Yamaha Fz6n Manual

							4-55
HANDLEBARCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14Removing the handlebar
Grip end
Handlebar grip (left)
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right handlebar switch
Throttle grip
Throttle cable
Front brake light switch connector
Front brake master cylinder holder
Front brake master cylinder
Upper handlebar holder
Handlebar2
1
1
1
1
1
1
1
2
1
1
1
2
1Remove the parts in the order listed.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
23 Nm (2.3 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
11 Nm (1.1 m
kg, 8.0 ft
lb)
EAS00664
HANDLEBAR 
						

							4-56
1
HANDLEBARCHAS
WARNING
NOTE:
WARNING
EAS00666
REMOVING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

grip end

handlebar grip 
1
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
3. Disconnect:

clutch switch connector
4. Remove:

left handlebar switch 
1

clutch cable 2

clutch lever holder 3
5. Remove:

grip end

front brake light switch connector

right handlebar switch 
1

throttle grip 2

front brake master cylinder holder 3

front brake master cylinder
EAS00668
CHECKING THE HANDLEBAR
1. Check:

handlebar 
1
Bends / cracks / damage 
 Replace.
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it. 
						

							4-57
HANDLEBARCHAS
WARNING
23 Nm (2.3 m
kg, 17 ft
lb)
CAUTION:
NOTE:
NOTE:
NOTE:
EAS00672
INSTALLING THE HANDLEBAR
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Install:

handlebar 
1

upper handlebar holders 2

upper handlebar holder caps 3

First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.

Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
Align the match marks 
a on the handlebar with
the upper surface of the lower handlebar hold-
ers.
3. Install:

throttle cables

right handlebar switch 
1

throttle grip 2
Align the projections a on the handlebar switch
with the holes 
b in the handlebar.
4. Install:

front brake master cylinder 
1

front brake master cylinder holder 2
Refer to “ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYL-
INDER”.

There should be 17 mm (0.67 in) of clearance
between the right handlebar switch and front
brake master cylinder.

Align the mating surfaces of the master cylin-
der bracket with the punch mark (right handle-
bar switch side) 
a on the handlebar. 
						

							4-58
HANDLEBARCHAS
26 Nm (2.6 m
kg, 19 ft
lb)
NOTE:
NOTE:
26 Nm (2.6 m
kg, 19 ft
lb)
WARNING
5. Install:

grip end
6. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the 
flange of the throttle grip)
3 
 5 mm (0.12 
 0.20 in)
7. Install:

clutch lever holder 
1

clutch cable
Align the slit on the clutch lever holder with the
punch mark 
a on the handlebar.
8. Adjust:

clutch cable free play
Refer to “ADJUST THE CLUTCH CABLE
FREE PLAY” in chapter 3.
Clutch cable free play (at the end
of the clutch lever)
10 
 15 mm (0.39 
 0.59 in)
9. Install:

left handlebar switch
Align the projection 
a on the left handlebar
switch with the hole 
b on the handlebar.
10. Install:

handlebar grip

grip end
a. Apply a thin coat of rubber adhesive onto the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Do not touch the handlebar grip until the
rubber adhesive has fully dried. 
						

							4-59
STEERING HEADCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the under bracket
Front wheel
Front fender
Front fork
Handlebar
Front cowling inner panel (left and right)
Fuel tank
Main switch coupler
Steering stem nut
Washer
Upper bracket
Horn stay
Lock washer2
1
1
1
1
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “HANDLEBAR”.
Refer to “COWLINGS” in chapter3.
Refer to “FUEL TANK” in chapter 3.
Disconnect.
Refer to “FRONT FORK”.
30 Nm (3.0 m
kg, 22 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
110 Nm (11 m
kg, 80 ft
lb)
EAS00676
STEERING HEAD
UNDER BRACKET 
						

							4-60
STEERING HEADCHAS
Order Job / Part Q’ty Remarks
7
8
9
10
11
12
13
14
15
16Upper ring nut
Rubber washer
Lower ring nut
Under bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race1
1
1
1
1
2
1
1
1
2
For installation, reverse the removal 
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
110 Nm (11 m
kg, 80 ft
lb) 
						

							4-61
STEERING HEADCHAS
WARNING
NOTE:
WARNING
EAS00677
REMOVING THE UNDER BRACKET
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

steering stem nut

washer

upper bracket

lock washer

rubber washer

ring nut 
1
(with the steering nut wrench 2)
Hold the lower ring nut with the exhaust and
steering nut wrench, and then remove the upper
rung nut with the ring nut wrench.
Steering nut wrench
90890-01403, YU-33975
Securely support the under bracket so that
there is no danger of it falling over.
EAS00682
CHECKING THE STEERING HEAD
1. Wash:

bearing balls

bearing races
Recommended cleaning solvent
Kerosene
2. Check:

bearing balls 
1

bearing races 2
Damage / pitting 
 Replace. 
						

							4-62
STEERING HEADCHAS
CAUTION:
NOTE:
3. Replace:

bearing balls

bearing races
a. Remove the bearing races 
1 from the steer-
ing head pipe with a long rod 
2 and hammer.
b. Remove the bearing race 
3 from the lower
bracket with a floor chisel 
4 and hammer.
c. Install a new dust seal and new bearing
races.
If the bearing race is not installed properly,
the steering head pipe could be damaged.

Always replace the bearing balls and bearing
races as a set.

Whenever the steering head is disassembled,
replace the dust seal.
4. Check:

upper bracket

lower bracket
(along with the steering stem)
Bends / cracks / damage 
 Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:

upper bearing

lower bearing

bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:

under bracket

lower ring nut 
1

rubber washer 2

upper ring nut 3

lock washer 4
Refer to “CHECKING THE STEERING
HEAD”. 
						

							4-63
STEERING HEADCHAS
110 Nm (11 m
kg, 80 ft
lb)
3. Install:

upper bracket

washer

steering stem nut
4. Install:

front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”. 
						

							4-64
REAR SHOCK ABSORBER ASSEMBLYCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the rear shock absorber 
assembly
Rear wheel
Self-locking nut / collar / bolt
(Swingarm-rear shock absorber)
Self-locking nut / washer / bolt
(Frame-rear shock absorber)
Rear shock absorber
Oil seal / bearing1/1/1
1/1/1
1
2/1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
For installation, reverse the removal 
procedure.
40 Nm (4.0 m
kg, 29 ft
lb)
40 Nm (4.0 m
kg, 29 ft
lb)
EAS00685
REAR SHOCK ABSORBER ASSEMBLY