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Yamaha FZ6-N 2004 Service Manual

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  • Page 3 Service Manual together with the following manual. FZ6-S(S) 2004 SERVICE MANUAL: 5VX1-AE1 FZ6-N(S) 2004 SUPPLEMENTARY SERVICE MANUAL E2003 by Yamaha Motor Co., Ltd. First Edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 4: Important Manual Information

    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 maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 5: How To Use This Manual

    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 The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........ELECTRICAL SPECIFICATIONS .
  • Page 8 SIGNALING SYSTEM ......... CIRCUIT DIAGRAM .

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 1B31 (EUR), 1B32 (AUS) Dimensions Overall width 755 mm (29.7 in) Overall height 1,085 mm (42.7 in) Weight Wet (with oil and a full fuel tank) 201 kg (443 lb) Maximum load (except motorcycle) 196 kg (432 lb) ELECTRICAL SPECIFICATIONS...

  • Page 10: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Connecting rod caps (for EUR) 15 + 150_ 1.5 + 150_ 11 + 150_ Connecting rod caps (for OCE) Bolt 15 + 120_ 1.5 + 120_ 11 + 120_ CHASSIS TIGHTENING TORQUES...

  • Page 11: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS Radiator Oil cooler –3–...
  • Page 12 SPEC COOLING SYSTEM DIAGRAMS Water pump Oil cooler Radiator –4–...
  • Page 13 SPEC COOLING SYSTEM DIAGRAMS Radiator Thermostat –5–...

  • Page 14: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Left handlebar switch lead A Clamp the right handlebar switch lead and handle- Main switch and immobilizer lead bar. Point the tip of the clamp downward in front of Clutch cable the handlebar. Throttle cables B Route the branched lead behind the main switch Right handlebar switch lead and immobilizer lead.
  • Page 15 SPEC CABLE ROUTING Right handlebar switch lead C Route the horn lead inner side of the coolant reser- Throttle cables voir tank hose. Horn lead D Clamp the horn lead and radiator hose (the external Wire harness side only). Horn lead should be positioned inside of Rear brake light switch lead the hose.
  • Page 16 SPEC CABLE ROUTING I Pull down the mark-painted sections of the fuel tank N Install the right handlebar switch lead coupler breather hose, fuel tank drain hose and coolant res- through the hole of the bracket 2 from the downside. ervoir tank breather hose to be lower than the clamp O Route the starter motor lead by the inner side of the position of the muffler stay.
  • Page 17 SPEC CABLE ROUTING Left handlebar switch lead Rear turn signal light lead (right) Main switch and immobilizer lead Rear turn signal light lead (left) Meter lead and left handlebar switch lead Speed sensor lead Clutch cable Side stand switch lead Battery negative lead coupler Oil level switch lead Starter relay lead...
  • Page 18 SPEC CABLE ROUTING A To the headlight bulb. N Clamp the rear turn signal lead and license plate B Route it inside (in the width direction of the vehicle) light lead to the frame. Hook the clamp to the brack- of the left handlebar switch lead.
  • Page 19 SPEC CABLE ROUTING 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.
  • Page 20 SPEC CABLE ROUTING Right handlebar switch lead Seat lock cable Throttle cables Rectifier/regulator Battery positive lead E.C.U Coolant reservoir tank hose Fuel tank drain hose Battery cover Cover Connecter cover Starter relay lead Fuel tank breather hose Battery negative lead Brake fluid reservoir hose Battery negative lead coupler Lean angle cut-off switch...
  • Page 21 SPEC CABLE ROUTING A To the meter. I Set the 4-pin coupler in the connector cover after B Either right or left side arrangement for the left han- wiring it. dlebar switch lead coupler and radiator fan motor J To the sidestand switch. coupler can be accepted.
  • Page 22 SPEC CABLE ROUTING W Attach the rectifier regulator lead to the clamp of the AG Pass the spark plug leads #1 and #4 through the rectifier bracket. slit of the cover 2. X To the engine ground. AH Pass the spark plug lead #2 through the inner Y To the fuel injection.
  • Page 23 SPEC CABLE ROUTING AO Route the spark plug leads #2 and #3 behind the air cut-off valve hose. –15–...
  • Page 24 SPEC CABLE ROUTING Fuel pump assembly a Fuel piping connector attachment directions. (fuel Fuel tank breather hose pump side) Fuel tank drain hose 1. It is inserted until it makes a click sound the connec- Fuel hose tor, and it checks that a connector does not fall out. It Clip takes care that a foreign substance does not enter Clamp...
  • Page 25 SPEC CABLE ROUTING 1 Coolant breather hose D Spittle is turned back. 2 Coolant reservoir tank E Insert the clamp certainly. 3 Coolant reservoir tank hose F It may open and close to direction of which. All 4 Clamp notches gear at the time of attachment. 5 Fuel tank drain hose G Pass the coolant reservoir tank hose inside of the clamp.

