Yamaha Fz6n Manual
Have a look at the manual Yamaha Fz6n Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
4-5 FRONT WHEEL AND BRAKE DISCSCHAS CAUTION: c. Remove the wheel bearings 3 with a gener- al bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing inner race 1 or balls 2. Contact should be made only with the outer race 3. Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal. EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: brake disc Damage / galling Replace. 2. Measure: brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) Front: 0.1 mm (0.004 in) Rear: 0.15 mm (0.006 in) a. Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflec- tion, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the deflection 2 3 mm (0.08 0.12 in) below the edge of the brake disc.
4-6 FRONT WHEEL AND BRAKE DISCSCHAS NOTE: 3. Measure: brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification Replace. Brake disc thickness limit (minimum) Front: 4.5 mm (0.18 in) Rear: 4.5 mm (0.18 in) 4. Adjust: brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 18 Nm (1.8 mkg, 13 ftlb) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. EAS00545 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: wheel axle oil seal lips Recommended lubricant Lithium-soap-based grease 2. Lift the wheel up between the fork legs.
4-7 FRONT WHEEL AND BRAKE DISCSCHAS NOTE: 72 Nm (7.2 mkg, 52 ftlb) 23 Nm (2.3 mkg, 17 ftlb) CAUTION: 40 Nm (4.0 mkg, 29 ftlb) NOTE: 10 Nm (1.0 mkg, 7.2 ftlb) WARNING NOTE: NOTE: 3. Insert the wheel axle. Install the tire and wheel with the mark 1 point- ing in the direction of wheel rotation. 4. Lower the front wheel so that it is on the ground. 5. Tighten: wheel axle wheel axle pinch bolt Before tightening the wheel axle pinch bolt, push down hard in the handlebar several times and check if the front fork rebounds smoothly. 6. Install: brake calipers (left and right) Make sure that there is enough space between the brake pads before installing the brake cali- pers onto the brake discs. 7. Install: brake hose holder Make sure the brake hose is routed properly. EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE After replacing the tire, wheel or both, the front wheel static balance should be adjusted. Adjust the front wheel static balance with the brake discs installed. 1. Remove: balancing weight(s) 2. Find: front wheel’s heavy spot Place the front wheel on a suitable balancing stand.
4-8 FRONT WHEEL AND BRAKE DISCSCHAS NOTE: a. Spin the front wheel. b. When the front wheel stops, put an “X 1” mark at the bottom of the wheel. c. Turn the front wheel 90 so that the “X 1” mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an “X 2” mark at the bottom of the wheel. f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”. 3. Adjust: front wheel static balance a. Install a balancing weight 1 onto the rim ex- actly opposite the heavy spot “X”. Start with the lightest weight. b. Turn the front wheel 90 so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that posi- tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. 4. Check: front wheel static balance a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.
4-9 REAR WHEEL AND BRAKE DISCCHAS Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8 9 10Removing the rear wheel Brake caliper Lock nut (left and right) Adjusting nut (left and right) Wheel axle nut Washer Rear wheel axle Washer Drive chain puller (left and right) Rear wheel Rear brake caliper bracket1 2 2 1 1 1 1 2 1 1Remove the parts in the order listed. Place the motorcycle on a suitable stand so that the rear wheel is elevated. Loosen. Loosen. For installation, reverse the removal procedure. NOTE: 27 Nm (2.7 mkg, 20 ftlb) 22 Nm (2.2 mkg, 16 ftlb) 120 Nm (12 mkg, 87 ftlb) EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL
4-10 REAR WHEEL AND BRAKE DISCCHAS Order Job / Part Q’ty Remarks 1 2 3 4 5 6 7 8Removing the rear brake disc and rear wheel sprocket Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel1 1 2 2 2 1 6 1Remove the parts in the order listed. For installation, reverse the removal procedure. 30 Nm (3.0 mkg, 22 ftlb) 100 Nm (10 mkg, 72 ftlb) EAS00556 REAR BRAKE DISC AND REAR WHEEL SPROCKET
4-11 REAR WHEEL AND BRAKE DISCCHAS Order Job / Part Q’ty Remarks Disassembling the rear wheel Collar Bearing Spacer Oil seal Circlip Bearing1 1 1 1 1 1Disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 3 2 4 5 6 EAS00560
4-12 REAR WHEEL AND BRAKE DISCCHAS WARNING NOTE: NOTE: NOTE: EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: brake caliper 1 Do not depress the brake pedal when removing the brake caliper. 3. Loosen: locknut 1 adjusting nut 2 4. Remove: wheel axle nut 3 wheel axle 4 washer rear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket. 5. Remove: left collar 1 rear wheel drive hub 2 rear wheel drive hub damper right collar
4-13 REAR WHEEL AND BRAKE DISCCHAS EAS00565 CHECKING THE REAR WHEEL 1. Check: wheel axle rear wheel wheel bearings oil seals Refer to “CHECKING THE FRONT WHEEL”. 2. Check: tire rear wheel Damage / wear Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: radial wheel runout lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”. EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: rear wheel drive hub 1 Cracks / damage Replace. rear wheel drive hub dampers 2 Damage / wear Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: rear wheel sprocket More than 1 / 4 tooth a wear Replace the rear wheel sprocket. Bent teeth Replace the rear wheel sprock- et. bCorrect 1Drive chain roller 2Rear wheel sprocket
4-14 REAR WHEEL AND BRAKE DISCCHAS NOTE: 120 Nm (12 mkg, 87 ftlb) 27 Nm (2.7 mkg, 20 ftlb) 22 Nm (2.2 mkg, 16 ftlb) 2. Replace: rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 100 Nm (10 mkg, 72 ftlb) Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: wheel axle wheel bearings oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: collars rear brake caliper bracket rear wheel washer rear wheel axle 3. Adjust: drive chain slack Drive drain slack 45 55 mm (1.77 2.17 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 4. Tighten: wheel axle nut brake caliper bolts (front) brake caliper bolts (rear)