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Yamaha FZ6-SS Manuals
Manuals and User Guides for Yamaha FZ6-SS. We have
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Yamaha FZ6-SS manuals available for free PDF download: Service Manual, Owner's Manual, Assembly Manual
Yamaha FZ6-SS Service Manual (435 pages)
Yamaha Motorcycle Service manual
Brand:
Yamaha
| Category:
Motorcycle
| Size: 14.51 MB
Table of Contents
Specifications
5
Table of Contents
6
Important Manual Information
3
How to Use this Manual
4
Periodic Checks and Adjustments
5
Chassis
5
Engine
5
Cooling System
5
Fuel Injection System
5
Electrical System
5
Troubleshooting
15
Chapter 1 General Information
17
Motorcycle Identification
17
Vehicle Identification Number
17
Model Label
17
Gen Info
17
Features
18
Outline of Fi System
18
Fi System
19
Instrument Function
20
Important Information
22
Preparation for Removal and Disassembly
22
Replacement Parts
22
Gaskets, Oil Seals and O-Rings
22
Lock Washers/Plates and Cotter Pins
23
Bearings and Oil Seals
23
Circlips
23
Checking the Connections
24
Special Tools
25
Chapter 2 Specifications
28
Spec
28
General Specifications
28
Engine Specifications
29
Chassis Specifications
37
Electrical Specifications
41
Conversion Table
44
General Tightening Torque Specifications
44
Tightening Torques
45
Engine Tightening Torques
45
Chassis Tightening Torques
48
Lubrication Points and Lubricant Types
50
Engine
50
Chassis
51
Cooling System Diagrams
52
Engine Oil Lubrication Chart
56
Lubrication Diagrams
57
Cable Routing
63
Chapter 3 Periodic Checks and Adjustments
78
Introduction
78
Periodic Maintenance Chart for the Emission Control System
78
General Maintenance and Lubrication Chart
78
Chk Adj
78
Seat
80
Fuel Tank
81
Removing the Fuel Tank
83
Removing the Fuel Pump
83
Installing the Fuel Pump
84
Installing the Fuel Tank
84
Cowlings
85
Air Filter Case
86
Battery Box and Battery Box Bracket
87
Engine
88
Adjusting the Valve Clearance
88
Synchronizing the Throttle Bodies
94
Adjusting the Engine Idling Speed
96
Adjusting the Throttle Cable Free Play
97
Checking the Spark Plugs
99
Measuring the Compression Pressure
100
Checking the Engine Oil Level
103
Changing the Engine Oil
104
Measuring the Engine Oil Pressure
106
Adjusting the Clutch Cable Free Play
108
Cleaning the Air Filter Element
109
Checking the Throttle Body Joints
110
Checking the Fuel and Breather Hoses
111
Checking the Crankcase Breather Hose
111
Checking the Exhaust System
112
Checking the Coolant Level
113
Checking the Cooling System
114
Changing the Coolant
115
Chassis
118
Adjusting the Front Brake
118
Adjusting the Rear Brake
119
Checking the Brake Fluid Level
120
Checking the Front and Rear Brake Pads
121
Adjusting the Rear Brake Light Switch
122
Checking the Front and Rear Brake Hoses
122
Bleeding the Hydraulic Brake System
124
Adjusting the Shift Pedal
124
Adjusting the Drive Chain Slack
125
Lubricating the Drive Chain
126
Checking and Adjusting the Steering Head
127
Checking the Front Fork
129
Adjusting the Rear Shock Absorber Assembly
130
Checking the Tires
131
Checking and Lubricating the Cables
134
Lubricating the Levers and Pedals
134
Lubricating the Sidestand
134
Lubricating the Centerstand
134
Lubricating the Rear Suspension
135
Electrical System
136
Checking and Charging the Battery
136
Checking the Fuses
142
Replacing the Headlight Bulbs
144
Adjusting the Headlight Beams
145
Chapter 4 Chassis
146
Chas
146
Front Wheel and Brake Discs
146
Removing the Front Wheel
148
Checking the Front Wheel
148
Checking the Brake Discs
150
Installing the Front Wheel
151
Adjusting the Front Wheel Static Balance
152
Rear Wheel and Brake Disc
154
Rear Wheel and Brake Disc Rear Wheel
154
Rear Brake Disc and Rear Wheel Sprocket
155
Removing the Rear Wheel
157
Checking the Rear Wheel
158
Checking the Rear Wheel Drive Hub
158
Checking and Replacing the Rear Wheel Sprocket
158
Installing the Rear Wheel
159
Adjusting the Rear Wheel Static Balance
160
Front and Rear Brakes
161
Front Brake Pads
161
Replacing the Front Brake Pads
164
Replacing the Rear Brake Pads
166
Front Brake Master Cylinder
168
Disassembling the Front Brake Master Cylinder
170
Disassembling the Rear Brake Master Cylinder
172
Master Cylinder
173
Disassembling the Front Brake Calipers
173
Disassembling the Rear Brake Caliper
182
Calipers
183
