Summary of FZ6-N 2004
Page 3: Foreword
Foreword this supplementary service manual has been prepared to introduce new service and data for the fz6-n(s) 2004. For complete service information procedures it is necessary to use this supplementa- ry service manual together with the following manual. Fz6-s(s) 2004 service manual: 5vx1-ae1 fz6-...
Page 4: Notice
Note: warning caution: eas00002 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintena...
Page 5: How To Use This Manual
1 2 4 8 3 5 6 7 eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 ...
Page 6: Gen
22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng fi elec cool chk adj trbl shtg chas eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic che...
Page 7: Contents
Contents specifications general specifications 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical specifications 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 8
Signaling system 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chec...
Page 9: Spec
–1– general specifications spec specifications general specifications item standard limit model code 1b31 (eur), 1b32 (aus) sss dimensions overall width overall height 755 mm (29.7 in) 1,085 mm (42.7 in) sss sss weight wet (with oil and a full fuel tank) maximum load (except motorcycle) 201 kg (443 ...
Page 10: Spec
–2– tightening torques spec see note 1 note 1: tightening torques engine tightening torques item fastener thread q’ty tightening torque remarks item fastener size q ty nm m s kg ft s lb remarks connecting rod caps (for eur) nut m7 8 15 + 150 _ 1.5 + 150 _ 11 + 150 _ connecting rod caps (for oce) bol...
Page 11: Spec
–3– cooling system diagrams spec 1 radiator 2 oil cooler cooling system diagrams.
Page 12: Spec
–4– cooling system diagrams spec 1 water pump 2 oil cooler 3 radiator.
Page 13: Spec
–5– cooling system diagrams spec 1 radiator 2 thermostat.
Page 14: Spec
–6– cable routing spec a clamp the right handlebar switch lead and handle- bar. Point the tip of the clamp downward in front of the handlebar. B route the branched lead behind the main switch and immobilizer lead. C pass the main switch and immobilizer lead, left han- dlebar switch lead and clutch c...
Page 15: Spec
–7– cable routing spec 1 right handlebar switch lead 2 throttle cables 3 horn lead 4 wire harness 5 rear brake light switch lead 6 neutral switch lead 7 fuel tank breather hose 8 crankshaft position sensor lead 9 meter lead and left handlebar lead a pass the right handlebar switch lead through the h...
Page 16: Spec
–8– n install the right handlebar switch lead coupler through the hole of the bracket 2 from the downside. O route the starter motor lead by the inner side of the air cut-off valve hose. P pass the ignition coil leads #1 and #4 through inner side of the air cut-off valve hose, and then between the f...
Page 17: Spec
–9– cable routing spec 16 rear turn signal light lead (right) 17 rear turn signal light lead (left) 18 speed sensor lead 19 side stand switch lead 20 oil level switch lead 21 a.C. Magneto lead 22 throttle cable (return side) 23 throttle cable (pull side) 24 radiator fan motor lead 25 oil level gauge...
Page 18: Spec
–10– a to the headlight bulb. B route it inside (in the width direction of the vehicle) of the left handlebar switch lead. C to the auxiliary light socket. D to the meter. E line up the left handlebar switch lead coupler and fan motor lead coupler behind the head pipe. F to the immobilizer. G to the...
Page 19: Spec
–11– v pass the fuel tank drain hose through the clamp lo- cated under the coolant reservoir tank. W route it behind the starter motor lead. X point the bend-r section of the throttle cable (pull side) to the inner side horizontally. It is also possible to visually check the bend-r section. Y point ...
Page 20: Spec
–12– 14 seat lock cable 15 rectifier/regulator 16 e.C.U 17 fuel tank drain hose 18 cover 19 starter relay lead 20 battery negative lead 21 battery negative lead coupler 22 handlebar switch lead 23 clutch cable 24 cover 2 25 spark plug lead 26 air cut-off valve hose 1 right handlebar switch lead 2 th...
Page 21: Spec
–13– cable routing spec a to the meter. B either right or left side arrangement for the left han- dlebar switch lead coupler and radiator fan motor coupler can be accepted. C point the l-shape terminal to the front side of the ve- hicle. D hook the starter motor lead to the alternate pawls on the ba...
Page 22: Spec
–14– ag pass the spark plug leads #1 and #4 through the slit of the cover 2. Ah pass the spark plug lead #2 through the inner hole of the cover 2. Ai pass the spark plug lead #3 through the outer hole of the cover 2. Aj route the spark plug lead #4 behind the air cut-off valve hose. Ak point the spa...
Page 23: Spec
–15– cable routing spec ao route the spark plug leads #2 and #3 behind the air cut-off valve hose..
