Yamaha Fz6 N Service Manual
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TIGHTENING TORQUES 2-16 EAS20340 ENGINE TIGHTENING TORQUESItem Thread size Q’ty Tightening torque Remarks Spark plugs M10 4 18 Nm (1.8 m·kg, 13 ft·lb) Cylinder head bolt M10 10 See NOTE Cylinder head bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft caps bolt M6 20 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap oil check bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) Air indication system reed valve cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) Air cut-off valve stay bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft sprocket bolt M7 4 20 Nm (2.0 m·kg, 14 ft·lb) Connecting rod cap bolt M7 8 15 Nm (1.5 m·kg, 11 ft·lb) + 120 ° Generator rotor bolt M12 1 75 Nm (7.5 m·kg, 54 ft·lb) Timing chain tensioner bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Thermostat cover bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Coolant hose joint bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Water pump cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Water pump bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Thermo sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb) Coolant drain bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Radiator bolt M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Radiator stay and crankcase M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Radiator cap stopper bolt M5 1 5 Nm (0.5 m·kg, 3.6 ft·lb) Radiator hose stay bolt M10 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pan bolt M6 12 12 Nm (1.2 m·kg, 8.7 ft·lb) Center oil pan bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil cooler union bolt M20 1 63 Nm (6.3 m·kg, 46 ft·lb) Engine oil drain bolt M14 1 43 Nm (4.3 m·kg, 31 ft·lb) Oil filter union bolt M20 1 70 Nm (7.0 m·kg, 51 ft·lb) Oil filter M20 1 17 Nm (1.7 m·kg, 12 ft·lb) Oil pump chain gui de bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pipe bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Throttle body joint bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb) Air filter case cover M5 6 1.2 Nm (0.12 m·kg, 0.9 ft·lb) Throttle body and throttle body joint M4 4 3 Nm (0.3 m·kg, 2.2 ft·lb) Throttle body and air filter case M5 4 3 Nm (0.3 m·kg, 2.2 ft·lb) Front exhaust pipe nut M8 8 20 Nm (2.0 m·kg, 14 ft·lb) Rear exhaust pipe bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) E M LT LT LT LT E LT LT
TIGHTENING TORQUES 2-17 Catalyst pipe and catalyst pipe stay boltM8 1 20 Nm (2.0 m·kg, 14 ft·lb) Muffler joint bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) See NOTE Catalyst joint bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) See NOTE Exhaust pipe stay bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) Catalyst pipe stay bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) Muffler stay bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) Muffler protector screw M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb) Crankcase bolt (main journal) M8 10 See NOTE Crankcase bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankcase bolt M6 12 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bolt M8 2 24 Nm (2.4 m·kg, 17 ft·lb) Generator rotor cover bolt M6 9 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt M6 7 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cable holder bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Pickup coil rotor cover bolt M6 7 12 Nm (1.2 m·kg, 8.7 ft·lb) Pickup coil rotor cover bolt M8 1 15 Nm (1.5 m·kg, 11 ft·lb) Shift shaft cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb) Breather plate screw M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Stator coil screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Pickup rotor cover clamp screw M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Drive sprocket cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil gallery bolt M16 2 8 Nm (0.8 m·kg, 5.8 ft·lb) Generator rotor cover and stator coil lead clamp screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Breather hose cover bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pipe bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Starter clutch screw M8 3 32 Nm (3.2 m·kg, 23 ft·lb) Starter motor cover bolt M6 2 3.4 Nm (0.34 m·kg, 2.3 ft·lb) Clutch pressure plate screw M6 6 8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch boss nut M20 1 90 Nm (9.0 m·kg, 65 ft·lb) Use a lock washer Drive sprocket nut M20 1 85 Nm (8.5 m·kg, 61 ft·lb) Use a lock washer Transmission bearing housing screw M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Shift drum retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Item Thread size Q’ty Tightening torque Remarks E E E E LT E LT LT LT LT LT LT
