Yamaha FZ6-SS - Disassembling the Front Brake Master Cylinder

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4-25

FRONT AND REAR BRAKES

CHAS

Order Job/Part Q’ty Remarks

Disassembling the front brake

master cylinder

Dust boot

Circlip

Master cylinder kit

Spring

Master cylinder

Push rod

Disassemble the parts in the order listed.

For assembly, reverse the disassembly

procedure.

EAS00585

Main Page

Specifications5
- Table of Contents6
Default Chapter3
- Important Manual Information3
- How to Use this Manual4
Periodic Checks and Adjustments5
Chassis5
Engine5
Cooling System5
Fuel Injection System5
Electrical System5
Troubleshooting15
Chapter 1 General Information17
Motorcycle Identification17
- Vehicle Identification Number17
- Model Label17
Gen Info17
Features18
- Outline of Fi System18
- Fi System19
- Instrument Function20
Important Information22
- Preparation for Removal and Disassembly22
- Replacement Parts22
- Gaskets, Oil Seals and O-Rings22
- Lock Washers/Plates and Cotter Pins23
- Bearings and Oil Seals23
- Circlips23
Checking the Connections24
Special Tools25
Chapter 2 Specifications28
Spec28
General Specifications28
Engine Specifications29
Chassis Specifications37
Electrical Specifications41
Conversion Table44
General Tightening Torque Specifications44
Tightening Torques45
- Engine Tightening Torques45
- Chassis Tightening Torques48
Lubrication Points and Lubricant Types50
- Engine50
- Chassis51
Cooling System Diagrams52
Engine Oil Lubrication Chart56
Lubrication Diagrams57
Cable Routing63
Chapter 3 Periodic Checks and Adjustments78
Introduction78
Periodic Maintenance Chart for the Emission Control System78
General Maintenance and Lubrication Chart78
Chk Adj78
Seat80
Fuel Tank81
- Removing the Fuel Tank83
- Removing the Fuel Pump83
- Installing the Fuel Pump84
- Installing the Fuel Tank84
Cowlings85
Air Filter Case86
Battery Box and Battery Box Bracket87
Engine88
- Adjusting the Valve Clearance88
- Synchronizing the Throttle Bodies94
- Adjusting the Engine Idling Speed96
- Adjusting the Throttle Cable Free Play97
- Checking the Spark Plugs99
- Measuring the Compression Pressure100
- Checking the Engine Oil Level103
- Changing the Engine Oil104
- Measuring the Engine Oil Pressure106
- Adjusting the Clutch Cable Free Play108
- Cleaning the Air Filter Element109
- Checking the Throttle Body Joints110
- Checking the Fuel and Breather Hoses111
- Checking the Crankcase Breather Hose111
- Checking the Exhaust System112
- Checking the Coolant Level113
- Checking the Cooling System114
- Changing the Coolant115
Chassis118
- Adjusting the Front Brake118
- Adjusting the Rear Brake119
- Checking the Brake Fluid Level120
- Checking the Front and Rear Brake Pads121
- Adjusting the Rear Brake Light Switch122
- Checking the Front and Rear Brake Hoses122
- Bleeding the Hydraulic Brake System124
- Adjusting the Shift Pedal124
- Adjusting the Drive Chain Slack125
- Lubricating the Drive Chain126
- Checking and Adjusting the Steering Head127
- Checking the Front Fork129
- Adjusting the Rear Shock Absorber Assembly130
- Checking the Tires131
- Checking and Lubricating the Cables134
- Lubricating the Levers and Pedals134
- Lubricating the Sidestand134
- Lubricating the Centerstand134
- Lubricating the Rear Suspension135
Electrical System136
- Checking and Charging the Battery136
- Checking the Fuses142
- Replacing the Headlight Bulbs144
- Adjusting the Headlight Beams145
Chapter 4 Chassis146
Chas146
Front Wheel and Brake Discs146
- Removing the Front Wheel148
