Yamaha Fz6n Manual

6-4
RADIATORCOOL
EAS00456
INSTALLING THE RADIATOR
1. Install:

radiator

coolant hoses
2. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:

cooling system
Leaks 
 Repair or replace any faulty part.
4. Measure:

radiator cap opening pressure
Below the specified pressure 
 Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”. 

6-5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the oil cooler
Radiator assembly
Engine oil
Oil cooler outlet hose
Union bolt
Washer
Oil cooler
O-ring
Oil cooler inlet hose
Oil cooler inlet pipe
Water jacket joint hose
Water jacket joint1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “RADIATOR”.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
63 Nm (6.3 m
kg, 46 ft
lb)
OIL COOLERCOOL
EAS00457
OIL COOLER 

6-6
OIL COOLERCOOL
Order Job / Part Q’ty Remarks
10
11
12O-ring
Water pump outlet hose
Radiator outlet hose1
1
1
For installation, reverse the removal 
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
63 Nm (6.3 m
kg, 46 ft
lb) 

6-7
OIL COOLERCOOL
63 Nm (6.3 m
kg, 46 ft
lb)
NOTE:
EAS00458
CHECKING THE OIL COOLER
1. Check:

oil cooler
Cracks / damage 
 Replace.
2. Check:

oil cooler inlet hose

oil cooler outlet hose
Cracks / damage / wear 
 Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:

mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:

O-ring 
New

oil cooler 
1

washer 2 New

union bolt 
3

Before installing the oil cooler, lubricate the
union bolt and O-ring...

6-8
Order Job / Part Q’ty Remarks
1
2
3Removing the thermostat
Seat
Front cowling inner panel (left and right)
Fuel tank
Air filter case
Coolant
Throttle body assembly
Radiator inlet hose
Thermostat cover
Thermostat1
1
1Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
Refer to “COWLINGS”
Refer to “FUEL TANK”
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “THROTTLE BODIES” in 
chapter 7.
For installation, reverse the removal...

6-9
1
THERMOSTATCOOL
NOTE:
EAS00462
CHECKING THE THERMOSTAT
1. Check:

thermostat 
1
Does not open at 71 
 85C (160 
 185F)

 Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermo-
stat and thermometer’s indicated tempera-
ture.
1Thermometer
2Water
3Thermostat
4Container
AFully closed
BFully open
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat...

6-10
THERMOSTATCOOL
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00466
INSTALLING THE THERMOSTAT
1. Install:

thermostat
Install the thermostat with its breather hole 
a
facing up.
2. Install:

thermostat cover
Before installing the thermostat cover to the cyl-
inder head, lubricate the O-ring with a thin coat
of lithium soap based grease.
3. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
4. Check:

cooling system
Leaks 
 Repair...

6-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the water pump
Coolant
Radiator outlet hose
Water pump outlet hose
Water pump breather hose
Water pump1
1
1
1Remove the parts in the order listed.
It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)...

6-12
Order Job / Part Q’ty Remarks
Disassembling the water pump
Water pump cover
O-ring
Impeller shaft
Circlip
Water pump seal
Oil seal
Bearing
Water pump housing
O-ring
Copper washer1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
10 Nm (1.0 m
kg, 7.2 ft
lb)
8
9
10
WATER PUMPCOOL 

6-13
WATER PUMPCOOL
NOTE:
NOTE:
NOTE:
NOTE:
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:

water pump cover

O-ring

circlip

impeller shaft
2. Remove:

water pump seal 
1
Remove the water pump seal from the outside
of the water pump housing.
2Water pump housing
3. Remove:

oil seal 
1
(with a thin, flat-head screwdriver)
Remove the oil seal from the outside of the wa-
ter pump housing.
4. Remove:

bearing 
1
Remove the bearing from inside of the water
pump housing.
5. Remove:

rubber damper holder...