TIGHTENING TORQUES 2-18 NOTE: Cylinder head bolt1 First, tighten the bolts to approximately 19 Nm (1.9 m·kg, 14 ft·lb) with a torque wrench following the tightening order. 2 Retighten the bolts 50 Nm (5.0 m·kg, 36 ft·lb) with a torque wrench. Crankcase bolt (main journal) 1 First, tighten the bolts to approximately 12 Nm (1 .2 m·kg, 8.7 ft·lb) with a torque wrench following the tightening order. 2 Retighten the bolts 25 Nm (2.5 m·kg, 18 ft·lb) with a torque wrench. 3 Loosen the all bolts one by one following the ti ghtening order and then tighten them to 27 Nm (2.7 m·kg, 20 ft·lb) again. Muffler joint bolt Retighten the bolt at 1000 km (600 ml). Catalyst joint bolt Retighten the bolt at 1000 km (600 ml). O 2 sensor M18 1 45 Nm (4.5 m·kg, 33 ft·lb) Shift shaft spring stopper screw M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Shift rod nut M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Left thread Shift rod nut M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Shift rod joint M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Pickup coil rotor bolt M8 1 35 Nm (3.5 m·kg, 25 ft·lb) Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Neutral switch M10 1 20 Nm (2.0 m·kg, 14 ft·lb) Oil level switch bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Item Thread size Q’ty Tightening torque Remarks LT LT
TIGHTENING TORQUES 2-19 Cylinder head tightening sequence. Crankcase tightening sequence.
TIGHTENING TORQUES 2-20 EAS20350 CHASSIS TIGHTENING TORQUESItem Thread size Q’ty Tightening torque Remarks Upper bracket pinch bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb) Steering stem nut M22 1 110 Nm (11 m·kg, 80 ft·lb) Upper bracket and upper handle- bar holder M8 4 23 Nm (2.3 m·kg, 17 ft·lb) Lower bracket pinch bolt – 2 30 Nm (3.0 m·kg, 22 ft·lb) Lower ring nut M25 1 18 Nm (1.8 m·kg, 13 ft·lb) See NOTE Front fork cap bolt M35 2 24 Nm (2.4 m·kg, 17 ft·lb) Damper rod assembly bolt M10 2 23 Nm (2.3 m·kg, 17 ft·lb) Front wheel axle pinch bolt M8 1 23 Nm (2.3 m·kg, 17 ft·lb) Front brake master cylinder bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Front brake master cylinder cap screw M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) Front brake hose union blot M10 2 30 Nm (3.0 m·kg, 22 ft·lb) Front brake hose holder and front fork M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Front cowling stay and frame M8 2 33 Nm (3.3 m·kg, 24 ft·lb) Front cowling bracket and frame M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Front fender and front fork M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb) Clutch lever holder pinch bolt M6 1 11 Nm (1.1 m·kg, 8.0 ft·lb) Engine mount bolts (left of front side) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount bolts (left of rear side) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount bolts (right of front side) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount self locking nut (upper) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount self locking nut (lower) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Pivot shaft and frame M18 1 120 Nm (12 m·kg, 87 ft·lb) Rear shock absorber and frame M10 1 40 Nm (4.0 m·kg, 29 ft·lb) Rear shock absorber and rear arm M10 1 40 Nm (4.0 m·kg, 29 ft·lb) Seal guard and rear arm M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Rear fender and rear arm M6 3 7 Nm (0.7 m·kg, 5.0 ft·lb) Rear brake hose holder and rear arm M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank bracket and frame M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank bracket and fuel tank M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank and rear frame M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank and fuel tank cap M5 5 6 Nm (0.6 m·kg, 4.3 ft·lb) Fuel pump and fuel tank M5 6 4 Nm (0.4 m·kg, 2.9 ft·lb) Ignition coil and battery box M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb)
