Yamaha 2007 FZ6-S Manuals

Manuals and User Guides for Yamaha 2007 FZ6-S. We have 1 Yamaha 2007 FZ6-S manual available for free PDF download: Service Manual

Yamaha 2007 FZ6-S Service Manual

Yamaha 2007 FZ6-S Service Manual (538 pages)

Brand: Yamaha | Category: Motorcycle | Size: 19.42 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- 1 General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
    
    Outline of the Abs
    18
    
    Abs Component Functions
    22
    
    Abs Operation
    28
    
    Abs Self-Diagnosis Function
    32
    
    Abs Warning Light and Operation
    35
  - Important Information
    37
    
    Preparation for Removal and Disassembly
    37
    
    Replacement Parts
    37
    
    Gaskets, Oil Seals and O-Rings
    37
    
    Lock Washers/Plates and Cotter Pins
    37
    
    Bearings and Oil Seals
    38
    
    Circlips
    38
  - Checking the Connections
    39
  - Special Tools
    40
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  54
- Electrical Specifications
  57
- Tightening Torques
  60
- Lubrication Points and Lubricant Types
  68
  - Engine
    68
  - Chassis
    69
- Lubrication System Chart and Diagrams
  70
  - Engine Oil Lubrication Chart
    70
  - Lubrication Diagrams
    72
- Cooling System Diagrams
  84
- Cable Routing
  92
Periodic Checks and Adjustments

131
- Periodic Maintenance
  
  134
  - Introduction
    134
- Engine
  
  137
  - Adjusting the Valve Clearance
    137
  - Synchronizing the Throttle Bodies
    139
  - Adjusting the Exhaust Gas Volume (Standard)
    141
  - Adjusting the Exhaust Gas Volume (High-Grade)
    141
  - Adjusting the Engine Idling Speed
    142
  - Adjusting the Throttle Cable Free Play
    143
  - Checking the Spark Plugs
    144
  - Measuring the Compression Pressure
    145
  - Checking the Engine Oil Level
    146
  - Changing the Engine Oil
    147
  - Measuring the Engine Oil Pressure
    148
  - Adjusting the Clutch Cable Free Play
    149
  - Cleaning the Air Filter Element
    150
  - Checking the Throttle Body Joints
    151
  - Checking the Fuel Line
    151
  - Checking the Crankcase Breather Hose
    151
  - Checking the Exhaust System
    152
  - Checking the Coolant Level
    152
  - Checking the Cooling System
    153
  - Changing the Coolant
    153
- Chassis
  
  156
  - Adjusting the Front Disc Brake
    156
    
    Adjusting the Rear Disc Brake
    156
    
    Checking the Brake Fluid Level
    157
    
    Checking the Front Brake Pads
    157
    
    Checking the Rear Brake Pads
    158
    
    Checking the Front Brake Hoses
    158
    
    Checking the Rear Brake Hose
    158
    
    Adjusting the Rear Brake Light Switch
    158
    
    Bleeding the Hydraulic Brake System
    159
    
    Adjusting the Shift Pedal
    161
    
    Adjusting the Drive Chain Slack
    161
    
    Lubricating the Drive Chain
    162
    
    Checking and Adjusting the Steering Head
    162
    
    Checking the Front Fork
    163
    
    Adjusting the Rear Shock Absorber Assembly
    164
    
    Checking the Tires
    164
    
    Checking the Wheels
    167
    
    Checking and Lubricating the Cables
    167
    
    Lubricating the Levers
    167
    
    Lubricating the Pedal
    167
    
    Lubricating the Sidestand
    167
    
    Lubricating the Centerstand
    167
    
    Lubricating the Rear Suspension
    167
Chassis

171
- General Chassis
  
  174
- Front Wheel
  
  180
- Rear Wheel
  
  188
- Front Brake
  
  196
  - Introduction
    204
  - Checking the Front Brake Discs
    204
  - Front Brake
    204
  - Replacing the Front Brake Pads
    205
  - Removing the Front Brake Calipers
    207
  - Disassembling the Front Brake Calipers
    207
  - Checking the Front Brake Calipers
    208
  - Assembling the Front Brake Calipers
    209
  - Installing the Front Brake Calipers
    209
  - Removing the Front Brake Master Cylinder
    211
  - Checking the Front Brake Master Cylinder
    211
  - Assembling the Front Brake Master Cylinder
    212
  - Installing the Front Brake Master Cylinder
    212
- Rear Brake
  
