Yamaha FZ6-SS Manuale utente

CONCERNING CRATE DAMAGE:

WARNING

CAUTION:

EAA00002

FOREWORD

This Assembly Manual contains the information required for the correct assembly of this Yamaha motor-

cycle prior to delivery to the customer. Since some external parts of the motorcycle have been removed at

the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should

be noted that the assembled motorcycle should be thoroughly cleaned, inspected, and adjusted prior to

delivery to the customer.

EAA00005

NOTICE

The service specifications given in this assembly manual are based on the model as manufactured.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and signifi-

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

appear in future editions of this manual where applicable.

The procedures below are described in the order that the procedures are carried out correctly and com-

pletely. Failure to do so can result in poor performance and possible harm to the motorcycle and/or rider.

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the

motorcycle operator, a bystander, or a person checking or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to

the motorcycle.

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

EAA00001

FZ6-SS

FZ6-SSC

ASSEMBLY MANUAL

E2003 by Yamaha Motor Corporation,

U.S.A. First Edition, November 2003

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11666-17-50

(1) (2)

(3) (4)

(5) (6)

(7)

(8)

EAA00008

SYMBOLS USED IN THE

ASSEMBLY MANUAL

In order to simplify descriptions in this as-

sembly manual, the following symbols are

used:

(1): Coat with lithium-soap-based grease.

(2): Tighten to 10 Nm.

(10 Nm = 1.0 mSkg, 7.2 ftSlb)

(3): Towards the front of the motorcycle

(4): Clearance required

(5): Install so that the arrow mark faces up-

ward.

(6): Apply motor oil.

(7): Made of rubber or plastics

(8):

A: Ref. No. (indicating the order of op-

erations.)

B: Part name

C: Quantity of parts per motorcycle

D: Place where parts are held

V: Stored in plastic bag

C: Stored in carton box

S: Fixed inside the steel frame

and/ or contained in the Styro-

foam tray (upper or lower)

*: Temporarily installed or secured

E: Size or material of parts

d / D: Diameter of part

ȏ: Length of part

e.g., 5 = 5 mm (0.2 in)

(1) (2)

(3) (4)

(5) (5)

EAA00040

PREPARATION

To assemble the motorcycle correctly, sup-

plies (e.g. oils, greases, and shop rags) and

sufficient working space are required.

Workshop

The workshop where the motorcycle is as-

sembled should be clean, spacious, and

have a level floor.

Self-protection

Protect your eyes with suitable safety

glasses or goggles when using compressed

air, when grinding or when doing any opera-

tion which may cause particles to fly off.

Protect hands and feet by wearing safety

gloves or shoes.

EAA00050

SYMBOLS USED ON

CRATE CARTON

(1) Contents of the transport package are

fragile, therefore the package must be

handled with care.

(2) Indicates correct upright position of the

transport package.

(3) Transport package must be kept away

from rain.

(4) Insertion of the forklift arms from this

side can cause damage.

(5) Lift arm inserting position.

If the forklift arms cannot be inserted under

the transport package in alignment with the

two yellow labels, adjust the arms so that

they are positioned evenly in relation to

these marks while taking care not to dam-

age the package contents.

–1–

NOTE:

EAA00060

UNPACKING

1. Remove the frame cover (1).

To remove the frame cover, cut the vinyl

bands around the cover using a cutter or

scissors.

2. Remove the carton boxes (2) and (3).

Remove the front wheel (4).

3. Remove the packing frame bolts (5) and

upper handlebar holders (6).

4. Remove the bolts (7).

5. Remove the packing frames (8). (Lift up

and then move to the side.)

Remove the bolts while holding the frame.

Before starting the assembly, check for

damaged or missing parts. Check both the

parts contained in the carton boxes and on

the motorcycle for damage, scratches, and

other defects.

–2–

EAA00070

PARTS LOCATION

(1) Carton box 1.

(2) Carton box 2.

(3) Front tire.

–3–

7EAA00080

(1) Carton box 1

1. Screws and special nuts (windshield)

2. Upper handlebar holders

3. Rivets

4. Screws

5. Bolts

6. Plugs

7. Nuts

8. Screws

9. Washers

10.Screws

11. Nuts

12.Bands

13.Inner panels

14.Windshield trims

15.Rear view mirrors

16.Windshield

17.Front fender

18.Owner’s manual

(2) Carton box 2

1. Handlebar

2. Gnip end (right)

3. Bolts (upper handlebar holders)

4. Front brake master cylinder bracket

5. Bolts (front brake master cylinder brack-

et)

6. Screws (left handlebar switch)

7. Collars

(3) Front tire

–4–

EAA00100

SETUP PROCEDURES

Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

–5–

1 Handlebar holders 2 V

2 Hexagon head bolt 4 V d = 8 (0.31), ȏ= 30 (1.18)

3 Plug 4 V

4 Handlebar 1 C

1 Screw 1 d = 5 (0.20), ȏ= 45 (1.77)

2 Screw 1 d = 5 (0.20), ȏ= 20 (0.79)

3 Grip end 1 V

1 Front tire 1 S

2 Collar 2 V

3 Axle 1

4 Hexagon head bolt 1

CAUTION:

WARNING

NOTE:

CAUTION:

EAA00014

EAA00102

1. HANDLEBAR

A: Clean the right handlebar end.

