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Yamaha FZ6-ST Supplementary Service Manual

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Download this manual See also: Supplementary Service Manual, Owner's Manual
FZ6-ST
FZ6-STC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-18-43
5VX-28197-11

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Summary of Contents for Yamaha FZ6-ST

  • Page 1 FZ6-ST FZ6-STC SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-43 5VX-28197-11...
  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the FZ6-ST/FZ6-STC. For complete service information procedures it is necessary to use this Supple- mentary Service Manual together with the following manual. FZ6-SS/FZ6-SSC SERVICE MANUAL: LIT-11616-17-50 (5VX-28197-10)

  • Page 4: Important Manual Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • 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. The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ......ENGINE SPECIFICATIONS ....... . CHASSIS SPECIFICATIONS .

  • Page 8: Specifications

    GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS / SPEC CHASSIS SPECIFICATIONS / ELECTRICAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit 5VX8 (USA except for CAL) • • • Model code 5VX9 (CAL) • • • ENGINE SPECIFICATIONS Item Standard Limit Piston Diameter D 65.475 ~ 65.490 mm (2.5778 ~ 2.5783 •...

  • Page 9: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m•kg ft•lb Connecting rod caps Bolt 15+120° 1.5+120° 11+120° CHASSIS TIGHTENING TORQUES Tightening torque Thread Item Remarks size m•kg ft•lb Pivot shaft and frame 12.5 Sidestand switch nut Shift rod and shift arm bolt...

  • Page 10: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Left handlebar switch lead Clamp the right and left handlebar switch leads Main switch lead and handlebars. Point the tip of the clamp Clutch cable downward in front of the handlebars. Throttle cables Clamp the horn lead and main switch lead Right handlebar switch lead (upper side only) to the inner tube.
  • Page 11 SPEC CABLE ROUTING Point the lead, which comes from the terminal, to the front side of the vehicle body. There should be no slack of leads between the band and terminals. Clamp the brake hose to the inner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm (0.04 to 0.20 in).
  • Page 12 SPEC CABLE ROUTING Main switch lead License plate light lead Stay assembly Rear turn signal light lead (right) Left handlebar switch lead Rear turn signal light lead (left) Clutch cable Speed sensor lead Throttle cables Sidestand switch lead Battery negative lead coupler Oil level switch lead Starter relay lead A.C.
  • Page 13 SPEC CABLE ROUTING Route the throttle cables above the stay assy 1. Clamp the rear turn signal light lead and license Route the main switch lead above the clutch plate light lead to the frame. Hook the clamp to cable. the bracket.
  • Page 14 SPEC CABLE ROUTING To the rear turn signal light (left) Make sure to pass the neutral switch lead Pass the fuel tank drain hose through the clamp through the hole of the flap. located under the coolant reservoir tank. Clamp the seat lock wire to the frame as shown Route it behind the starter motor lead.
  • Page 15 SPEC CABLE ROUTING Right handlebar switch lead E.C.U Throttle cables Fuel tank drain hose Battery positive lead Cover Coolant reservoir tank hose Starter relay lead Battery cover Battery negative lead Connecter cover Battery negative lead coupler Fuel tank breather hose Clutch cable Brake fluid reservoir hose Connecter cover...
  • Page 16 SPEC CABLE ROUTING Either right or left side arrangement for the left Set the 4-pin coupler in the connector cover handlebar switch lead coupler and radiator fan after wiring it. motor coupler can be accepted. To the sidestand switch. Point the L-shape terminal to the front side of To the speed sensor.
  • Page 17 SPEC CABLE ROUTING Point the tip of the clamp to the outside of the Plate the adjuster of the clutch cable above vehicle. the cover. Insert the enwinding clamp of the wire harness Route the starter relay lead outside of the into the hole of the rear frame.
  • Page 18 SPEC CABLE ROUTING Point the spark plug caps of #1 to #4 to the direc-tion as shown in the illustration. Route the spark plug lead #3 under the air cut-off valve hose. Route the spark plug lead #2 behind the air cut-off valve hose.
  • Page 19 SPEC CABLE ROUTING Fuel pump assembly Fuel piping connector attachment directions. Fuel tank breather hose (except for CAL) (fuel pump side) Fuel tank drain hose 1. It is inserted until it makes a click sound the con- Fuel hose nector, and it checks that a connector does not Clip fail out.
  • Page 20 SPEC CABLE ROUTING except for CAL Front side. Coolant breather hose Pass the coolant reservoir tank hose hangs Coolant reservoir tank down downward from back of the bolt. Coolant reservoir tank hose Insert this portion securely. Clamp Spittle is turned back. Fuel tank drain hose Insert the clamp certainly.

  • Page 21: Chassis

    CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHASSIS SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers. •...
  • Page 22 CHAS SWINGARM AND DRIVE CHAIN CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol- vents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 23: Engine Engine

    ENGINE EAS00192 ENGINE ENGINE INSTALLING THE ENGINE 1. Install: • rear engine mounting bolts NOTE: NOTE: Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 2. Install: • right front engine mounting bolt • left front engine mounting bolts NOTE: NOTE: Do not fully tighten the bolts.
  • Page 24 ENGINE 5. Tighten • right front engine mounting bolts 55 Nm (5.5 m•kg, 40 ft•lb) 6. Install: • shift arm bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: NOTE: • Before installing, make sure to align the punch mark of the shift shaft with the punch mark of the shift arm.

  • Page 25: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS 15Nm (1.5 m•kg, 11ft•lb) + 120° Order Job / Part Q'ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Refer to “CRANKCASE”. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip...

  • Page 26: 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: • connecting rod cap • big end bearings NOTE: NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 27: Checking The Big End Bearings

    CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.028 ~ 0.052 mm (0.0011 ~ 0.0020 in) The following procedure applies to all of the connecting rods.
  • Page 28 CONNECTING RODS AND PISTONS e. Tighten the connecting rod bolts. NOTE: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable con- dition. • connecting rod bolts Connecting rod bolt 24.5 Nm (2.5 m•kg, 17.7 ft•lb) f.
  • Page 29 CONNECTING RODS AND PISTONS k. Tighten the connecting rod bolts. Connecting rod bolt 15 Nm (1.5 m•kg, 11 ft•lb) + 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 30 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 replacement big end bearings. 2.

  • Page 31: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons. 1. Install: • top ring • 2nd ring • upper oil ring rail • oil ring expander • lower oil ring rail NOTE: NOTE: Be sure to install the piston rings so that the...
  • Page 32 CONNECTING RODS AND PISTONS 4. Offset: • piston ring end gaps Top ring Lower oil ring rail Upper oil ring rail 2nd ring Oil ring expander 5. Lubricate: • crankshaft pins • big end bearings • connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil...
  • Page 33 CONNECTING RODS AND PISTONS 7. Tighten: NOTE: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable con- dition. • connecting rod bolts. 24.5 Nm (2.5 m•kg, 17.7 ft•lb) a. Replace the connecting rod bolts with new ones.
  • Page 34 CONNECTING RODS AND PISTONS 9. Tighten: • connecting rod bolts 15 Nm (1.5 m•kg, 11 ft•lb) + 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 36 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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