  214
  - Introduction
    219
  - Checking the Rear Brake Disc
    219
  - Replacing the Rear Brake Pads
    219
  - Removing the Rear Brake Caliper
    220
  - Disassembling the Rear Brake Caliper
    220
  - Checking the Rear Brake Caliper
    221
  - Assembling the Rear Brake Caliper
    221
  - Installing the Rear Brake Caliper
    222
  - Removing the Rear Brake Master Cylinder
    223
  - Checking the Rear Brake Master Cylinder
    223
  - Assembling the Rear Brake Master Cylinder
    224
  - Installing the Rear Brake Master Cylinder
    224
- Abs (Anti-Lock Brake System)
  
  226
  - [D-5] Maintenance of the Hydraulic Unit
    228
  - Hydraulic Unit Operation Test
    229
  - [D-6-5] Trial Run
    232
- Handlebar
  
  233
  - Removing the Handlebars
    234
  - Checking the Handlebar
    234
  - Installing the Handlebar
    234
- Front Fork
  
  237
  - Removing the Front Fork Legs
    239
  - Disassembling the Front Fork Legs
    239
  - Checking the Front Fork Legs
    240
  - Assembling the Front Fork Legs
    241
  - Installing the Front Fork Legs
    243
- Steering Head
  
  245
  - Removing the Lower Bracket
    247
  - Checking the Steering Head
    247
  - Installing the Steering Head
    248
- Rear Shock Absorber Assembly
  
  249
- Swingarm
  
  252
  - Removing the Swingarm
    254
  - Checking the Swingarm
    254
  - Installing the Swingarm
    255
- Chain Drive
  
  256
  - Removing the Drive Chain
    257
  - Checking the Drive Chain
    257
  - Checking the Drive Sprocket
    258
  - Checking the Rear Wheel Sprocket
    258
  - Checking the Rear Wheel Drive Hub
    258
  - Installing the Drive Chain
    258
Engine

259
- Engine Removal
  
  267
  - Installing the Engine
    267
- Camshafts
  
  269
  - Removing the Camshafts
    271
  - Checking the Camshafts
    272
  - Checking the Timing Chain and Camshaft Sprocket
    273
  - Checking the Timing Chain Guides
    273
  - Checking the Timing Chain Tensioner
    274
  - Installing the Camshafts
    274
- Cylinder Head
  
  277
  - Removing the Cylinder Head
    278
  - Checking the Cylinder Head
    278
  - Installing the Cylinder Head
    278
- Valves and Valve Springs
  
  281
  - Removing the Valves
    282
  - Checking the Valves and Valve Guides
    283
  - Checking the Valve Seats
    284
  - Checking the Valve Springs
    286
  - Checking the Valve Lifters
    287
  - Installing the Valves
    287
- Generator and Starter Clutch
  
  289
  - Removing the Generator
    291
  - Removing the Starter Clutch
    291
  - Checking the Starter Clutch
    292
  - Installing the Starter Clutch
    292
  - Installing the Generator
    293
- Pickup Rotor
  
  294
  - Removing the Pickup Rotor
    295
  - Installing the Pickup Rotor
    295
- Electric Starter
  
  297
  - Checking the Starter Motor
    299
  - Assembling the Starter Motor
    300
  - Installing the Starter Motor
    300
- Oil Pump
  
  301
  - Removing the Oil Pan
    304
  - Checking the Oil Pump
    304
  - Checking the Relief Valve
    304
  - Checking the Oil Delivery Pipes
    305
  - Checking the Oil Strainer
    305
  - Checking the Oil Nozzles
    305
  - Assembling the Oil Pump
    305
  - Installing the Oil Pump
    306
  - Installing the Oil Strainer
    306
  - Installing the Oil Pan
    306
- Clutch
  
  307
  - Removing the Clutch
    310
  - Checking the Friction Plates
    310
  - Checking the Clutch Plates
    311
  - Checking the Clutch Springs
    311
  - Checking the Clutch Housing
    311
  - Checking the Clutch Boss
    311
  - Checking the Pressure Plate
    312
  - Checking the Pull Lever Shaft and Pull Rod
    312
  - Installing the Clutch
    312
- Shift Shaft
  
  314
  - Checking the Shift Shaft
    315
  - Checking the Stopper Lever
    315
  - Installing the Shift Shaft
    315
- Crankcase
  
  316
  - Disassembling the Crankcase
    318
  - Checking the Crankcase
    318
  - Checking the Bearings and Oil Seals
    318
  - Checking the Oil Pump Drive Chain
    318
  - Assembling the Crankcase
    319
- Crankshaft
  
