Yamaha Fz6 N Service Manual

							
ENGINE SPECIFICATIONS
2-6
PistonPiston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Limit 0.05 mm (0.0020 in)
Diameter D 65.475–65.490 mm (2.5778–2.5783 in)
Height H 4.0 mm (0.16 in)
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Limit 0.072 mm (0.0028 in)
 
Piston ring
Top ringRing type Barrel
Dimensions (B  × T) 0.90  × 2.45 mm (0.04  × 0.10 in)
End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in)
Limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring Ring type Taper
Dimensions (B  × T) 0.80  × 2.50 mm (0.03  × 0.10 in)
End gap (installed) 0.70–0.80 mm (0.0276–0.0315 in)
Limit 1.15 mm (0.0453 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.125 mm (0.0049 in) 
						

							
ENGINE SPECIFICATIONS
2-7
Oil ringDimensions (B  × T) 1.50  × 2.00 mm (0.06  × 0.08 in)
End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)
 
Connecting rod Oil clearance (using plastigauge®) 0 .028–0.052 mm (0.0011–0.0020 in)
Limit 0.08 mm (0.0032 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green
 
Crankshaft Width A 51.850–52.550 mm (2.04–2.06 in)
Width B 268.80–270.00 mm (10.58–10.63 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in)
Big end radial clearance 0.038–0.062 mm (0.0015–0.0024 in)
Small end free play 0.32–0.50 mm (0.01–0.02 in)
Journal oil clearance (using plastigauge®) 0.028–0.052 mm (0.0011–0.0020 in)
Limit 0.10 mm (0.0039 in)
Bearing color code 0.White 1.Blue 2.Black 3.Brown 4.Green
 
ClutchClutch type Wet, multiple-disc
Clutch release method Outer pull, rack and pinion pull
Clutch release method operation Cable operation
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 6 pcs
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 2 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch plate thickness 2.20–2.40 mm (0.087–0.094 in)
Plate quantity 1 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 55.00 mm (2.17 in)
Limit 52.30 mm (2.06 in)
Spring quantity 6 pcs
  
						

							
ENGINE SPECIFICATIONS
2-8
TransmissionTransmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 86/44 (1.955)
Secondary reduction system Chain drive
Secondary reduction ratio 46/16 (2.875)
Operation Left foot operation
Gear ratio1st 37/13 (2.846)
2nd 37/19 (1.947)
3rd 28/18 (1.556)
4th 32/24 (1.333)
5th 25/21 (1.190)
6th 26/24 (1.083)
Main axle runout limit 0.02 mm (0.0008 in)
Drive axle runout limit 0.02 mm (0.0008 in)
 
Shifting mechanismShift mechanism type Shift drum
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in)
 
Air filter
Air filter element Oil-coated paper element
 
Fuel pumpPump type Electrical
Model/manufacturer 5VX/DENSO
Maximum consumption amperage 5.5 A
Output pressure 250.0 kPa (36.3 psi) (2.50 kgf/cm²)
 
Fuel injectorModel/quantity 0290 x 4
Manufacturer DENSO
 
Throttle bodyType/quantity 36EIDW-B1/1 (FZ6-SHG(W)/FZ6-SAHG/FZ6- NHG(W)/FZ6-NAHG) 
36EIDW-B7/1 (FZ6-S/FZ6-SA (4P53)/FZ6-N/
FZ6-NA) 
36EIDW-B10/1 (FZ6-SA (4P54))
Manufacturer MIKUNI
ID mark 4P54 00 (FZ6-SA (4P54))  5VX1 03 (FZ6-SHG(W)/FZ6-SAHG/FZ6-
NHG(W)/FZ6-NAHG) 
5S31 00 (FZ6-S/FZ6-SA (4P53)/FZ6-N/FZ6-
NA)
Throttle valve size #50
 
Throttle position sensor Resistance 4.0–6.0 k Ω
Output voltage (at idle) 0.63–0.73 V Adjusted by tachometer
 