  • Page 26: Periodic Checks And Adjustments

    S The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING...
  • Page 27 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ANNUAL 1,000 km) ITEM CHECK OR MAINTENANCE JOB CHECK CHECK Sidestand switch S Check operation. (See page 3-57, 8-4) Front fork S Check operation and for oil leakage. (See page 3-52) Shock absorber S Check operation and shock absorber for oil leakage.

  • Page 28: Cowlings

    COWLINGS COWLINGS 23 Nm (2.3 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Seat Refer to “SEAT”. Rear cowling Frame side cover For installation, reverse the removal procedure.

  • Page 29: Electrical System

    REPLACING THE HEADLIGHT BULBS 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 bulb 2 WARNING Since the headlight bulb gets extremely hot,...

  • Page 30: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS 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 Direction Headlight beam is raised. Headlight beam is Direction lowered.

  • Page 31: Engine

    CONNECTING RODS AND PISTONS EAS00252 ENGINE CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg, 11 ftSlb) +120_ 15 Nm (1.5 mSkg, 11 ftSlb) +150_ Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Refer to “CRANKCASE”.

  • Page 32: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS 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 NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 33: Checking The Big End Bearings (For Eur)

    CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS (for EUR) 1. Measure: S crankshaft-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 following procedure applies to all of the connecting rods.
  • Page 34 CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Connecting rod nut 15 Nm (1.5 mSkg, 11 ftSlb) + 150_ f. Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts.
  • Page 35 CONNECTING RODS AND PISTONS 2. Select: S big end bearings (P1 X P4) NOTE: 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”...

  • Page 36: Checking The Big End Bearings (For Oce)

    CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS (for OCE) 1. Measure: S crankshaft-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 following procedure applies to all of the connecting rods.
  • Page 37 CONNECTING RODS AND PISTONS e. Tighten the connecting rod bolts. NOTE: 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 mSkg, 17.7 ftSlb) f.
  • Page 38 CONNECTING RODS AND PISTONS k. Tighten the connecting rod bolts. Connecting rod bolt 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ CAUTION: 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 CONNECTING RODS AND PISTONS 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. crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings.
  • Page 40 CONNECTING RODS AND PISTONS 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 NOTE:...
  • Page 41 CONNECTING RODS AND PISTONS 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 lubricant...
  • Page 42 CONNECTING RODS AND PISTONS 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_).

  • Page 43: (For Oce)

    CONNECTING RODS AND PISTONS 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 NOTE:...
  • Page 44 CONNECTING RODS AND PISTONS 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 lubricant...
  • Page 45 CONNECTING RODS AND PISTONS 7. Tighten: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts. 24.5 Nm (2.5 mSkg, 17.7 ftSlb) a. Replace the connecting rod bolts with new ones.
  • Page 46 CONNECTING RODS AND PISTONS 9. Tighten: S connecting rod bolts 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ CAUTION: 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.

  • Page 47: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS”...
  • Page 48 COOL RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Radiator fan For installation, reverse the removal procedure. –40–...

  • Page 49: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” Fuel tank Refer to “FUEL TANK”...

  • Page 50: Water Pump

    COOL WATER PUMP EAS00468 WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.

  • Page 51: Electrical System

    ELEC CHECKING THE SWITCHES EAS00731 ELECTRICAL SYSTEM CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.

  • Page 52: Ignition System

    ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Ignition coil #1 and #4 Battery ignition coil #2 and #3 Starting circuit cut-off relay Spark plug Sidestand switch Engine stop switch Neutral switch Fuse (ignition) Lean angle cut-off switch Clutch switch Crankshaft position sensor –44–...

  • Page 53: Troubleshooting

    ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark). THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 54 ELEC IGNITION SYSTEM EAS00743 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 Spark plug cap resistance S Crank the engine by pushing the starter...
  • Page 55 ELEC IGNITION SYSTEM Negative tester probe ! Crankshaft position sensor resis- spark plug lead tance Positive tester probe ! 248 X 372 Ω at 20_C (68_F) spark lug lead (between gray and black) S Is the crankshaft position sensor OK? Replace the crank- shaft position sen- sor.
  • Page 56 ELEC IGNITION SYSTEM EAS00752 Positive tester probe ! 11. Sidestand switch sky blue S Check the sidestand switch for continuity. Negative tester probe ! Refer to “CHECKING THE SWITCHES”. blue/yellow S Is the sidestand switch OK? Positive tester probe ! continuity blue/green Negative tester probe !
  • Page 57 ELEC IGNITION SYSTEM 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? Replace the ECU. Properly connect or repair the ignition system’s wiring. –49–...