  321
  - Removing the Connecting Rods and Pistons
    323
  - Removing the Crankshaft Assembly
    323
  - Checking the Cylinder and Piston
    324
  - Checking the Piston Rings
    324
  - Checking the Piston Pins
    325
  - Checking the Big End Bearings
    326
  - Installing the Connecting Rod and Piston
    329
  - Checking the Crankshaft
    331
  - Checking the Crankshaft Journal Bearings
    331
  - Installing the Crankshaft
    333
- Transmission
  
  335
  - Removing the Transmission
    339
  - Checking the Shift Forks
    339
  - Checking the Shift Drum Assembly
    339
  - Checking the Transmission
    340
  - Installing the Transmission
    340
Cooling System

343
- Checking the Radiator
  346
  - Installing the Radiator
    346
- Oil Cooler
  
  347
  - Checking the Oil Cooler
    348
  - Installing the Oil Cooler
    348
- Thermostat
  
  349
  - Checking the Thermostat
    350
  - Installing the Thermostat Assembly
    350
- Water Pump
  
  352
  - Disassembling the Water Pump
    354
  - Checking the Water Pump
    354
  - Assembling the Water Pump
    355
  - Installing the Water Pump
    356
Fuel System

357
- Fuel Tank
  
  359
  - Checking the Fuel Pump Body
    359
  - Checking the Fuel Pump Operation
    359
  - Installing the Fuel Pump
    359
  - Removing the Fuel Pump
    359
  - Removing the Fuel Tank
    359
  - Installing the Fuel Tank
    360
- Throttle Bodies
  
  361
  - Checking the Injectors
    363
  - Checking the Throttle Bodies
    363
  - Checking the Fuel Pressure
    363
  - Adjusting the Throttle Position Sensor
    363
- Air Induction System
  
  366
  - Checking the Air Induction System
    369
  - Installing the Air Induction System
    369
Electrical System

371
- General Information
  371
- Ignition System
  
  374
  - Circuit Diagram
    374
  - Troubleshooting
    376
- Electric Starting System
  
  378
  - Circuit Diagram
    378
  - Starting Circuit Cut-Off System Operation
    380
  - Troubleshooting
    381
- Charging System
  
  384
  - Circuit Diagram
    384
  - Troubleshooting
    386
- Lighting System
  
  388
  - Circuit Diagram
    388
  - Troubleshooting
    390
- Signaling System
  
  392
  - Circuit Diagram
    392
  - Troubleshooting
    394
- Cooling System
  
  400
  - Circuit Diagram
    400
  - Troubleshooting
    402
- Fuel Injection System
  
  404
  - Circuit Diagram
    404
  - Ecu Self-Diagnostic Function
    406
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    407
  - Troubleshooting Method
    409
  - Diagnostic Mode
    410
  - Troubleshooting Details
    416
- Fuel Pump System
  
  430
  - Circuit Diagram
    430
  - Troubleshooting
    432
- Immobilizer System
  
  434
  - Circuit Diagram
    434
  - General Information
    436
  - Part Replacement and Key Code Registration Requirements
    436
  - Troubleshooting
    440
  - Self-Diagnosis Fault Code Indication
    440
- Abs (Anti-Lock Brake System)
  
  444
- Electrical Components
  
  478
  - Checking the Switches
    482
  - Checking the Bulbs and Bulb Sockets
    485
  - Checking the Leds
    486
  - Checking the Fuses
    486
  - Checking and Charging the Battery
    487
  - Checking the Relays
    490
  - Checking the Abs Motor Relay
    491
  - Checking the Solenoid Valves and Motor
    492
  - Checking the Turn Signal/Hazard Relay
    493
  - Checking the Relay Unit (Diode)
    493
  - Checking the Spark Plug Caps
    494
  - Checking the Ignition Coils
    494
  - Checking the Crankshaft Position Sensor
    495
  - Checking the Lean Angle Sensor
    496
  - Checking the Wheel Sensor
    496
  - Checking the Startor Motor Operation
    497
  - Checking the Stator Coil
    497
  - Checking the Rectifier/Regulator
    497
  - Checking the Horn
    498
  - Checking the Engine Oil Level Gauge
    498
  - Checking the Fuel Sender
    499
  - Checking the Speed Sensor
    499
  - Checking the Radiator Fan Motor
    500
  - Checking the Coolant Temperature Sensor
    500
  - Checking the Throttle Position Sensor
    501
  - Checking the Fuel Pump
    501
  - Checking the Air Induction System Solenoid
    502
  - Checking the Intake Air Pressure Sensor
    502
  - Checking the Intake Air Temperature Sensor
    503
  - Troubleshooting
    505
    
    Wiring Diagram
    512

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