Page 24: Spec
–16– cable routing spec a fuel piping connector attachment directions. (fuel pump side) 1. It is inserted until it makes a click sound the connec- tor, and it checks that a connector does not fall out. It takes care that a foreign substance does not enter into a seal portion. (working groves should ...
Page 25: Spec
–17– cable routing spec d spittle is turned back. E insert the clamp certainly. F it may open and close to direction of which. All notches gear at the time of attachment. G pass the coolant reservoir tank hose inside of the clamp. H insert in certainly. I to the fuel tank drain tube (left). J air op...
Page 26: Chk
–18– introduction/periodic maintenance and lubrication intervals chk adj note: eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more re...
Page 27: Chk
–19– note: periodic maintenance and lubrication intervals chk adj no. Item check or maintenance job odometer reading ( 1,000 km) annual check 1 10 20 30 40 check 16 * sidestand switch (see page 3-57, 8-4) s check operation. Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 17 * front fork (see page 3-52) s check operation and for oil le...
Page 28: Chk
–20– order job / part q’ty remarks 1 2 removing the cowlings seat rear cowling frame side cover 1 2 remove the parts in the order listed. Refer to “seat”. For installation, reverse the removal procedure. 23 nm (2.3 m skg, 17 ftslb) 10 nm (1.0 m skg, 7.2 ftslb) 23 nm (2.3 m skg, 17 ftslb) cowlings ch...
Page 29: Chk
–21– replacing the headlight bulbs chk adj warning caution: eas00183 electrical system replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Disconnect: s headlight bulb cover s headlight coupler 1 2. Remove: s headlight bulb holder 1 3. Remove: s headlight...
Page 30: Chk
–22– adjusting the headlight beams chk adj a b a b eas00185 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: s headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b . Direction headlight beam is raised. Direction headlight be...
Page 31: Eng
–23– order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the connecting rods and pistons lower crankcase connecting rod cap big end lower bearing big end upper bearing piston pin clip piston pin piston connecting rod top ring 2nd ring oil ring 4 4 4 8 4 4 4 4 4 4 remove the parts in the orde...
Page 32: Eng
–24– connecting rods and pistons eng note: caution: note: note: eas00393 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: s connecting rod cap 1 s big end bearings identify the position of each big end bearing so that it c...
Page 33: Eng
–25– connecting rods and pistons eng caution: note: note: checking the big end bearings (for eur) 1. Measure: scrankshaft-pin-to-big-end-bearing clear- ance out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.038 x 0.062 mm (0.0015 x 0.0024 in) the foll...
Page 34: Eng
–26– connecting rods and pistons eng caution: warning caution: note: e. Tighten the connecting rod nuts. Connecting rod nut 15 nm (1.5 m skg, 11 ftslb) + 150_ f. Replace the connecting rod bolts with new ones. Tighten the connecting rod bolts using the plastic-region tightening angle method. Always ...
Page 35: Eng
–27– connecting rods and pistons eng note: 2. Select: s big end bearings (p1 x p4) s the numbers a stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “p1” x “p4” refer to the bearings shown in the crankshaft illustr...
Page 36: Eng
–28– connecting rods and pistons eng caution: note: note: checking the big end bearings (for oce) 1. Measure: scrankshaft-pin-to-big-end-bearing clear- ance out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.038 x 0.062 mm (0.0015 x 0.0024 in) the foll...
Page 37: Eng
–29– connecting rods and pistons eng note: note: e. Tighten the connecting rod bolts. Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts connecting rod bolt 24.5 nm (2.5 m skg, 17.7 ftslb) f. Replace the connecting rod bolts...
Page 38: Eng
–30– connecting rods and pistons eng caution: warning caution: k. Tighten the connecting rod bolts. Connecting rod bolt 15 nm (1.5 m skg, 11 ftslb) + 120_ tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. L. Clean the connecting rod bolts. M...
Page 39: Eng
–31– connecting rods and pistons eng note: q. Remove the connecting rod and big end bearings. Refer to “removing the connecting rods and pistons”. R. Measure the compressed plastigauge width on the crankshaft pin. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select re-...
Page 40: Eng
–32– connecting rods and pistons eng note: note: installing the connecting rod and piston (for eur) the following procedure applies to all of the connecting rods and pistons. 1. Install: s top ring 1 s 2nd ring 2 s upper oil ring rail 3 s oil ring expander 4 s lower oil ring rail 5 be sure to instal...
Page 41: Eng
–33– connecting rods and pistons eng note: 15 nm (1.5 m skg, 11 ftslb) + 150_ caution: 4. Offset: s piston ring end gaps a top ring b lower oil ring rail c upper oil ring rail d 2nd ring e oil ring expander 5. Lubricate: s crankshaft pins s big end bearings s connecting rod big end inner surface (wi...