Caliper
184
Front Fork
190
Front Fork Legs
190
Removing the Front Fork Legs
193
Disassembling the Front Fork Legs
193
Checking the Front Fork Legs
195
Assembling the Front Fork Legs
196
Installing the Front Fork Legs
199
Handlebar
200
Removing the Handlebar
201
Checking the Handlebar
201
Installing the Handlebar
202
Steering Head
204
Under Bracket
204
Removing the under Bracket
206
Checking the Steering Head
206
Installing the Steering Head
207
Rear Shock Absorber Assembly
209
Removing the Rear Shock Absorber Assembly
210
Handling the Rear Shock Absorber
211
Disposing of a Rear Shock Absorber
211
Checking the Rear Shock Absorber Assembly
211
Installing the Rear Shock Absorber Assembly
212
Swingarm and Drive Chain
213
Removing the Swingarm
215
Removing the Drive Chain
216
Checking the Swingarm
216
Installing the Swingarm
217
Checking the Drive Chain
218
Chapter 5 Engine
220
Drive Sprocket
220
Exhaust Pipe
221
Leads and Hoses
222
Engine
222
Installing the Engine
225
Eng
220
Camshafts
227
Cylinder Head Cover
227
Removing the Camshafts
230
Checking the Camshafts
231
Checking the Timing Chain, Camshaft Sprockets
233
And Timing Chain Guides
233
Checking the Timing Chain Tensioner
233
Installing the Camshafts
234
Cylinder Head
238
Removing the Cylinder Head
239
Checking the Cylinder Head
239
Installing the Cylinder Head
240
Valves and Valve Springs
241
Removing the Valves
243
Checking the Valves and Valve Guides
244
Checking the Valve Seats
246
Checking the Valve Springs
248
Starter Clutch and Generator
251
Stator Coil Assembly
251
Removing the Generator
253
Removing the Starter Clutch
254
Checking the Starter Clutch
255
Installing the Starter Clutch
255
Installing the Generator
256
Shift Shaft
258
Shift Shaft and Stopper Lever
258
Checking the Shift Shaft
260
Checking the Stopper Lever
260
Installing the Shift Shaft
260
Crankshaft Position Sensor and Pickup Rotor
261
Removing the Pickup Rotor
263
Installing the Pickup Rotor
263
Clutch
265
Clutch Cover
265
Checking the Clutch Plates
269
Checking the Clutch Springs
269
Checking the Clutch Housing
270
Checking the Clutch Boss
270
Checking the Pressure Plate
270
Checking the Pull Lever Shaft and Pull Rod
271
Installing the Clutch
271
Oil Pan and Oil Pump
274
Removing the Oil Pan
277
Checking the Oil Pump
277
Installing the Oil Strainer
280
Installing the Oil Pan
280
Crankcase
281
Checking the Crankcase
284
Checking the Bearings and Oil Seals
284
Checking the Timing Chain
284
Assembling the Crankcase
284
Connecting Rods and Pistons
286
Removing the Connecting Rods and Pistons
287
Removing the Crankshaft Assembly
288
Checking the Cylinder and Piston
288
Checking the Piston Rings
289
Checking the Piston Pins
290
CHECKING the BIG END BEARINGS (Except for CAL)
292
CHECKING the BIG END BEARINGS (for CAL)
295
(For CAL)
295
Crankshaft
306
Checking the Crankshaft
307
Checking the Crankshaft Journal Bearings
307
Installing the Crankshaft
310
Transmission
311
Transmission, Shift Drum Assembly and Shift Forks
311
Removing the Transmission
317
Checking the Shift Forks
317
Checking the Shift Drum Assembly
318
Checking the Transmission
318
Installing the Transmission
319
Chapter 6 Cooling System
321
Cool
321
Radiator
321
Checking the Radiator
323
Installing the Radiator
324
Oil Cooler
325
Checking the Oil Cooler
327
Installing the Oil Cooler
327
Thermostat
328
Checking the Thermostat
329
Installing the Thermostat
330
Water Pump
331
Disassembling the Water Pump
333
Checking the Water Pump
334
Assembling the Water Pump
334
Installing the Water Pump
336
Chapter 7 Fuel Injection System
337
Wiring Diagram
338
Ecu's Self-Diagnostic Function
339
Fail-Safe Action
340
Fail-Safe Actions Table
340
Troubleshooting Chart
342
Diagnostic Mode
343
Troubleshooting Details
349
Throttle Bodies
361
Injectors
363
Checking the Injectors
364
Checking the Throttle Bodies
364
Checking the Fuel Pump and Pressure Regulator Operation
365
Checking and Adjusting the Throttle Position Sensor
366
Air Induction System
368
Air Injection
368
Air Cut-Off Valve
368
Air Induction System Diagrams
369
Checking the Air Induction System
370
Chapter 8 Electrical System
372
Elec
372
Electrical Components
372
Checking Switch Continuity
374
Checking the Switches
375
Checking the Bulbs and Bulb Sockets
376
Types of Bulbs
376
Checking the Condition of the Bulbs
376
