Yamaha Fz6n Manual
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1-5 FEATURES GEN INFO Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4. Push the “RESET” button to set the minutes. 5. Push the “SELECT” button and then release it to start the clock.
1-6 IMPORTANT INFORMATION GEN INFO springlip oil grease lip EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, eliminate all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylin- ders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an as- sembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disas- sembly. This will speed up assembly and al- low for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS00022 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur- faces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.
1-7 IMPORTANT INFORMATION GEN INFO CAUTION: EAS00023 LOCK WASHERS / PLATES AND COTTER PINS After removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. 1Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur- faces. 1Bearing EAS00025 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4Shaft
1-8 CHECKING THE CONNECTIONS GEN INFO NOTE: NOTE: NOTE: EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust / stains Connect and disconnect sev- eral times. 3. Check: all connections Loose connection Connect properly. If the pin 1 on the terminal is flattened, bend it up. 4. Connect: lead coupler connector Make sure all connections are tight. 5. Check: continuity (with the pocket tester) Pocket tester 90890-03112, YU-3112 If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores.
1-9 SPECIAL TOOLS GEN INFO NOTE: 1 21 EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. For others, use part number starting with “90890-”. Tool No. Tool name / FunctionIllustration Flywheel puller 90890-01362 YU-33270-B Adapter 90890-04089 YM-33282Flywheel puller Adapter This tool is used to remove the generator ro- tor. 90890-01701 YS-01880-A Sheave holder This tool is used to hold the generator rotor when removing or installing the generator ro- tor bolt or pickup coil rotor bolt. 90890-01304 YU-01304 Piston pin puller This tool is used to remove the piston pins. Radiator cap tester 90890-01325 YU-24460-01 Adapter 90890-01352 YU-33984Radiator cap tester Adapter These tools are used to check the cooling system. 90890-01403 YU-33975 Steering nut wrench This tool is used to loosen or tighten the steer- ing stem ring nuts. 90890-01460 -01326 Damper rod holder T-handle These tool are used for holding the damper rod when removing or installing the damper rod. Pivot shaft wrench 90890-01471 YM-01471 Pivot shaft wrench adapter 90890-01476Pivot shaft wrench Pivot shaft wrench adapter This tool is used to loosen or tighten the pivot adjust bolt and engine mount adjust bolt.
1-10 SPECIAL TOOLS GEN INFO Tool No.Tool name / FunctionIllustration 90890-01426 YU-38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge. Fork seal driver 90890-01367 YM-33963 Fork seal driver attachment 90890-01374 YM-8020-AFork seal driver weight Fork seal driver attachment This tool is used to install the front fork’s oil seal and dust seal. Vacuum gauge 90890-03094 YU-08030 Vacuum gauge This gauge is used to synchronize the carbu- retors. Compression gauge 90890-03081 YU-33223 Adapter 90890-04136Compression gauge Adapter These tools are used to measure engine compression. 90890-03112 YU-3112 Pocket tester This tool is used to check the electrical sys- tem. Oil pressure gauge 90890-03153 YU-03153 Adapter 90890-03139Oil pressure gauge Adapter These tools are used to measure engine oil pressure. 90890-03176 YM-03176 Fuel pressure adapter This tool is needed to measure fuel pressure. 90890-03153 YU-03153 Pressure gauge This tool used is to measure fuel pressure. 90890-04044 YM-04044 Piston ring compressor This tool is used to compress piston rings when installing the cylinder. Valve spring compressor 90890-04019 YM-04019 Attachment 90890-04108 YM-01253Valve spring compressor Attachment These tools are used to remove or install the valve assemblies.
