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  4. FZ6-SS
  5. Assembly Manual

Yamaha FZ6-SS Assembly Manual

Other manuals for FZ6-SS: Service Manual, Owner's Manual, Owner's Manual
Manual is about: Yamaha Motorcycle Service manual

Summary of FZ6-SS

  • Page 2

    Concerning crate damage: warning caution: eaa00002 foreword this assembly manual contains the information required for the correct assembly of this yamaha motor- cycle prior to delivery to the customer. Since some external parts of the motorcycle have been removed at the yamaha factory for the conve...

  • Page 3

    (1) (2) (3) (4) (5) (6) (7) (8) eaa00008 symbols used in the assembly manual in order to simplify descriptions in this as- sembly manual, the following symbols are used: (1): coat with lithium-soap-based grease. (2): tighten to 10 nm. (10 nm = 1.0 m skg, 7.2 ftslb) (3): towards the front of the moto...

  • Page 4

    (1) (2) (3) (4) (5) (5) eaa00040 preparation to assemble the motorcycle correctly, sup- plies (e.G. Oils, greases, and shop rags) and sufficient working space are required. Workshop the workshop where the motorcycle is as- sembled should be clean, spacious, and have a level floor. Self-protection pr...

  • Page 5

    –1– note: note: note: eaa00060 unpacking 1. Remove the frame cover (1). To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the carton boxes (2) and (3). Remove the front wheel (4). 3. Remove the packing frame bolts (5) and upper handlebar holders (6...

  • Page 6

    –2– eaa00070 parts location (1) carton box 1. (2) carton box 2. (3) front tire..

  • Page 7

    –3– 7 eaa00080 (1) carton box 1 1. Screws and special nuts (windshield) 2. Upper handlebar holders 3. Rivets 4. Screws 5. Bolts 6. Plugs 7. Nuts 8. Screws 9. Washers 10. Screws 11. Nuts 12. Bands 13. Inner panels 14. Windshield trims 15. Rear view mirrors 16. Windshield 17. Front fender 18. Owner’s ...

  • 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

    –5– 1 handlebar holders 2 v 2 hexagon head bolt 4 v d = 8 (0.31), ȏ = 30 (1.18) 3 plug 4 v 4 handlebar 1 c 1 screw 1 d = 5 (0.20), ȏ = 45 (1.77) 2 screw 1 d = 5 (0.20), ȏ = 20 (0.79) 3 grip end 1 v 1 front tire 1 s 2 collar 2 v 3 axle 1 4 hexagon head bolt 1 caution: warning warning note: caution: e...

  • Page 10

    –6– 1 front fender 1 s 2 bolt 2 v d = 6 (0.24), ȏ = 22 (0.87) 3 bolt 2 v d = 6 (0.24), ȏ = 25 (0.98) 4 collar 2 v d = 6 (0.24) 1 bolt 1 v d = 5 (0.20), ȏ = 45 (1.77) 2 bolt 1 v d = 5 (0.20), ȏ = 30 (1.18) 1 bracket 1 v 2 hexagon head bolt 2 v d = 6 (0.24), ȏ = 20 (0.79) 3 master cylinder 1 4 brake l...

  • Page 11

    –7– 1 band 2 v 1 clutch cable 1 2 clutch switch lead coupler 1 1 windshield 1 c 2 special nut 5 v 3 screw 5 v 4 windshield trims 2 c note: warning warning caution: eaa00049 eaa00137 7. Clutch cable a: lubricate the pivoting part of the clutch lever. Recommended lubricants: yamaha cable lube or motor...

  • Page 12

    –8– 1 rear view mirror 2 c 2 nut 4 v 1 inner panel 2 c 2 screw 2 v d = 6 (0.24), ȏ = 16 (0.63) 3 washer 2 v d = 6 (0.24) 4 screw 2 v d = 5 (0.20), ȏ = 12 (0.47) 5 rivet 2 v 6 screw 2 d = 6 (0.24), ȏ = 16 (0.63) 7 washer 2 d = 6 (0.24) 1 battery 1 2 battery cover 1 3 bolt 2 d = 6 (0.24), ȏ = 25 (0.98...