  • Page 58: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM –50–...
  • Page 59 ELEC LIGHTING SYSTEM Main switch Fuse (main) Battery High beam indicator light Fuse (headlight) Fuse (ignition) Fuse (park) License plate light Tail/ brake light Pass switch Dimmer switch Dimmer relay Auxiliary light Headlight –51–...

  • Page 60: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) Any of the following fail to light: headlight, S Is the battery OK? high beam indicator light, taillight, licence light or meter light. Check: S Clean the battery 1.
  • Page 61 ELEC LIGHTING SYSTEM 6. Dimmer relay S Disconnect the dimmer relay from the cou- pler. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the dimmer relay as shown. Positive battery lead ! red/yellow Negative battery lead ! yellow/black Positive tester probe ! red/yellow Negative tester probe ! blue/black S Does the dimmer relay have continuity be-...

  • Page 62: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00788 Headlight CHECKING THE LIGHTING SYSTEM Positive tester probe ! yellow 1. The headlight and the high beam indicator Negative tester probe ! black light fail to come on. Headlight coupler (wire harness side) 1. Headlight bulb and socket High beam S Check the headlight bulb and socket for con- tinuity.

  • Page 63: Lighting System

    ELEC LIGHTING SYSTEM EAS00792 EAS00790 2. The license plate light fails to come on. 3. The tail/brake light fails to come on. 1. License plate light bulb and socket 1. Tail/brake light bulb and socket S Check the license plate light bulb and socket S Check the tail/brake light bulb and socket for for continuity.
  • Page 64 ELEC LIGHTING SYSTEM EAS00791 3. Voltage 4. The auxiliary light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Auxiliary light and socket auxiliary light coupler (wire harness side) as S Check the auxiliary light bulb and socket for shown.

  • Page 65: Signaling System

    ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM –57–...
  • Page 66 ELEC SIGNALING SYSTEM Main switch Fuse (backup) Fuse (main) Battery Starting circuit cut-off relay Neutral switch Fuel pump Oil level waning light Neutral indicator light Multi-function meter Turn signal indicator light Oil level switch Front brake light switch Fuse (signal) Fuse (ignition) Fuse (park) Turn signal relay...

  • Page 67: Troubleshooting

    ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING S Any of the following fail to light: turn sig- nal light, brake light or an indicator light. S Clean the battery S The horn fails to sound. terminals. S Recharge or re- Check: place the battery. 1.
  • Page 68 ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket horn connector at the horn terminal as S Check the tail/brake light bulb and socket for shown.
  • Page 69 ELEC SIGNALING SYSTEM S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown/ green at the turn signal relay coupler (wire wiring circuit This circuit is OK. harness side). from the main switch S Is the voltage within specification? to the tail/brake light coupler is faulty and must be repaired.
  • Page 70 ELEC SIGNALING SYSTEM Left turn signal light Positive tester probe ! ground Negative tester probe ! chocolate Replace the meter Right turn signal light assembly. Positive tester probe ! ground Negative tester probe ! dark green 2. Neutral switch S Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”.
  • Page 71 ELEC SIGNALING SYSTEM EAS00802 S Are the tester readings correct? 5. The oil level warning light fails to come on. 1. Oil level warning light (LEDs) S Check the oil level warning light for continu- ity. Replace the starting When the main switch is turn to “ON”, the oil circuit cut-off relay.
  • Page 72 ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel level warning light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) S Drain the fuel from the fuel tank and remove as shown.
  • Page 73 ELEC SIGNALING SYSTEM 2. Voltage S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! green/white Negative tester probe ! black/white S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) of green/white and black/white...
  • Page 74 FZ6-N(S) 2004 WIRING DIAGRAM Main switch Left handlebar switch A.C. magneto Clutch switch Rectifier/ regulator Pass switch Fuse (backup) Dimmer switch Fuse (fuel injection) Hazard switch Immobilizer unit Turn signal switch Fuse (main) Horn switch Starter relay Horn Starter motor Dimmer relay Battery Auxiliary light...
  • Page 77 FZ6-N(S) 2004 WIRING DIAGRAM COLOR CODE ..Black G / B ..Green / Black ..Brown G / L ..Green / Blue G / W ..Green / White .

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