Checking the Condition of the Bulb Sockets
377
CHECKING the Leds
378
Ignition System
379
Circuit Diagram
379
Troubleshooting
380
Electric Starting System
385
Circuit Diagram
385
Starting Circuit Cut-Off System Operation
386
Troubleshooting
387
Starter Motor
390
Checking the Starter Motor
392
Assembling the Starter Motor
393
Charging System
395
Circuit Diagram
395
Troubleshooting
396
Lighting System
398
Circuit Diagram
398
Troubleshooting
400
Checking the Lighting System
402
Signaling System
405
Circuit Diagram
405
Troubleshooting
407
Checking the Signaling System
407
Cooling System
414
Circuit Diagram
414
Troubleshooting
415
Fuel Pump System
418
Circuit Diagram
418
Troubleshooting
420
Checking the Fuel Pump
422
Self-Diagnosis
423
Troubleshooting
426
Starting Failures
426
Engine
426
Fuel System
426
Electrical Systems
426
Chapter 9
427
Engine
427
Fuel System
427
Electrical Systems
427
Poor Medium-And-High-Speed Performance
427
Trbl Shtg
427
Incorrect Engine Idling Speed
427
Faulty Gear Shifting
428
Shifting Is Difficult
428
Shift Pedal Does Not Move
428
Jumps out of Gear
428
Faulty Clutch
428
Clutch Slips
428
Clutch Drags
428
Overheating
429
Engine
429
Cooling System
429
Fuel System
429
Chassis
429
Electrical Systems
429
Overcooling
429
Poor Braking Performance
429
Faulty Front Fork Legs
430
Leaking Oil
430
Malfunction
430
Unstable Handling
430
Faulty Lighting or Signaling System
431
Headlight Does Not Come on
431
Headlight Bulb Burnt out
431
Tail/Brake Light Does Not Come on
431
Tail/Brake Light Bulb Burnt out
431
Turn Signal Does Not Come on
431
Turn Signal Blinks Slowly
431
Turn Signal Remains Lit
431
Turn Signal Blinks Quickly
431
Horn Does Not Sound
431
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Yamaha FZ6-SS Owner's Manual (108 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 4.25 MB
Table of Contents
Important Manual Information
4
Table of Contents
7
Safety Information
9
Location of Important Labels
13
Description
16
Left View
16
Right View
17
Controls and Instruments
18
Instrument and Control Functions
19
Main Switch/Steering Lock
19
Indicator and Warning Lights
20
Multi-Function Meter Unit
22
Handlebar Switches
26
Clutch Lever
27
Shift Pedal
28
Brake Lever
28
Brake Pedal
28
Fuel Tank Cap
29
Fuel
29
Catalytic Converters
30
Seat
31
Helmet Holder
31
Storage Compartment
32
Adjusting the Shock Absorber Assembly
32
Sidestand
33
Ignition Circuit Cut-Off System
34
Pre-Operation Checks
36
Pre-Operation Check List
37
Operation and Important Riding Points
39
Starting the Engine
39
Shifting
40
Engine Break-In
42
Parking
42
Periodic Maintenance and Minor Repair
43
Periodic Maintenance
43
Owner's Tool Kit
43
Periodic Maintenance Chart for the Emission Control System
45
General Maintenance and Lubrication Chart
46
Removing and Installing Panels
51
Checking the Spark Plugs
52
Canister (for California Only)
53
Engine Oil and Oil Filter Cartridge
54
Coolant
56
Replacing the Air Filter Element
60
Checking the Engine Idling Speed
61
Checking the Throttle Cable Free Play
62
Valve Clearance
62
Tires
62
Cast Wheels
65
Accessories and Replacement Parts
65
Adjusting the Clutch Lever Free Play
66
Rear Brake Light Switch
67
Checking the Front and Rear Brake Pads
67
Checking the Brake Fluid Level
68
Changing the Brake Fluid
69
Drive Chain Slack
69
Cleaning and Lubricating the Drive
70
Chain
70
Checking and Lubricating the Cables
71
Checking and Lubricating the Throttle Grip and Cable
71
Checking and Lubricating the Brake and Shift Pedals
72
Checking and Lubricating the Brake and Clutch Levers
72
Checking and Lubricating the Centerstand and Sidestand
73
Lubricating the Swingarm Pivots
73
Checking the Front Fork
74
Checking the Steering
74
Checking the Wheel Bearings
75
Battery
75
Replacing the Fuses
77
Replacing a Headlight Bulb
78
Replacing the Tail/Brake Light Bulb
79
Replacing a Turn Signal Light Bulb
80
Replacing the License Plate Light Bulb
81
Front Wheel
81
To Install the Front Wheel
82
Rear Wheel
82
Troubleshooting
84
Troubleshooting Charts
85
Motorcycle Care and Storage
87
Matte Color Caution
87
Care
87
Storage
89
Specifications
91
Consumer Information
94
Identification Numbers
94
Model Label
95
Reporting Safety Defects
96
Motorcycle Noise Regulation
97
Maintenance Record
98
Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
100
Yamaha Extended Service (Y.e.s.)