TIGHTENING TORQUES 2-21 Seat lock and frame M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Licence plate light screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Rear reflector bolt M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Flap and bracket 6 M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Bracket 6 and rear frame M6 2 19 Nm (1.9 m·kg, 14 ft·lb) Tail/brake right unit screw M6 2 3 Nm (0.3 m·kg, 2.2 ft·lb) Rear fender cover bolt M5 4 4 Nm (0.4 m·kg, 2.9 ft·lb) Seat handle bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb) Muffler and rear fender bolt M6 4 7 Nm (0.7 m·kg, 5.0 ft·lb) Side cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Lean angle sensor bolt M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) Coolant reservoir tank cover bolt M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Front wheel axle shaft bolt M18 1 72 Nm (7.2 m·kg, 52 ft·lb) Front brake caliper bolt M10 4 40 Nm (4.0 m·kg, 29 ft·lb) Front brake disc bolt M6 10 18 Nm (1.8 m·kg, 13 ft·lb) Brake caliper bleed screw M7 3 6 Nm (0.6 m·kg, 4.3 ft·lb) Rear wheel axle nut M24 1 120 Nm (12 m·kg, 87 ft·lb) Rear brake disc and rear wheel M8 5 30 Nm (3.0 m·kg, 22 ft·lb) Rear brake caliper bolt front and rear brake caliper bracketM8 1 27 Nm (2.7 m·kg, 20 ft·lb) Rear brake caliper bolt rear and rear brake caliper bracket M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Rear wheel sprocket and rear wheel drive hub M10 6 100 Nm (10 m·kg, 72 ft·lb) Chain adjusting bolt lock nut M8 2 16 Nm (1.6 m·kg, 12 ft·lb) Rear brake hose union bolt M10 1 30 Nm (3.0 m·kg, 22 ft·lb) Sidestand bolt M10 1 46 Nm (4.6 m·kg, 33 ft·lb) Sidestand bracket and frame M10 2 63 Nm (6.3 m·kg, 46 ft·lb) Sidestand switch screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Footrest bracket and frame M8 4 30 Nm (3.0 m·kg, 22 ft·lb) Rear brake reservoir tank and bracket M6 1 3 Nm (0.3 m·kg, 2.2 ft·lb) Rear master cylinder and footrest bracket M8 2 23 Nm (2.3 m·kg, 17 ft·lb) Centerstand bolt M10 2 73 Nm (7.3 m·kg, 53 ft·lb) Front wheel sensor bolt (with ABS) M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Rear wheel sensor bolt (with ABS) M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) ECU bolt (engine control unit) M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Bracket and hydraulic unit bracket 1 bolt (with ABS) M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb) Hydraulic unit bracket 1 and hydraulic unit bracket 2 bolt (with ABS) M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) Item Thread size Q’ty Tightening torque Remarks LT LT
TIGHTENING TORQUES 2-22 NOTE: Lower ring nut1. First, tighten the ring nut to approximately 52 Nm (5.2 m·kg, 38 ft·lb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut to specification. Engine mount bolts and engine mount self locking nut Refer to INSTALLING THE ENGINE on page 5-6. Hydraulic unit bracket 1 and stay bolt (with ABS) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Rear wheel sensor rotor bolt (with ABS) M5 5 6 Nm (0.6 m·kg, 4.3 ft·lb) Stay and frame bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) Hydraulic unit and brake hose union bolt (with ABS) M10 4 30 Nm (3.0 m·kg, 22 ft·lb) Item Thread size Q’ty Tightening torque Remarks LT
LUBRICATION POINTS AND LUBRICANT TYPES 2-23 EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings and bushes Crankshaft pins Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surface Piston cooler (O-ring) Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No.1215 Cylinder head cover semicircular Yamaha bond No.1215 Crankcase mating surface Yamaha bond No.1215 Generator rotor cover (stator coil assembly lead grommet) Yamaha bond No.1215 Pickup rotor cover (crankshaft position sensor lead grommet) Yamaha bond No.1215 LS LS E E E E M E M M M E E E E E E LS E E E M M E E E E
LUBRICATION POINTS AND LUBRICANT TYPES 2-24 EAS20380 CHASSISLubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end, oil seal and bush Engine mount bolts (rear upper and lower) Shift pedal shaft Shift shaft joint Rear footrest ball and metal-to-metal moving parts Main stand metal-to-metal moving parts LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART