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Yamaha FZ6-SS User Manual
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EAS00010
FZ6-SS
/
FZ6-SSC
SERVICE MANUAL

2003 by Y
amaha Motor
Corporation, U.S.A.
First edition, November 2003
All rights reserved. Any reproduction
or unauthorized use without the written
permission
of
Y
amaha
Motor
Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P
/
N LIT
-1
1616-17-50
1
3
Table of Contents
Specifications
5
Table of Contents
6
Default Chapter
3
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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Assembly Manual
26 pages
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Yamaha FZ6-SS Specifications
General
Brand
Yamaha
Model
FZ6-SS
Category
Motorcycle
Language
English
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