1-11 SPECIAL TOOLS GEN INFO Tool No.Tool name / FunctionIllustration Middle driven shaft bearing driver 90890-04058 YM-4058 Mechanical seal installer 90890-04078 YM-33221Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal. 90890-04086 YM-91042 Clutch holding tool This tool is used to hold the clutch boss when removing or installing the clutch boss nut. 90890-04101 Valve lapper This tool is needed to remove and install the valve lifter. 90890-04111 Valve guide remover (φ4) This tool is used to remove or install the valve guides. 90890-04112 Valve guide installer (φ4) This tool is used to install the valve guides. 90890-04113 YM-04113 Valve guide reamer (φ4) This tool is used to rebore the new valve guides. 90890-06754 YM-34487 Ignition checker This tool is used to check the ignition system components. 90890-06756 YB-35956 Vacuum/pressure pump gauge set This tool used to measure the vacuum pres- sure. 90890-85505 ACC-11001- 05-01 Yamaha bond No. 1215 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
2-1 GENERAL SPECIFICATIONSSPEC SPECIFICATIONS GENERAL SPECIFICATIONS ItemStandardLimit Model code5VX3 (USA except for CAL) 5VX4 (CAL) Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,095 mm (82.5 in) 750 mm (29.5 in) 1,215 mm (47.8 in) 795 mm (31.3 in) 1,440 mm (56.7 in) 145 mm (5.71 in) 2,800 mm (110.2 in) Weight Wet (with oil and a full fuel tank) Maximum load (except motorcycle) 207 kg (456 lb) (USA except for CAL) 208 kg (459 lb) (CAL) 190 kg (419 lb) (USA except for CAL) 189 kg (417 lb) (CAL)
2-2 2 ENGINE SPECIFICATIONSSPEC ENGINE SPECIFICATIONS ItemStandardLimit Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Liquid-cooled, 4-stroke, DOHC 600 cm3 (36.61 cu.in) Forward-inclined parallel 4-cylinder 65.5 44.5 mm (2.58 1.75 in) 12.2 : 1 1,250 1,350 r / min 29 kPa (218 mmHg, 8.6 inHg) 1,550 kPa (15.50 kg / cm 2,15.50 bar, 220.46 psi) at 400 r / min Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Unleaded gasoline only 19.4 L (4.25 lmp gal, 5.1 US gal) 3.6 L (0.79 lmp gal, 0.9 US gal) Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature Relief valve opening pressure Wet sump At 5C (40F) or higher Yamalube 4 (20W40) or SAE 20W40 type SE motor oil At 15C (60F) or lower Yamalube 4 (10W30) or SAE 10W30 type SE motor oil 3.4 L (2.99 Imp qt, 3.59 US qt) 2.5 L (2.20 lmp qt, 2.64 US qt) 2.8 L (2.47 lmp qt, 2.96 US qt) 240 kPa at 6,600 r / min (2.4 kg / cm 2 at 6,600 r / min) (2.4 bar at 6,600 r / min) (34.1 psi at 6,600 r / min) 96C (205F) 450 550 kPa (4.5 5.5 kg / cm 2, 4.5 5.5 bar, 65.3 79.8 psi)
2-3 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Oil filter Oil filter type Bypass valve opening pressure Formed 80 120 kPa (0.8 1.2 kg / cm2, 0.8 1.2 bar, 11.6 17.4 psi) Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Trochoid 0.03 0.09 mm (0.0012 0.0035 in) 0.03 0.08 mm (0.0012 0.0032 in) 0.15 mm (0.0059 in) 0.15 mm (0.0059 in) Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max. impeller shaft tilt 2.0 L (1.76 lmp pt, 2.11 US qt) 93.3 122.7 kPa (0.93 1.23 kg/cm2, 0.93 1.23 bar, 13.5 17.8 psi) 300 mm (11.81 in) 188 mm (7.4 in) 24 mm (0.94 in) 0.27 L (0.24 lmp qt, 0.29 US qt) Single suction centrifugal pump 86 / 44 31 / 31 (1.955) 0.15 mm (0.006 in) Starting system typeElectric starter Spark plugs Model (manufacturer) quantity Spark plug gap CR9EK (NGK) 4 0.6 0.7 mm (0.0236 0.0276 in) Cylinder head Volume Max. warpage 10.3 10.9 cm3 (0.63 0.67 cu.in) 0.05 mm (0.002 in)