Yamaha FZ6-N 2004 Manuale utente

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

FZ6-N(S)2004.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementa-

ry Service Manual together with the following manual.

FZ6-S(S) 2004 SERVICE MANUAL: 5VX1-AE1

FZ6-N(S) 2004

SUPPLEMENTARY

SERVICE MANUAL

E2003 by Yamaha Motor Co., Ltd.

First Edition, December 2003

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EAS00002 NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-

al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

shouldhaveabasic understanding of mechanics and the techniquestorepairthese types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-

hicle unsafe and unfit for use.

YamahaMotorCompany, Ltd. is continually striving to improve all ofitsmodels.Modificationsandsig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

FailuretofollowWARNINGinstructionscouldresultin severe injuryordeathto

themotorcycleoperator, a bystander orapersoncheckingorrepairingthemo-

torcycle.

ACAUTIONindicates special precautions that must betakento avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

exceptin Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”),where the sub-sectiontitle(s) ap-

pears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 intheexplodeddiagramsindi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum-disulfide oil

21 Wheel-bearing grease

22 Lithium-soap-based grease

23 Molybdenum-disulfide grease

Symbols 24 to 25 intheexplodeddiagramsindi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DIAGRAMS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 18. . . . .

COWLINGS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING THE HEADLIGHT BULBS 21. . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE HEADLIGHT BEAMS 22. . . . . . . . . . . . . . . . . . . . . .

ENGINE

CONNECTING RODS AND PISTONS 23. . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVING THE CONNECTING RODS AND PISTONS 24. . . . . . . .

CHECKING THE BIG END BEARINGS (for EUR) 25. . . . . . . . . . . . . .

CHECKING THE BIG END BEARINGS (for OCE) 28. . . . . . . . . . . . . .

INSTALLING THE CONNECTING ROD AND PISTON

(for EUR) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE CONNECTING ROD AND PISTON

(for OCE) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM

RADIATOR 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM

CHECKING THE SWITCHES 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE LIGHTING SYSTEM 54. . . . . . . . . . . . . . . . . . . . . . . .

SIGNALING SYSTEM 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SIGNALING SYSTEM 59. . . . . . . . . . . . . . . . . . . . . .

FZ6-N(S) 2004 WIRING DIAGRAM

–1–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 1B31 (EUR), 1B32 (AUS) SSS

Dimensions

Overall width

Overall height 755 mm (29.7 in)

1,085 mm (42.7 in)

SSS

Weight

Wet (with oil and a full fuel tank)

Maximum load (except motorcycle) 201 kg (443 lb)

196 kg (432 lb)

SSS

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Bulbs (voltage/wattage quantity)

Headlight

Auxiliary light

Tail/brake light

Turn signal light

Licence light

Meter light

12V 60 W/55 W 1

12 V 5 W 1

12 V 5 W/21 W 1

12 V 10 W 4

12 V 5 W 1

SSS

Starting circuit cut-off relay

Model (manufacture) G8R-30Y-V3 (OMRON) SSS

–2–

TIGHTENING TORQUES SPEC

See

NOTE 1

NOTE 1:

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Item

Fastener

Thread

’

Tightening torque

Remarks

Item

Fastener

size

Qty

Nm mSkg ftSlb

Remarks

Connecting rod caps (for EUR) Nut M7 8 15 + 150_1.5 + 150_11 + 150_

Connecting rod caps (for OCE) Bolt M7 8 15 + 120_1.5 + 120_11 + 120_

CHASSIS TIGHTENING TORQUES

Item

Thread Tightening

Remarks

Item

size Nm mSkg ftSlb

Remarks

Radiator cover and radiator M6 8 0.8 7.2

Horn bracket and frame M6 7 0.7 5.1

Front frame and rear frame (upper) M10 41 4.1 30

Front frame and rear frame (lower) M10 41 4.1 30

Torepair,makesuretoapplytheliquidfixingagenttotheboltwithoutfixingagent(90149–10001)and

use it.

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