Apply light coat grease.

B: Install the handlebar holders

with the arrow mark facing for-

ward.

First tighten the bolts on the

front side, and then tighten the

bolts on the rear side.

C: Align the punch mark on the

handlebar with the top of the

lower handlebar holders.

D: Tighten the bolts to specifica-

tion.

Bolt:

23 Nm (2.3 mSkg, 17 ftSlb)

EAA00016

EAA00104

2. THROTTLE GRIP

A: Align the projection on the han-

dlebar switch with the hole in

the handlebar.

B: Tighten the bolt to specifica-

tion.

Bolt:

3.5 Nm (0.35 mSkg, 2.5 ftSlb)

C: Check the throttle grip for

smooth action.

Proper cable routing is essen-

tial to assure safe motorcycle

operation.

Refer to “CABLE ROUTING”.

D: Tighten the grip end.

Grip end:

26 Nm (2.6 mSkg, 19 ftSlb)

EAA00020

EAA00108

3. FRONT WHEEL

A: Clean the brake discs.

B: Clean the front wheel axle.

C: Clean the collar.

Take care not to get grease on

the brake discs or inner surface

of the brake pads. If you do so,

clean using a rag dampened

with a solvent. Foreign material

on the braking surface may

cause impaired braking action.

E: Lift the front wheel and install

the front wheel axle. Be sure

the arrow on the tire is pointed

in the rotating direction.

Do not depress the brake lever

when the calipers are off the brake

discs.

F: Tighten the wheel axle to speci-

fication.

Wheel axle:

72 Nm (7.2 mSkg, 52 ftSlb)

Before tightening the wheel axle

pinch bolt, stroke the front forks

several times to make sure of

proper fork operation.

G: Tighten the wheel axle pinch

bolt to specification.

Wheel axle pinch bolt:

23 Nm (2.3 mSkg, 17 ftSlb)

–6–

1 Front fender 1 S

2 Bolt 2 V d = 6 (0.24), ȏ= 22 (0.87)

3 Bolt 2 V d = 6 (0.24), ȏ= 25 (0.98)

4 Collar 2 V d = 6 (0.24)

1 Bolt 1 V d = 5 (0.20), ȏ= 45 (1.77)

2 Bolt 1 V d = 5 (0.20), ȏ= 30 (1.18)

1 Bracket 1 V

2 Hexagon head bolt 2 V d = 6 (0.24), ȏ= 20 (0.79)

3 Master cylinder 1

4Brake light switch connector 2

CAUTION:

WARNING

EAA00022

EAA00110

4. FRONT FENDER

A: Tighten the front fender bolts to

specification.

Bolt:

6 Nm (0.6 mSkg, 4.3 ftSlb)

Make sure the brake hose is

routed outside of the front fend-

er.

Be careful not to scratch the

front fender with the front fork

outer tube.

Proper cable routing is essen-

tial to assure safe motorcycle

operation.

Refer to “CABLE ROUTING”.

C: Clamp the front brake hose.

EAA00032

EAA00120

5. FRONT BRAKE MASTER

CYLINDER

A: Lubricate the pivoting parts of

the brake lever.

Recommended lubricants:

Yamaha cable lube or motor

oil

B: Make sure that the “UP” mark

with the bracket is pointed up-

ward.

C: Align the punch mark on the

handlebar with the gap of the

master cylinder bracket.

D: Tighten the bolts in stages and

maintain an equal gap on each

side of the bracket to specifica-

tion.

Bolt:

10 Nm (1.0 mSkg, 7.2 ftSlb)

E: Connect the front brake light

switch connector.

F: Check the brake lever for

smooth action.

Proper cable and hose routing

is essential to assure safe mo-

torcycle operation.

Refer to “CABLE ROUTING”.

EAA00035

EAA00123

6. HANDLEBAR SWITCH

A: Align the projection on the left

handlebar switch with the hole

in the handlebar.

Proper cable routing is essen-

tial to assure safe motorcycle

operation.

Refer to “CABLE ROUTING”.

B: Tighten the bolts to specifica-

tion.

Bolt:

3.5 Nm (0.35 mSkg, 2.5 ftSlb)

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