- Checking the Front Wheel148
- Checking the Brake Discs150
- Installing the Front Wheel151
- Adjusting the Front Wheel Static Balance152
- Rear Wheel and Brake Disc154
Rear Wheel and Brake Disc Rear Wheel154
- Rear Brake Disc and Rear Wheel Sprocket155
- Removing the Rear Wheel157
- Checking the Rear Wheel158
- Checking the Rear Wheel Drive Hub158
- Checking and Replacing the Rear Wheel Sprocket158
- Installing the Rear Wheel159
- Adjusting the Rear Wheel Static Balance160
Front and Rear Brakes161
- Front Brake Pads161
- Replacing the Front Brake Pads164
- Replacing the Rear Brake Pads166
- Front Brake Master Cylinder168
- Disassembling the Front Brake Master Cylinder170
- Disassembling the Rear Brake Master Cylinder172
- Master Cylinder173
- Disassembling the Front Brake Calipers173
- Disassembling the Rear Brake Caliper182
- Calipers183
- Caliper184
Front Fork190
- Front Fork Legs190
- Removing the Front Fork Legs193
- Disassembling the Front Fork Legs193
- Checking the Front Fork Legs195
- Assembling the Front Fork Legs196
- Installing the Front Fork Legs199
Handlebar200
- Removing the Handlebar201
- Checking the Handlebar201
- Installing the Handlebar202
Steering Head204
- Under Bracket204
- Removing the under Bracket206
- Checking the Steering Head206
- Installing the Steering Head207
Rear Shock Absorber Assembly209
- Removing the Rear Shock Absorber Assembly210
- Handling the Rear Shock Absorber211
- Disposing of a Rear Shock Absorber211
- Checking the Rear Shock Absorber Assembly211
- Installing the Rear Shock Absorber Assembly212
Swingarm and Drive Chain213
- Removing the Swingarm215
- Removing the Drive Chain216
- Checking the Swingarm216
- Installing the Swingarm217
- Checking the Drive Chain218
Chapter 5 Engine220
- Drive Sprocket220
- Exhaust Pipe221
- Leads and Hoses222
- Engine222
- Installing the Engine225
Eng220
Camshafts227
- Cylinder Head Cover227
- Removing the Camshafts230
- Checking the Camshafts231
- Checking the Timing Chain, Camshaft Sprockets233
- And Timing Chain Guides233
- Checking the Timing Chain Tensioner233
- Installing the Camshafts234
Cylinder Head238
- Removing the Cylinder Head239
- Checking the Cylinder Head239
- Installing the Cylinder Head240
Valves and Valve Springs241
- Removing the Valves243
- Checking the Valves and Valve Guides244
- Checking the Valve Seats246
- Checking the Valve Springs248
Starter Clutch and Generator251
- Stator Coil Assembly251
- Removing the Generator253
- Removing the Starter Clutch254
- Checking the Starter Clutch255
- Installing the Starter Clutch255
- Installing the Generator256
Shift Shaft258
- Shift Shaft and Stopper Lever258
- Checking the Shift Shaft260
- Checking the Stopper Lever260
- Installing the Shift Shaft260
Crankshaft Position Sensor and Pickup Rotor261
- Removing the Pickup Rotor263
- Installing the Pickup Rotor263
Clutch265
- Clutch Cover265
- Checking the Clutch Plates269
- Checking the Clutch Springs269
- Checking the Clutch Housing270
- Checking the Clutch Boss270
- Checking the Pressure Plate270
- Checking the Pull Lever Shaft and Pull Rod271
- Installing the Clutch271
Oil Pan and Oil Pump274
- Removing the Oil Pan277
- Checking the Oil Pump277
- Installing the Oil Strainer280
- Installing the Oil Pan280
Crankcase281
- Checking the Crankcase284
- Checking the Bearings and Oil Seals284
- Checking the Timing Chain284
- Assembling the Crankcase284
Connecting Rods and Pistons286
- Removing the Connecting Rods and Pistons287
- Removing the Crankshaft Assembly288
- Checking the Cylinder and Piston288
