Yamaha FZ6-SS, Assembly Manual

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Page 2: ...e procedures below are described in the order that the procedures are carried out correctly and com pletely Failure to do so can result in poor performance and possible harm to the motorcycle and or rider Follow the instructions in the Dealer Warranty Handbook Procedure Section Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol mea...

Page 3: ...ance required 5 Install so that the arrow mark faces up ward 6 Apply motor oil 7 Made of rubber or plastics 8 A Ref No indicating the order of op erations B Part name C Quantity of parts per motorcycle D Place where parts are held V Stored in plastic bag C Stored in carton box S Fixed inside the steel frame and or contained in the Styro foam tray upper or lower Temporarily installed or secured E S...

Page 4: ...ff Protect hands and feet by wearing safety gloves or shoes EAA00050 SYMBOLS USED ON CRATE CARTON 1 Contents of the transport package are fragile therefore the package must be handled with care 2 Indicates correct upright position of the transport package 3 Transport package must be kept away from rain 4 Insertion of the forklift arms from this side can cause damage 5 Lift arm inserting position I...

Page 5: ...emove the front wheel 4 3 Remove the packing frame bolts 5 and upper handlebar holders 6 4 Remove the bolts 7 5 Remove the packing frames 8 Lift up and then move to the side Remove the bolts while holding the frame Before starting the assembly check for damaged or missing parts Check both the parts contained in the carton boxes and on the motorcycle for damage scratches and other defects ...

Page 6: ... 2 EAA00070 PARTS LOCATION 1 Carton box 1 2 Carton box 2 3 Front tire ...

Page 7: ...hers 10 Screws 11 Nuts 12 Bands 13 Inner panels 14 Windshield trims 15 Rear view mirrors 16 Windshield 17 Front fender 18 Owner s manual 2 Carton box 2 1 Handlebar 2 Gnip end right 3 Bolts upper handlebar holders 4 Front brake master cylinder bracket 5 Bolts front brake master cylinder brack et 6 Screws left handlebar switch 7 Collars 3 Front tire ...

Page 8: ... 4 EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers Always follow the order as shown ...

Page 9: ... 0 35 mSkg 2 5 ftSlb C Check the throttle grip for smooth action Proper cable routing is essen tial to assure safe motorcycle operation Refer to CABLE ROUTING D Tighten the grip end Grip end 26 Nm 2 6 mSkg 19 ftSlb EAA00020 EAA00108 3 FRONT WHEEL A Clean the brake discs B Clean the front wheel axle C Clean the collar D Take care not to get grease on the brake discs or inner surface of the brake pa...

Page 10: ...120 5 FRONT BRAKE MASTER CYLINDER A Lubricate the pivoting parts of the brake lever Recommended lubricants Yamaha cable lube or motor oil B Make sure that the UP mark with the bracket is pointed up ward C Align the punch mark on the handlebar with the gap of the master cylinder bracket D Tighten the bolts in stages and maintain an equal gap on each side of the bracket to specifica tion Bolt 10 Nm ...

Page 11: ... into the le ver hole Next while pulling the outer cable in the direction op posite to the lever seat the out er cable into the cable socket Check the clutch lever for smooth action Refer to ADJUSTMENTS AND PREDELIVERY SERVICE C Install the clutch switch lead coupler Proper cable routing is essen tial to assure safe motorcycle operation Refer to CABLE ROUTING 8 BAND A Clamp the left handlebar swit...

Page 12: ...7 Nm 0 7 mSkg 5 1 ftSlb 11 INNER PANEL Remove the seat and fuel tank A Tighten the bolts to specifica tion Bolt 1 3 Nm 0 13 mSkg 0 9 ftSlb B Tighten the bolts to specifica tion Bolt 4 5 Nm 0 45 mSkg 3 3 ftSlb C Install the rivets EAA00189 12 BATTERY A Install the battery Refer to ADJUSTMENTS AND PREDELIVERY SERVICE B Install the battery cover Bolt 7 Nm 0 7 mSkg 5 1 ftSlb C First connect the positi...

Page 13: ...amp the right and left handlebar switch leads to the handlebar Point the tip of the clamp downword in front of the handlebar B Pass the throttle cables through the wire guide Route the right handlebar switch lead by the outside of the wire guide C Route the main switch lead and immobilizer lead above the clutch cable D Route the throttle cables above the stay 1 E Hook the starter motor lead to the...

Page 14: ... 10 EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters Always follow the order as shown ...

