20:1 Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min) Minimum–maximum 1350–1736 kPa (192.0–246.9 psi) (13.5–17.4 kgf/cm²) Starting system Electric starter Fuel Recommended fuel Regular unleaded gasoline only Unleaded gasoline only (AUS) Fuel tank capacity 19.4 L (5.13 US gal) (4.27 Imp.gal) Fuel reserve amount 3.6 L (0.95 US gal) (0.79 Imp.gal) Engine oil Lubrication system Wet sump Type SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 Recommended engine oil grade API service SG type or higher, JASO standard MA Engine oil quantity Total amount 3.40 L (3.59 US qt) (2.99 Imp.qt) Without oil filter cartridge replacement 2.50 L (2.64 US qt) (2.20 Imp.qt) With oil filter cartridge replacement 2.80 L (2.96 US qt) (2.46 Imp.qt) Oil pressure 240 kPa at 6,600 r/min (2.4 kg/cm² at 6,600 r/min) (2.4 bar at 6,600 r/min) (34.1 psi at 6,600 r/min) Oil filter Oil filter type Formed Oil pump Oil pump type Trochoid Inner-rotor-to-outer-rotor-tip clearanc e 0.030–0.090 mm (0.0012–0.0035 in) Limit 0.15 mm (0.0059 in) Outer-rotor-to-oil-pump-housing clearanc e 0.030–0.080 mm (0.0012–0.0032 in) Limit 0.150 mm (0.0059 in) Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) Relief valve operating pressure 450.0–550.0 kPa (65.3–79.8 psi) (4.50–5.50 kgf/cm²) Pressure check location Main gallery
ENGINE SPECIFICATIONS 2-3 Cooling systemRadiator capacity (including all routes ) 2.00 L (2.11 US qt) (1.76 Imp.qt) Radiator capacity 0.60 L (0.63 US qt) (0.53 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 93–123 kPa (13.2–17.5 psi) (0.93–1.23 kgf/ cm²) Radiator core Width 300.0 mm (11.81 in) Height 188.0 mm (7.40 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single su ction centrifugal pump Reduction ratio 86/44 × 31/31 (1.955) Max. impeller shaft tilt 0.15 mm (0.006 in) Spark plug (s) Manufacturer/model NGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Volume 10.33–10.93 cm³ (0.63–0.67 cu.in) Warpage limit 0.05 mm (0.0020 in) CamshaftDrive system Chain drive (right) Camshaft cap inside diameter 23.008–23.029 mm (0.9058–0.9067 in) Camshaft journal diameter 22.967–22.980 mm (0.9042–0.9047 in) Camshaft-journal-to-camshaft-cap clear ance 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions Intake A 32.450–32.550 mm (1.2776–1.2815 in) Limit 32.400 mm (1.2756 in) Intake B 24.950–25.050 mm (0.9823–0.9862 in) Limit 24.900 mm (0.9803 in) Exhaust A 32.450–32.550 mm (1.2776–1.2815 in) Limit 32.400 mm (1.2756 in) Exhaust B 24.950–25.050 mm (0.9823–0.9862 in) Limit 24.900 mm (0.9803 in)
ENGINE SPECIFICATIONS 2-4 Camshaft runout limit 0.060 mm (0.0024 in) Timing chainModel/number of links 92RH2015/120 Tensioning system Automatic Valve clearance (cold)Intake 0.13–0.20 mm (0.0051–0.0079 in) Exhaust 0.23–0.30 mm (0.0091–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake) 1.140–1.980 mm (0.0449–0.0780 in) Valve face width B (exhaust) 1.140–1.980 mm (0.0449–0.0780 in) Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve margin thickness D (intake) 0.60–0.80 mm (0.0236–0.0315 in) Limit 0.5 mm (0.02 in) Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in) Limit 0.5 mm (0.02 in) Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in) Limit 3.950 mm (0.1555 in) Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in) Limit 3.935 mm (0.1549 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.042 mm (0.1591 in) Valve guide inside diameter (exhaust) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.042 mm (0.1591 in)
ENGINE SPECIFICATIONS 2-5 Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.040 mm (0.0016 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve springInner spring Free length (intake) 37.04 mm (1.46 in) Limit 35.20 mm (1.39 in) Free length (exhaust) 41.79 mm (1.65 in) Limit 39.70 mm (1.56 in) Installed length (intake) 30.02 mm (1.18 in) Installed length (exhaust) 36.12 mm (1.42 in) Spring rate K1 (intake) 10.50 N/mm (59.96 lb/in) (1.07 kgf/mm) Spring rate K2 (intake) 17.00 N/mm (97.07 lb/in) (1.73 kgf/mm) Spring rate K1 (exhaust) 30.26 N/mm (172.78 lb/in) (3.09 kgf/mm) Spring rate K2 (exhaust) 49.53 N/mm (282.82 lb/in) (5.05 kgf/mm) Installed compression spring force (intake) 69–79 N (15.51–17.76 lbf) (7.04–8.06 kgf) Installed compression spring force (exhaust) 160–184 N (35.97–41.36 lbf) (16.32–18.76 kgf) Spring tilt (intake) 2.5 °/1.6 mm (0.06 in) Spring tilt (exhaust) 2.5 °/1.8 mm (0.07 in) Winding direction (intake) Counter clockwise Winding direction (exhaust) Clockwise Outer spring Free length (intake) 38.40 mm (1.51 in) Limit 36.50 mm (1.44 in) Installed length (intake) 32.52 mm (1.28 in) Spring rate K1 (intake) 20.80 N/mm (118.77 lb/in) (2.12 kgf/mm) Spring rate K2 (intake) 33.30 N/mm (190.14 lb/in) (3.40 kgf/mm) Installed compression spring force (intake) 114–132 N (25.63–29.67 lbf) (11.62–13.46 kgf) Spring tilt (intake) 2.5 °/1.7 mm (0.07 in) Winding direction (intake) Clockwise Cylinder Bore 65.500–65.510 mm (2.5787–2.5791 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in)