Yamaha Fz6n Manual

4-25
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake 
master cylinder
Dust boot
Circlip
Master cylinder kit
Spring
Master cylinder
Push rod1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
4
5
6
EAS00585 

4-26
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the rear brake master 
cylinder
Brake fluid
Brake fluid reservoir cap
Rear brake fluid reservoir diaphragm
holder
Rear brake fluid reservoir diaphragm 
Brake fluid reservoir tank
Brake fluid reservoir hose
Union bolt
Copper washer
Brake hose
Master cylinder assembly1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the...

4-27
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear brake master
cylinder
Dust boot
Circlip
Master cylinder kit
Spring
Master cylinder body1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
4
5
EAS00587 

4-28
AB
CD
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE 
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:

brake light switch coupler 
1
(from the brake light switch)
2. Remove:

union bolt 
1

copper washers 2

brake hoses 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove:

brake lever

master cylinder bracket...

4-29
FRONT AND REAR BRAKESCHAS
NOTE: 3. Check:

rear brake fluid reservoir 
1
Cracks / damage 
 Replace.

rear brake fluid reservoir diaphragm 
2
Cracks / damage 
 Replace.
4. Check:

front brake master cylinder reservoir 
1
Cracks / damage 
 Replace.

front brake master cylinder reservoir dia-
phragm 
2
Damage / wear 
 Replace.
5. Check:

brake hoses
Cracks / damage / wear 
 Replace.
Refer to “CHECKING THE FRONT AND
REAR BRAKE HOSES” in chapter 3.
EAS00589
DISASSEMBLING THE REAR BRAKE 
MASTER CYLINDER...

4-30
FRONT AND REAR BRAKESCHAS
a
WARNING
NOTE:
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
EAS00598
ASSEMBLING AND INSTALLING THE 
FRONT BRAKE MASTER CYLINDER

Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.

Never use solvents on internal brake com-
ponents.
Recommended brake fluid
DOT 4
1. Install:

master cylinder kit

circlip 
New

brake master cylinder 
1

Install the brake master cylinder holder with
the “UP” mark facing up....

4-31
FRONT AND REAR BRAKESCHAS
NOTE:
WARNING

While holding the brake hose, tighten the
union bolt as shown.

Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
3. Fill:

brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing...

4-32
FRONT AND REAR BRAKESCHAS
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
WARNING
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:

brake master cylinder kit

circlip

dust boot
2. Install:

copper washers 
New

brake hoses

union bolt
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection 
a as shown.
3. Fill:

brake...

4-33
FRONT AND REAR BRAKESCHAS
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:

brake fluid level
Below the minimum level mark 
a 
 Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Adjust:

brake pedal position 
a
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake...

4-34
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the front brake calipers
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper
Brake pad
Brake caliper bracket1
2
1
1
2
1Remove the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal 
procedure.
NOTE:
10 Nm (1.0 m
kg, 72 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
40 Nm (4.0...