102
Yamaha FZ6-SS Owner's Manual (90 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 4.74 MB
Table of Contents
Important Manual Information
4
Table of Contents
6
Safety Information
8
Description
12
Left View
12
Right View
13
Controls and Instruments
14
Instrument and Control Functions
15
Immobilizer System
15
Main Switch/Steering Lock
16
Indicator and Warning Lights
17
LCD Tachometer
19
Multi-Function Display
19
Anti-Theft Alarm (Optional)
22
Handlebar Switches
22
Clutch Lever
24
Shift Pedal
24
Brake Lever
24
Brake Pedal
25
Fuel Tank Cap
25
Fuel
26
Fuel Tank Breather Hose
27
Catalytic Converter
27
Seat
27
Storage Compartment
28
Adjusting the Shock Absorber Assembly
29
Sidestand
30
Ignition Circuit Cut-Off System
30
Pre-Operation Checks
32
Pre-Operation Check List
33
Operation and Important Riding Points
35
Starting the Engine
35
Shifting
36
Tips for Reducing Fuel Consumption
37
Engine Break-In
37
Parking
38
Periodic Maintenance and Minor Repair
39
Owner's Tool Kit
39
Periodic Maintenance and Lubrication Chart
40
Removing and Installing Panels
43
Checking the Spark Plugs
44
Engine Oil and Oil Filter Cartridge
45
Coolant
48
Replacing the Air Filter Element
50
Adjusting the Engine Idling Speed
51
Checking the Throttle Cable Free Play
52
Valve Clearance
52
Tires
52
Cast Wheels
55
Adjusting the Clutch Lever Free Play
55
Adjusting the Rear Brake Light Switch
56
Checking the Front and Rear
56
Brake Pads
56
Checking the Brake Fluid Level
57
Changing the Brake Fluid
58
Drive Chain Slack
58
Cleaning and Lubricating the Drive Chain
60
Checking and Lubricating the Cables
60
Checking and Lubricating the Throttle Grip and Cable
61
Checking and Lubricating the Brake and Shift Pedals
61
Checking and Lubricating the Brake and Clutch Levers
62
Checking and Lubricating the Centerstand and Sidestand
62
Lubricating the Swingarm Pivots
63
Checking the Front Fork
63
Checking the Steering
64
Checking the Wheel Bearings
64
Battery
65
Replacing the Fuses
66
Replacing the Headlight Bulb
67
Replacing the Tail/Brake Light Bulb
68
Replacing a Turn Signal Light Bulb
69
Replacing the License Plate Light Bulb
69
Replacing an Auxiliary Light Bulb
70
Front Wheel
71
Rear Wheel
72
Troubleshooting
74
Troubleshooting Charts
75
Motorcycle Care and Storage
77
Care
77
Storage
79
Specifications
81
Consumer Information
84
Identification Numbers
84
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Yamaha FZ6-SS Assembly Manual (27 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 1.09 MB
Table of Contents
Symbols Used in the Assembly Manual
3
Parts Location
6
Setup Procedures
8
Throttle Grip
9
Front Wheel
9
Front Fender
10
Front Brake Master Cylinder
10
Handlebar Switch
10
Clutch Cable
11
Rear View Mirrors
12
Cable Routing
13
Adjustments and Predelivery Service
14
Checking the Tire Pressure
15
Checking the Engine Oil Level
16
Checking the Coolant Level
16
Adjusting the Front Brake
18
Adjusting the Rear Brake
18
Checking the Brake Fluid Level
19
Bleeding the Hydraulic Brake System
19
Adjusting the Clutch Cable Free Play
20
Adjusting the Rear Shock Absorber Assembly
20
Adjusting the Headlight Beams
22
Adjusting the Digital Clock
22
Service Data
23
Standard Equipment
23
Owner's Tool Kit
23
Tightening Torques
24
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