Page 15: ...es when working near batteries KEEP OUT OF THE REACH OF CHIL DREN D If the voltage is lower than 12 8 V the battery must be charged If this is not done the life of the battery will be shortened drastically Refer to the service manual for battery charging instructions D Never remove the strip of caps nor add any water or electrolyte EAA01009 B CHECKING THE TIRE PRESSURE 1 Check D tire pressure Out ...

Page 16: ...slippage There fore do not add any chemical addi tives D Do not allow foreign materials to en ter the crankcase API Service SE SF and SG type or equivanlent e g SF SE SF SE CC SF SE SD 5 Start the engine warm it up for several minutes and then turn it off 6 Check the engine oil level again Before checking the engine oil level wait a few minutes until the oil has settled 7 Install D dipstick EAA010...

Page 17: ...ng speed is increased Direction b Engine idling speed is decreased EAA01022 F ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting throttle cable free play the engine idling speed should be adjusted 1 Measure D throttle cable free play a Out of specification Adjust Throttle cable free play at the flange of the throttle grip 3 X 5 mm 0 12 X 0 20 in 2 Adjust a Loosen the locknut 1 b Turn the ad...

Page 18: ...in loss of control and possibly an accident Therefore check the brake system and bleed if necessary EAA01027 H ADJUSTING THE REAR BRAKE 1 Measure D brake pedal position a below the bottom of the footrest brack et Out of specification Adjust Brake pedal position top of the footrest 25 8 mm 1 02 in 2 Adjust D brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b...

Page 19: ... low D brake operation is faulty D Be careful not to spill any brake fluid or allow the brake fluid reservoir to over flow D When bleeding the hydraulic brake sys tem make sure that there is always enough brake fluid before applying the brake Ignoring this precaution could al low air to enter the hydraulic brake sys tem considerably lengthening the bleeding procedure D If bleeding is difficult it ...

Page 20: ...ee play is decreased EAA01050 L ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling over Spring preload Never go beyond the maximum or mini mum adjustment positions 1 Adjust D spring preload Adjust the spring preload with the special wrench and extension bar included in the owner s tool kit a Turn the adjusting ring 1 in direction a o...

Page 21: ...a or b until the specified drive chain slack is obtained Direction a Drive chain is tightened Direction b Drive chain is loosened D To maintain the proper wheel alignment adjust both sides evenly D Push the rear wheel forward to make sure that there is no clearance between the swingarm end plates and the ends of the swingarm c Tighten the wheel axle nut to specifica tion Wheel axle nut 120 Nm 12 m...

Page 22: ...dlight beam moves to the right 4 Install D front cowling inner panels EAA00185 P ADJUSTING THE DIGITAL CLOCK Turn the key to ON To change the display to the clock mode push the SELECT button 3 for at least one second To change the display back to the prior mode push the SELECT button 3 1 Adjust D digital clock 1 a Push the SELECT button 3 and RE SET button 2 together for at least two seconds b Whe...

Page 23: ... Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 5 kgf cm2 35 6 psi 90 kg load X Maximum load Front 250 kPa 2 5 kgf cm2 35 6 psi Rear 290 kPa 2 9 kgf cm2 41 3 psi High speed riding Front 225 kPa 2 25 kgf cm2 33 psi Rear 250 kPa 2 5 kgf cm2 35 6 psi Load is the total weight of cargo rider passenger and accessories EAA10100 STANDARD EQUIPMENT 1 Owner s manual 1 pc 2 Owner s tool kit 1 pc EAA10200 O...

Page 24: ...olts left of rear side M10 55 5 5 40 Engine mount bolts right of front side M10 55 5 5 40 Engine mount self locking nut upper M10 55 5 5 40 Engine mount self locking nut lower M10 55 5 5 40 Pivot shaft and frame M18 120 12 87 Rear shock absorber and frame M10 40 4 0 29 Rear shock absorber and rear arm M10 40 4 0 29 Seal guard and rear arm M6 7 0 7 5 1 Rear fender and rear arm M6 7 0 7 5 1 Rear bra...

Page 25: ... rear brake caliper bracket M8 27 2 7 20 Rear brake caliper bolt rear and rear brake caliper bracket M8 22 2 2 16 Rear wheel sprocket and rear wheel drive hub M10 100 10 72 Chain adjusting bolt lock nut M8 16 1 6 12 Rear brake hose union bolt M10 30 3 0 22 Sidestand bolt lock nut M10 46 4 6 33 Sidestand bracket and frame M10 63 6 3 46 Sidestand switch screw M5 4 0 4 2 9 Footrest bracket and frame ...

Page 26: ...PRINTED IN USA ...