Yamaha FZ6-SS Assembly Manual
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Also See for FZ6-SS:
- Owner's manual (108 pages) ,
- Owner's manual (90 pages) ,
- Service manual (435 pages)
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Table of Contents
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Summary of Contents for Yamaha FZ6-SS
- Page 2 Since some external parts of the motorcycle have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the assembled motorcycle should be thoroughly cleaned, inspected, and adjusted prior to delivery to the customer.
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Page 3: Symbols Used In The Assembly Manual
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 mSkg, 7.2 ftSlb) (3): Towards the front of the motorcycle (4): Clearance required (5): Install so that the arrow mark faces up- ward. - Page 4 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 Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or when doing any opera-...
- Page 5 EAA00060 UNPACKING 1. Remove the frame cover (1). NOTE: 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).
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Page 6: Parts Location
EAA00070 PARTS LOCATION (1) Carton box 1. (2) Carton box 2. (3) Front tire. –2–... - Page 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.
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Page 8: Setup Procedures
EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown. –4–... -
Page 9: Throttle Grip
EAA00014 EAA00102 1. HANDLEBAR A: Clean the right handlebar end. Apply light coat grease. B: Install the handlebar holders with the arrow mark facing for- ward. CAUTION: First tighten the bolts on the front side, and then tighten the bolts on the rear side. C: Align the punch mark on the Handlebar holders handlebar with the top of the... -
Page 10: Front Fender
F: Check the brake lever for the brake lever. smooth action. Recommended lubricants: WARNING Yamaha cable lube or motor Proper cable and hose routing is essential to assure safe mo- B: Make sure that the “UP” mark torcycle operation. Refer to “CABLE ROUTING”. -
Page 11: Clutch Cable
Refer to “ADJUSTMENTS AND the clutch lever. PREDELIVERY SERVICE”. Recommended lubricants: C: Install the clutch switch lead Yamaha cable lube or motor coupler. WARNING Proper cable routing is essen- B: To install the clutch cable, be tial to assure safe motorcycle sure to proceed as follows: operation. -
Page 12: Rear View Mirrors
10. REAR VIEW MIRRORS A: Tighten the rear view mirrors nuts. Nut: 7 Nm (0.7 mSkg, 5.1 ftSlb) Rear view mirror 11. INNER PANEL NOTE: 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. -
Page 13: Cable Routing
EAA00900 CABLE ROUTING WARNING 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 lead (9) Battery negative lead... -
Page 14: Adjustments And Predelivery Service
EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters. Always follow the order as shown. –10–... -
Page 15: Checking The Tire Pressure
EAA01000 WARNING A. CHECKING AND CHARGING D Do not attempt boost charging under THE BATTERY any circumstances. D Battery electrolyte is poisonous and NOTE: dangerous, causing severe burns, The battery used in this motorcycle is a etc. It contains sulfuric acid. Avoid maintenance free (MF) “Valve Regulated contact with skin, eyes or clothing. -
Page 16: Checking The Engine Oil Level
EAA01013 Quantity C. CHECKING THE ENGINE OIL Without oil filter cartridge replacement LEVEL 2.5 L (2.20 Imp qt, 2.64 US qt) 1. Stand the motorcycle on a level surface. CAUTION: NOTE: D Engine oil also lubricates the clutch D Place the motorcycle on a suitable stand. D Make sure that the motorcycle is upright. - Page 17 EAA01020 3. Adjust: D engine idling speed E. ADJUSTING THE ENGINE IDLING SPEED a. Turn the throttle stop screw (1) in direc- tion (a) or (b) until the specified engine NOTE: idling speed is obtained. Prior to adjusting the engine idling speed, the throttle bodies synchronization should Direction (a) be adjusted properly, the air filter should be...
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Page 18: Adjusting The Front Brake
EAA01023 WARNING G. ADJUSTING THE FRONT After adjusting the brake lever position, BRAKE make sure that the pin on the brake lever 1. Adjust: holder is firmly inserted in the hole in the D brake lever position adjusting dial. (distance (a) from the throttle grip to the CAUTION: brake lever) After adjusting the brake lever position,... -
Page 19: Checking The Brake Fluid Level
EAA01032 WARNING I. CHECKING THE BRAKE FLUID D Use only designated brake fluid. LEVEL Other brake fluids may cause the rub- 1. Stand the motorcycle on a level surface. er seals to deteriorate, causing leak- age and poor brake performance. NOTE: D Refill with the same type of brake D Place the motorcycle on a suitable... -
Page 20: Adjusting The Clutch Cable Free Play
EAA01036 2. Adjust: D clutch cable free play K. ADJUSTING THE CLUTCH CABLE FREE PLAY Handlebar side a. Turn the adjusting dial (1) in direction (b) 1. Measure: D clutch cable free play (a) or (c) until the specified clutch cable free Out of specification ! Adjust. - Page 21 4. Loosen: EAA01059 D wheel axle nut (1) M. ADJUSTING THE DRIVE CHAIN 5. Adjust: SLACK D drive chain slack NOTE: a. Loosen both locknuts (2). The drive chain slack must be checked at b. Turn both adjusting nuts (3) in direction the tightest point on the chain.
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Page 22: Adjusting The Headlight Beams
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. -
Page 23: Service Data
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): 0.13 X 0.20 mm (0.0051 X 0.0079 in) 0.23 X 0.30 mm (0.0091 X 0.0118 in) -
Page 24: Tightening Torques
TIGHTENING TORQUES Tightening Thread Item Item size mSkg ftSlb Engine: Spark plug Engine oil drain bolt Chassis: Upper bracket pinch blot Steering stem nut Upper bracket and upper handlebar holder Under bracket pinch blot – Lower ring nut See NOTE1 Front fork cap bolt Damper rod assembly bolt Pinch bolt (front wheel axle) - Page 25 Tightening Thread Item Item size mSkg ftSlb Rear mud guard and rear frame Engine stop switch and frame Coolant reserver tank bracket and stay 1, 2 Stay 1, 2 and frame Coolant reserver tank bracket and coolant reserver tank Front wheel axle shaft and bolt Front wheel axle pinch bolt Front brake caliper and front fork Front brake disc and front wheel...
- Page 26 PRINTED IN USA...
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