Idling condition
Engine idling speed 1250–1350 r/min
Intake vacuum 29.0 kPa (8.6 inHg) (218 mmHg)
Water temperature 95.0–105.0  °C (203.00–221.00  °F)
Oil temperature 75.0–85.0  °C (167.00–185.00  °F)
Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
  
						

							
CHASSIS SPECIFICATIONS
2-9
EAS20300
CHASSIS SPECIFICATIONS
ChassisFrame type Diamond
Caster angle 25.00  °
Trail 97.5 mm (3.84 in)
 
Front wheel Wheel type Cast wheel
Rim size 17M/C x MT3.50
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
 
Rear wheel
Wheel type Cast wheel
Rim size 17M/C x MT5.50
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
 
Front tireType Tubeless
Size 120/70 ZR17M/C (58W)
Manufacturer/model BRIDGESTONE/BT020F GG
Manufacturer/model DUNLOP/D252F
Wear limit (front) 0.8 mm (0.03 in)
 
Rear tireType Tubeless
Size 180/55 ZR17M/C (73W)
Manufacturer/model BRIDGESTONE/BT020R GG
Manufacturer/model DUNLOP/D252
Wear limit (rear) 0.8 mm (0.03 in)
 
Tire air pressure (measured on cold tires)Loading condition 0–90 kg (0–198 lb)
Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar)
Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) 
Loading condition 90–185 kg (198–408 lb) (FZ6-SA/FZ6-SAHG) 90–190 kg (198–419 lb) (FZ6-S/FZ6-SHG(W))
90–191 kg (198–421 lb) (FZ6-NA/FZ6-NAHG) 
90–196 kg (198–432 lb) (FZ6-N/FZ6-NHG(W))
Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar)
High-speed riding
Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar)
Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar)
 
Front brake Type Dual disc brake
Operation Right hand operation
Front disc brakeDisc outside diameter  × thickness 298.0  × 5.0 mm (11.73  × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness (inner) 4.5  mm (0.18 in) (FZ6-SHG(W)/FZ6-SAHG/
FZ6-NHG(W)/FZ6-NAHG)  
						

							
CHASSIS SPECIFICATIONS
2-10
6.0 mm (0.24 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6-
NA)
Limit 0.5 mm (0.02 in) (FZ6-SHG(W)/FZ6-SAHG/ FZ6-NHG(W)/FZ6-NAHG) 
0.8 mm (0.03 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6-
NA)
Brake pad lining thickness (outer) 4.5  mm (0.18 in) (FZ6-SHG(W)/FZ6-SAHG/
FZ6-NHG(W)/FZ6-NAHG) 
6.0 mm (0.24 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6-
NA)
Limit 0.5 mm (0.02 in) (FZ6-SHG(W)/FZ6-SAHG/ FZ6-NHG(W)/FZ6-NAHG) 
0.8 mm (0.03 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6-
NA)
Master cylinder inside diameter 16.00 mm (0.63 in)
Caliper cylinder inside diameter 30.20 mm (1.19 in)
Caliper cylinder inside diameter 27.00  mm (1.06 in) (FZ6-SHG(W)/FZ6-SAHG/
FZ6-NHG(W)/FZ6-NAHG)
25.4 mm (1.00 in) (FZ6-S/FZ6-SA/FZ6-N/FZ6-
NA)
Recommended fluid DOT 4
 
Rear brake Type Single disc brake
Operation Right foot operation
Brake pedal position (below the bottom of the
forest bracket) 25.8 mm (1.02 in)
Rear disc brakeDisc outside diameter  × thickness 245.0  × 5.0 mm (9.65  × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
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)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 38.10 mm (1.50 in)
Recommended fluid DOT 4
 
Steering Steering bearing type Angular bearing
Lock to lock angle (left) 35.0  °
Lock to lock angle (right) 35.0  °
 
