Yamaha FZ6-SS

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3-3

SEAT

CHK

ADJ

Order Job/Part Q’ty Remarks

Removing the seat

Seat 1

Remove the parts in the order listed.

For installation, reverse the removal

procedure.

EAS00038

SEAT

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 - Seat

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