Yamaha Fz6n Manual

EAS00010
FZ6-SS / FZ6-SSC
SERVICE MANUAL
2003 by Yamaha Motor
Corporation, U.S.A.
First edition, November 2003
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P / N LIT-11616-17-50 

NOTE:
WARNING
CAUTION:
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is...

12
4
8
3
5
6
7
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current...

22
1
3
5
7
9
2
4
8
6
2425
2321
192018
161715
1413
1112
10
GEN
INFOSPEC
ENG
FI ELECCOOL CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 
1 to 9 indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10Serviceable with engine mounted
11Filling fluid
12Lubricant...

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND 
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
1
SPEC2
3
ENG
4
COOL
5
FI
6
CHAS
7
ELEC8
TRBL
SHTG
9
CHK
ADJ
EAS00012
TABLE OF CONTENTS 

CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . 
MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
FEATURES1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
OUTLINE OF FI SYSTEM 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

ENGINE OIL LUBRICATION CHART2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
LUBRICATION DIAGRAMS2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
CABLE ROUTING2-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM3-1 ....

CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . 
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . . 
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . . 
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-46. . . . . . . . . . . . ....

FRONT AND REAR BRAKES4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
FRONT BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
REAR BRAKE PADS 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
REPLACING THE FRONT BRAKE PADS 4-19. . . . . . . . . . . . . . . . . . . . . 
REPLACING THE REAR BRAKE PADS 4-21. . . . . . . . . . . . . . . . . . . . . . 
FRONT BRAKE MASTER CYLINDER 4-23. . . . . . . . . . . . . ....