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm (5.12 in)
Fork spring free length 354.0 mm (13.94 in)
Limit 347 mm (13.56 in)
Collar length 131.5 mm (5.18 in)
Installed length 347.0 mm (13.66 in)
Spring rate K1 7.40 N/mm (42.25 lb/in) (0.75 kgf/mm)
Spring rate K2 11.80 N/mm (67.38 lb/in) (1.20 kgf/mm)
Spring stroke K1 0.0–70.0 mm (0.00–2.76 in)
Spring stroke K2 70.0–130.0 mm (2.76–5.12 in)
Inner tube outer diameter 43.0 mm (1.69 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Suspension oil 01 or equivalent
Quantity 467.0 cm³ (15.79 US oz) (16.47 Imp.oz)
Level 134.0 mm (5.28 in)
  
						

							
CHASSIS SPECIFICATIONS
2-11
Rear suspensionType Swingarm (monocross)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 50.0 mm (1.97 in)
Spring free length 185.0 mm (7.28 in)
Installed length 172.0 mm (6.77 in)
Spring rate K1 127.40 N/mm (727.45 lb/in) (12.99 kgf/mm)
Spring stroke K1 0.0–50.0 mm (0.00–1.97 in)
Optional spring available No
Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²)
Spring preload adjusting positions (Minimum) 1
Spring preload adjusting positions (Standard) 3
Spring preload adjusting positions (Maximum) 7
Swingarm radial free play 1.0 mm (0.039 in)
Swingarm axial free play 1.0 mm (0.039 in)
 
Drive chainType/manufacturer 50V4/DAIDO
Link quantity 118
Drive chain slack 45.0–55.0 mm (1.77–2.17 in)
15-link length limit 239.3 mm (9.42 in)
  
						

							
ELECTRICAL SPECIFICATIONS
2-12
EAS20310
ELECTRICAL SPECIFICATIONS
Vo l t a g eSystem voltage 12 V
 
Ignition systemIgnition system Transistorized coil ignition (digital)
Ignition system type DC. TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0  °/1300 r/min
 
Engine control unit
Model/manufacturer FUA0015/MITSUBISHI (FZ6-SHG(W)/FZ6- NHG(W))
FUA0018/MITSUBISHI (FZ6-NAHG/FZ6-
SAHG) 
FUA0019/MITSUBISHI (FZ6-SA/FZ6-NA) 
FUA0020/MITSUBISHI (FZ6-S/FZ6-N)
 
Ignition coil
Model/manufacturer JO383/DENSO
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 1.53–2.07  Ω at 20 °C (68 °F)
Secondary coil resistance 12.0–18.0 k Ω at 20 °C (68 °F)
 
Spark plug cap
Material Resin
Resistance 10.0 k Ω
 
AC magneto
Model/manufacturer F5VX/MORIC
Stator coil resistance 0.22–0.34  Ω at 20 °C (68 °F)
Standard output 14.0 V310 W5000 r/min
Rectifier/regulator Regulator type Semi conductor-short circuit
Model/manufacturer SH719AA/SHINDENGEN
No load regulated voltage 14.1–14.9 V
Rectifier capacity 25.0 A
Withstand voltage 240.0 V
 
Battery
Model GT12B-4
Voltage, capacity 12 V, 10.0 Ah
Specific gravity 1.320
Manufacturer GYM
Ten hour rate amperage 1.00 A
 
HeadlightBulb type Halogen bulb
 
Bulb voltage, wattage  × quantity
Headlight 12 V, 60 W/55.0 W  × 1 (FZ6-N/FZ6-NA/FZ6-
NHG(W)/FZ6-NAHG)
12 V, 55.0 W  × 1 (FZ6-S/FZ6-SA/FZ6-
SHG(W)/FZ6-SAHG)
Auxiliary light 12 V, 5.0 W  × 1 (FZ6-N/FZ6-NA/FZ6-NHG(W)/
FZ6-NAHG)  
						

							
ELECTRICAL SPECIFICATIONS
2-13
12 V, 5.0 W × 2 (FZ6-S/FZ6-SA/FZ6-SHG(W)/
FZ6-SAHG)
Tail/brake light 12 V, 5.0 W/21.0 W  × 1
Front turn signal light 12 V, 10.0 W  × 2
Rear turn signal light 12 V, 10.0 W  × 2
License plate light 12 V, 5.0 W  × 1
Meter lighting LED  (FZ6-SHG(W)/FZ6-SAHG/FZ6-NHG(W)/ FZ6-NAHG) 
EL backlight LCD (FZ6-S/FZ6-SA/FZ6-N/FZ6-
NA)
 
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
Oil level warning light LED
High beam indicator light LED
Coolant temperature warning light LED  (FZ6-SHG(W)/FZ6-SAHG/FZ6-NHG(W)/ FZ6-NAHG)
Engine trouble warning light LED
Immobilizer system indicator light LED
ABS warning light LED (FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6-SAHG)
 
Electric starting system System type Constant mesh
 
Starter motorModel/manufacturer SM-14/MITSUBA
Power output 0.60 kW
Armature coil resistance 0.0012–0.0022  Ω
Brush overall length 10.0 mm (0.39 in)
Limit 3.50 mm (0.14 in)
Brush spring force 7.16–9.52 N (25.77–34.27 oz) (730–971 gf)
Commutator diameter 28.0 mm (1.10 in)
Limit 27.0 mm (1.06 in)
Mica undercut (depth) 0.70 mm (0.03 in)
 
Starter relay Model/manufacturer MS5F-441/JIDECO
Amperage 180.0 A
Coil resistance 4.18–4.62  Ω at 20 °C (68 °F)
 
Horn
Horn type Plane
Quantity 1 pcs
Model/manufacturer HF-12/NIKKO
Maximum amperage 3.0 A
Coil resistance 1.01–1.11  Ω
Performance 105–118 dB/2m
 
Turn signal relay Relay type Full transistor
Model/manufacturer FE218BH/DENSO
Built-in, self-canceling device No
Turn signal blinking frequency 75.0–95.0 cycles/min
Wattage 10 W  × 2 + 3.4 W
 
Oil level switch
Model/manufacturer 5VX/SOMIC ISHIKAWA
  
						

							
ELECTRICAL SPECIFICATIONS
2-14
Fuel gaugeModel/manufacturer 5VX/DENSO
Sender unit resistance (full) 19.0–21.0  Ω
Sender unit resistance (empty) 139.0–141.0  Ω
 
Starting circuit cut-off relay
Model/manufacturer G8R-30Y-V3/OMRON
Coil resistance 162–198  Ω
 
Radiator fan motor relay
Model/manufacturer ACM33211M05/MATSUSHITA
Coil resistance 86.4–105.6  Ω
 
Headlight relay
Model/manufacturer ACM33211M05/MATSUSHITA
Coil resistance 86.4–105.6  Ω
 
Fuel injection system relay
Model/manufacturer G8R-30Y-R/OMRON
Resistance 162–198  Ω
 
Thermo unit
Model/manufacturer 8CC/MITSUBISHI
Resistance at 80 °C 290.0–354.0  Ω
 
Fuses
Main fuse 30.0 A
Headlight fuse 20.0 A
Taillight fuse 10.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Radiator fan fuse 20.0 A
Fuel injection system fuse 10.0 A
Backup fuse 10.0 A
ABS motor fuse 30.0 A (FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6- SAHG)
ABS control unit fuse 10.0 A ( FZ6-NA/FZ6-NAHG/FZ6-SA/FZ6-
SAHG)
Reserve fuse 30.0 A
Reserve fuse 20.0 A
Reserve fuse 10.0 A
  
						

							
TIGHTENING TORQUES
2-15
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE SPECIFI-
CATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread 
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided 
for each chapter of this manual. To avoid 
warpage, tighten multi-fastener assemblies in 
a crisscross pattern and progressive stages 
until the specified tightening torque is reached. 
Unless otherwise specified, tightening torque 
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut) B (bolt)General tightening 
torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94