Page 42: Eng
–34– connecting rods and pistons eng warning caution: note: b. Clean the connecting rod bolts and nuts. C. Tighten the connecting rod nuts. D. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod cap 3 . E. Tighten the nut further to reach the specified angle (150 _ ). When ...
Page 43: Eng
–35– connecting rods and pistons eng note: note: installing the connecting rod and piston (for oce) the following procedure applies to all of the connecting rods and pistons. 1. Install: s top ring 1 s 2nd ring 2 s upper oil ring rail 3 s oil ring expander 4 s lower oil ring rail 5 be sure to instal...
Page 44: Eng
–36– connecting rods and pistons eng note: 4. Offset: s piston ring end gaps a top ring b lower oil ring rail c upper oil ring rail d 2nd ring e oil ring expander 5. Lubricate: s crankshaft pins s big end bearings s connecting rod big end inner surface (with the recommended lubricant) recommended lu...
Page 45: Eng
–37– connecting rods and pistons eng note: 24.5 nm (2.5 m skg, 17.7 ftslb) note: note: 7. Tighten: install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts. A. Replace the connecting rod bolts with new ones. B. Clean the connectin...
Page 46: Eng
–38– connecting rods and pistons eng 15 nm (1.5 m skg, 11 ftslb) + 120_ caution: warning caution: 9. Tighten: s connecting rod bolts tighten the connecting rod bolts using the plastic-region tightening angle method. A. Clean the connecting rod bolts. B. Tighten the connecting rod bolts. C. Put a mar...
Page 47: Cool
–39– order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the radiator seat front cowling inner panel (left and right) fuel tank air filter case coolant coolant reservoir hose and protector throttle body hose water pump breather hose and protector radiator outlet hose radiator inlet hose and prote...
Page 48: Cool
–40– radiator cool order job / part q’ty remarks 9 radiator fan 1 for installation, reverse the removal procedure. 10 nm (1.0 m skg, 7.2 ftslb) 7 nm (0.7 m skg, 5.1 ftslb) 7 nm (0.7 m skg, 5.1 ftslb).
Page 49: Cool
–41– order job / part q’ty remarks 1 2 3 removing the thermostat seat front cowling inner panel (left and right) fuel tank air filter case coolant throttle body assembly radiator inlet hose and protector thermostat cover thermostat 1 1 1 remove the parts in the order listed. Refer to “seat” in chapt...
Page 50: Cool
–42– order job / part q’ty remarks 1 2 3 4 removing the water pump coolant radiator outlet hose water pump outlet hose water pump breather hose and protector water pump 1 1 1 1 remove the parts in the order listed. It is not necessary to remove the water pump unless the coolant level is extremely lo...
Page 51: Elec
–43– 11 oil level switch 12 neutral switch 13 rear brake light switch 14 fuse box 15 hazard switch 1 main switch 2 horn switch 3 dimmer switch 4 pass switch 5 turn signal switch 6 clutch switch 7 sidestand switch 8 engine stop switch 9 front brake light switch 10 start switch checking the switches e...
Page 52: Elec
–44– 1 main switch 7 fuse (main) 10 battery 11 starting circuit cut-off relay 12 sidestand switch 13 neutral switch 17 lean angle cut-off switch 18 crankshaft position sensor 21 ecu 28 ignition coil #1 and #4 29 ignition coil #2 and #3 30 spark plug 43 engine stop switch 50 fuse (ignition) 57 clutch...
Page 53: Elec
–45– yes no 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Minimum open-circuit voltage 12.8 v or more at 20 _c (68_f) s is the battery ok? S clean the battery terminals. S recharge or re- place the battery. Eas00739 yes no eas00741 3. Spa...
Page 54: Elec
–46– ignition system elec no yes 1 a 2 4. Ignition spark gap the following procedure applies to all of the spark plugs. S disconnect the spark plug cap from the spark plug. S connect the ignition checker and spark plug cap as shown. S set the main switch to “on”. S measure the ignition spark gap . S...
Page 55: Elec
–47– ignition system elec negative tester probe ! Spark plug lead positive tester probe ! Spark lug lead 1 2 s measure the secondary coil resistance. Secondary coil resistance 12 x 18 kΩ at 20_c (68_f) s is the ignition coil ok? Yes no replace the ignition coil. 7. Crankshaft position sensor resista...
Page 56: Elec
–48– ignition system elec eas00752 11. Sidestand switch s check the sidestand switch for continuity. Refer to “checking the switches”. S is the sidestand switch ok? Yes no replace the side- stand switch. Eas00763 12. Clutch switch s check the clutch switch for continuity. Refer to “checking the swit...