  • Page 13

    –9– warning eaa00900 cable routing proper cable and lead routing are essential to insure safe motor- cycle operation. (1) right handlebar switch lead (2) throttle cables (3) clutch cable (4) left handlebar switch lead (5) main switch lead (6) battery positive lead (7) battery cover (8) starter relay...

  • 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

    –11– note: warning caution: warning eaa01000 a. Checking and charging the battery the battery used in this motorcycle is a maintenance free (mf) “valve regulated lead acid battery”, it has been pre-filled with electrolyte at the factory so there is no need to add fluid at any time. 1. Check: using a...

  • Page 16

    –12– note: note: caution: note: note: note: caution: note: eaa01013 c. Checking the engine oil level 1. Stand the motorcycle on a level surface. D place the motorcycle on a suitable stand. D make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes, and then turn it off. 3. ...

  • Page 17

    –13– note: note: warning eaa01020 e. Adjusting the engine idling speed prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter should be clean, and the engine should have ade- quate compression. 1. Start the engine and let it warm u...

  • Page 18

    –14– note: warning caution: warning warning warning caution: eaa01023 g. Adjusting the front brake 1. Adjust: d brake lever position (distance (a) from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial (1) until the brake lever is in the desired ...

  • Page 19

    –15– a b a b note: warning caution: note: warning note: warning eaa01032 i. Checking the brake fluid level 1. Stand the motorcycle on a level surface. D place the motorcycle on a suitable stand. D make sure that the motorcycle is upright. 2. Check: d brake fluid level below the minimum level mark (a...

  • Page 20

    –16– warning caution: note: eaa01036 k. Adjusting the clutch cable free play 1. Measure: d clutch cable free play (a) out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 x 15 mm (0.39 x 0.59 in) 2. Adjust: d clutch cable free play handlebar side a. Turn the adju...

  • Page 21

    –17– note: caution: warning note: note: note: eaa01059 m. Adjusting the drive chain slack the drive chain slack must be checked at the tightest point on the chain. A drive chain that is too tight will over- load the engine and other vital parts, and one that is too loose can skip and dam- age the sw...

  • Page 22

    –18– eaa01065 o. Adjusting the headlight beams the following procedure applies to both of the headlights. 1. Remove: d front cowlling inner panels 2. Adjust: d headlight beam (vertically) a. Turn the adjusting screw (1) in direction (a) or (b). Direction (a) headlight beam is raised. Direction (b) h...

  • Page 23

    –19– eaa10000 appendices service data engine idling speed: 1,250 x 1,350 r/min spark plug: type: cr9ek (ngk) gap: 0.6 x 0.7 mm (0.0236 x 0.0276 in) fuel: recommended fuel: regular unleaded gasoline fuel tank capacity: total: 19.4 l (4.27 imp gal, 5.13 us gal) valve clearance (cold): in: 0.13 x 0.20 ...

  • Page 24

    –20– tightening torques item thread tightening item size nm m skg ftslb engine: spark plug m10 18 1.8 13 engine oil drain bolt m14 43 4.3 31 chassis: upper bracket pinch blot m8 30 3.0 22 steering stem nut m22 110 11 80 upper bracket and upper handlebar holder m8 23 2.3 17 under bracket pinch blot –...

  • Page 25

    –21– note 1: item thread tightening item size nm m skg ftslb rear mud guard and rear frame m6 7 0.7 5.1 engine stop switch and frame m4 2 0.2 1.4 coolant reserver tank bracket and stay 1, 2 m6 10 1.0 7.2 stay 1, 2 and frame m6 10 1.0 7.2 coolant reserver tank bracket and coolant reserver tank m6 4 0...

  • Page 26

    Printed in usa.