- Checking the Piston Rings289
- Checking the Piston Pins290
- CHECKING the BIG END BEARINGS (Except for CAL)292
- CHECKING the BIG END BEARINGS (for CAL)295
- (For CAL)295
Crankshaft306
- Checking the Crankshaft307
- Checking the Crankshaft Journal Bearings307
- Installing the Crankshaft310
Transmission311
- Transmission, Shift Drum Assembly and Shift Forks311
- Removing the Transmission317
- Checking the Shift Forks317
- Checking the Shift Drum Assembly318
- Checking the Transmission318
- Installing the Transmission319
Chapter 6 Cooling System321
Cool321
Radiator321
- Checking the Radiator323
- Installing the Radiator324
Oil Cooler325
- Checking the Oil Cooler327
- Installing the Oil Cooler327
Thermostat328
- Checking the Thermostat329
- Installing the Thermostat330
Water Pump331
- Disassembling the Water Pump333
- Checking the Water Pump334
- Assembling the Water Pump334
- Installing the Water Pump336
Chapter 7 Fuel Injection System337
- Wiring Diagram338
- Ecu's Self-Diagnostic Function339
- Fail-Safe Action340
- Fail-Safe Actions Table340
- Troubleshooting Chart342
- Diagnostic Mode343
- Troubleshooting Details349
Throttle Bodies361
- Injectors363
- Checking the Injectors364
- Checking the Throttle Bodies364
- Checking the Fuel Pump and Pressure Regulator Operation365
- Checking and Adjusting the Throttle Position Sensor366
Air Induction System368
- Air Injection368
- Air Cut-Off Valve368
- Air Induction System Diagrams369
- Checking the Air Induction System370
Chapter 8 Electrical System372
Elec372
Electrical Components372
Checking Switch Continuity374
Checking the Switches375
Checking the Bulbs and Bulb Sockets376
- Types of Bulbs376
- Checking the Condition of the Bulbs376
- Checking the Condition of the Bulb Sockets377
- CHECKING the Leds378
Ignition System379
- Circuit Diagram379
- Troubleshooting380
Electric Starting System385
- Circuit Diagram385
- Starting Circuit Cut-Off System Operation386
- Troubleshooting387
Starter Motor390
- Checking the Starter Motor392
- Assembling the Starter Motor393
Charging System395
- Circuit Diagram395
- Troubleshooting396
Lighting System398
- Circuit Diagram398
- Troubleshooting400
- Checking the Lighting System402
Signaling System405
- Circuit Diagram405
- Troubleshooting407
- Checking the Signaling System407
Cooling System414
- Circuit Diagram414
- Troubleshooting415
Fuel Pump System418
- Circuit Diagram418
- Troubleshooting420
- Checking the Fuel Pump422
Self-Diagnosis423
- Troubleshooting426
Starting Failures426
- Engine426
- Fuel System426
- Electrical Systems426
Chapter 9427
- Engine427
- Fuel System427
- Electrical Systems427
Poor Medium-And-High-Speed Performance427
Trbl Shtg427
Incorrect Engine Idling Speed427
Faulty Gear Shifting428
- Shifting Is Difficult428
- Shift Pedal Does Not Move428
- Jumps out of Gear428
Faulty Clutch428
- Clutch Slips428
- Clutch Drags428
Overheating429
- Engine429
- Cooling System429
- Fuel System429
- Chassis429
- Electrical Systems429
Overcooling429
Poor Braking Performance429
Faulty Front Fork Legs430
- Leaking Oil430
- Malfunction430
Unstable Handling430
Faulty Lighting or Signaling System431
- Headlight Does Not Come on431
- Headlight Bulb Burnt out431
- Tail/Brake Light Does Not Come on431
- Tail/Brake Light Bulb Burnt out431
- Turn Signal Does Not Come on431
- Turn Signal Blinks Slowly431
- Turn Signal Remains Lit431
- Turn Signal Blinks Quickly431
- Horn Does Not Sound431

Yamaha FZ6-SS - Disassembling the Front Brake Master Cylinder

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