Page 57: Elec
–49– ignition system elec eas00754 15. Wiring s check the entire ignition system’s wiring. Refer to “circuit diagram”. S is the ignition system’s wiring properly con- nected and without defects? Yes no properly connect or repair the ignition system’s wiring. Replace the ecu..
Page 58: Elec
–50– lighting system elec eas00780 lighting system circuit diagram.
Page 59: Elec
–51– lighting system elec 1 main switch 7 fuse (main) 10 battery 21 ecu 37 high beam indicator light 49 fuse (headlight) 50 fuse (ignition) 51 fuse (park) 54 license plate light 55 tail / brake light 58 pass switch 59 dimmer switch 64 dimmer relay 65 auxiliary light 66 headlight.
Page 60: Elec
–52– yes no s clean the battery terminals. S recharge or re- place the battery. Eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. Eas00784 yes no 4. Dimmer switch s check the dimmer switch for co...
Page 61: Elec
–53– s does the dimmer relay have continuity be- tween red / yellow and green? No yes replace the dimmer relay. Positive tester probe ! Red/yellow negative tester probe ! Blue/black 1 2 3 4 6. Dimmer relay s disconnect the dimmer relay from the cou- pler. S connect the pocket tester ( Ω 1) and bat- ...
Page 62: Elec
–54– 54 high beam indicator light (leds) positive tester probe ! Yellow negative tester probe ! Black / white yes no 1. Headlight bulb and socket s check the headlight bulb and socket for con- tinuity. Refer to “checking the bulbs and bulb sockets”. S are the headlight bulb and socket ok? Replace th...
Page 63: Elec
–55– 55 lighting system elec yes no 1. License plate light bulb and socket s check the license plate light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. S are the license plate light bulb and socket ok? Replace the license plate light bulb, sock- et or both. Eas0079...
Page 64: Elec
–56– 56 lighting system elec eas00791 4. The auxiliary light fails to come on. Yes no 1. Auxiliary light and socket s check the auxiliary light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. S are the auxiliary light .Bulb and socket ok? Replace the auxiliary light b...
Page 65: Elec
–57– 57 signaling system elec eas00793 signaling system circuit diagram.
Page 66: Elec
–58– 58 signaling system elec 1 main switch 4 fuse (backup) 7 fuse (main) 10 battery 11 starting circuit cut-off relay 13 neutral switch 14 fuel pump 21 ecu 33 oil level waning light 35 neutral indicator light 36 multi-function meter 38 turn signal indicator light 39 oil level switch 42 front brake ...
Page 67: Elec
–59– 59 yes no s clean the battery terminals. S recharge or re- place the battery. Eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. Yes no 1. Horn switch s check the horn switch for continuity. ...
Page 68: Elec
–60– 60 signaling system elec yes no 1. Tail / brake light bulb and socket s check the tail / brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. S are the tail / brake light bulb and socket ok? Replace the tail / brake light bulb, socket or both. Eas00797 2. ...
Page 69: Elec
–61– 61 signaling system elec no yes no the wiring circuit from the main switch to the tail / brake light coupler is faulty and must be repaired. This circuit is ok. Yes 1. Turn signal indicator light (leds) s check the turn signal indicator light for conti- nuity. Refer to “checking the leds”. S ar...
Page 70: Elec
–62– 62 signaling system elec yes no the wiring circuit from the turn signal switch to the turn sig- nal light connector is faulty and must be repaired. Left turn signal light positive tester probe ! Ground negative tester probe ! Chocolate right turn signal light positive tester probe ! Ground nega...
Page 71: Elec
–63– 63 signaling system elec yes no replace the starting circuit cut-off relay. Yes no 4. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. The wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paire...
Page 72: Elec
–64– 64 signaling system elec 3. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! Black/white negative tester probe ! Red/white 1 2 s turn the main switch to “on”. S measure the voltage (dc 12v) of black / white and red...
Page 73: Elec
–65– 65 signaling system elec yes no 2. Voltage s connect the pocket tester (dc 20 v) to the meter assembly coupler (wire harness side) as shown. The wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. Positive tester probe ! Green/white negative tes...
Page 74
56 left handlebar switch 57 clutch switch 58 pass switch 59 dimmer switch 60 hazard switch 61 turn signal switch 62 horn switch 63 horn 64 dimmer relay 65 auxiliary light 66 headlight (high beam) 67 rear turn signal light (right) 68 rear turn signal light (left) 69 front turn signal light (right) 70...
Page 77
Color code b black . . . . Br brown . . . . Ch chocolate . . . . Dg dark green . . . . G green . . . . Gy gray . . . . L blue . . . . Lg light green . . . . P pink . . . . R red . . . . Sb sky blue . . . . W white . . . . Y yellow . . . . B / g black / green . . . . B / l black / blue . . . . B / r ...