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2007 FZ6-NA
Yamaha 2007 FZ6-NA User Manual
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FRONT FORK
4-65
Disassembling
the front fork legs
Order
Job/Parts to remove
Q’ty
Remarks
1
Cap bolt
1
2O
-
r
i
n
g
1
3S
p
a
c
e
r
1
4
Washer
1
5
Front f
ork spring
1
6
D
ust seal
1
7
Oil seal cl
ip
1
8
D
amper rod assembly bolt
1
9
C
opper washer
1
10
Damper rod assembly
1
11
Oil seal
1
12
W
asher
1
13
Inner tube
1
14
Outer tube bushing
1
15
Inner tube bushing
1
16
Oil flow stopper
1
17
Outer tube
1
F
or assembly
, re
verse the disassembly
pro-
cedure.
237
239
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
General Tightening Torque Specifications
60
Engine Tightening Torques
61
Chassis Tightening Torques
65
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
Removing the Front Wheel
183
Checking the Front Wheel
183
[D-3] Maintenance of the Front Wheel Sensor and Sensor Rotor
184
Adjusting the Front Wheel Static Balance
186
Installing the Front Wheel
187
Rear Wheel
188
Removing the Rear Wheel
192
Checking the Rear Wheel
192
Checking the Rear Wheel Drive Hub
192
Checking and Replacing the Rear Wheel Sprocket
193
[D-4] Maintenance of the Rear Wheel Sensor and Sensor Rotor
193
Adjusting the Rear Wheel Static Balance
195
Installing the Rear Wheel
195
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
Handling the Rear Shock Absorber
250
Disposing of a Rear Shock Absorber
250
Removing the Rear Shock Absorber Assembly
250
Checking the Rear Shock Absorber Assembly
250
Installing the Rear Shock Absorber Assembly
251
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
Default Chapter
346
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
Default Chapter
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
Abs Components Chart
446
Abs Connector Location Chart
448
Abs Ecu and Abs Motor Relay
450
[D-1] Maintenance of the Abs Ecu
451
[D-2] Maintenance of the Abs Motor Relay
451
Abs Troubleshooting Outline
451
Basic Instruction for Troubleshooting
452
Basic Process for Troubleshooting
454
[A] Abs Malfunction Check Using the Abs Warning Light
455
[B] Detailed Abs Malfunction Check
455
[B-1] the Abs Warning Light Does Not Come on
455
[B-2] the Abs Warning Light Remains on
455
[B-3] the Abs Warning Light Flashes
456
[B-4] Malfunction Check by the Abs Self Diagnosis (Past Malfunction)
456
[B-5] Malfunction Check by the Abs Self Diagnosis (Present Malfunction)
458
[C] Determining the Cause and Location of the Malfunction
459
[C-1] Only the Abs Warning Light Does Not Come on When the Main Switch Is Set to "On
459
[C-2] Abs Warning Light and All Other Indicators Do Not Come on
459
[C-3] Abs Warning Light Flashes
460
[C-4] Abs Warning Light Flashes Every 0.5 Second
460
[C-5] Diagnosis by the Malfunction Code
460
[D-6-4] Deleting the Malfunction Code
474
[D-6-6] Delete Function Test
476
Specifications
476
[D-6] Final Check
477
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
4
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Yamaha 2007 FZ6-NA Specifications
General
Brand
Yamaha
Model
2007 FZ6-NA
Category
Motorcycle
Language
English
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