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Yamaha Manuals
Motorcycle
2007 FZ6-NA
Service manual
Yamaha 2007 FZ6-NA Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
How to Use this Manual
1 General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline of Fi System
Fi System
Instrument Functions
Outline of the Abs
Abs Component Functions
Abs Operation
Abs Self-Diagnosis Function
Abs Warning Light and Operation
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Chassis
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cooling System Diagrams
Cable Routing
Periodic Checks and Adjustments
Periodic Maintenance
Introduction
Engine
Adjusting the Valve Clearance
Synchronizing the Throttle Bodies
Adjusting the Exhaust Gas Volume (Standard)
Adjusting the Exhaust Gas Volume (High-Grade)
Adjusting the Engine Idling Speed
Adjusting the Throttle Cable Free Play
Checking the Spark Plugs
Measuring the Compression Pressure
Checking the Engine Oil Level
Changing the Engine Oil
Measuring the Engine Oil Pressure
Adjusting the Clutch Cable Free Play
Cleaning the Air Filter Element
Checking the Throttle Body Joints
Checking the Fuel Line
Checking the Crankcase Breather Hose
Checking the Exhaust System
Checking the Coolant Level
Checking the Cooling System
Changing the Coolant
Chassis
Adjusting the Front Disc Brake
Adjusting the Rear Disc Brake
Checking the Brake Fluid Level
Checking the Front Brake Pads
Checking the Rear Brake Pads
Checking the Front Brake Hoses
Checking the Rear Brake Hose
Adjusting the Rear Brake Light Switch
Bleeding the Hydraulic Brake System
Adjusting the Shift Pedal
Adjusting the Drive Chain Slack
Lubricating the Drive Chain
Checking and Adjusting the Steering Head
Checking the Front Fork
Adjusting the Rear Shock Absorber Assembly
Checking the Tires
Checking the Wheels
Checking and Lubricating the Cables
Lubricating the Levers
Lubricating the Pedal
Lubricating the Sidestand
Lubricating the Centerstand
Lubricating the Rear Suspension
Chassis
General Chassis
Front Wheel
Removing the Front Wheel
Checking the Front Wheel
[D-3] Maintenance of the Front Wheel Sensor and Sensor Rotor
Adjusting the Front Wheel Static Balance
Installing the Front Wheel
Rear Wheel
Removing the Rear Wheel
Checking the Rear Wheel
Checking the Rear Wheel Drive Hub
Checking and Replacing the Rear Wheel Sprocket
[D-4] Maintenance of the Rear Wheel Sensor and Sensor Rotor
Adjusting the Rear Wheel Static Balance
Installing the Rear Wheel
Front Brake
Introduction
Checking the Front Brake Discs
Front Brake
Replacing the Front Brake Pads
Removing the Front Brake Calipers
Disassembling the Front Brake Calipers
Checking the Front Brake Calipers
Assembling the Front Brake Calipers
Installing the Front Brake Calipers
Removing the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Introduction
Checking the Rear Brake Disc
Replacing the Rear Brake Pads
Removing the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Removing the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Abs (Anti-Lock Brake System)
[D-5] Maintenance of the Hydraulic Unit
Hydraulic Unit Operation Test
[D-6-5] Trial Run
Handlebar
Removing the Handlebars
Checking the Handlebar
Installing the Handlebar
Front Fork
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Chain Drive
Removing the Drive Chain
Checking the Drive Chain
Checking the Drive Sprocket
Checking the Rear Wheel Sprocket
Checking the Rear Wheel Drive Hub
Installing the Drive Chain
Engine
Engine Removal
Installing the Engine
Camshafts
Removing the Camshafts
Checking the Camshafts
Checking the Timing Chain and Camshaft Sprocket
Checking the Timing Chain Guides
Checking the Timing Chain Tensioner
Installing the Camshafts
Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Checking the Valve Lifters
Installing the Valves
Generator and Starter Clutch
Removing the Generator
Removing the Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Installing the Generator
Pickup Rotor
Removing the Pickup Rotor
Installing the Pickup Rotor
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Installing the Starter Motor
Oil Pump
Removing the Oil Pan
Checking the Oil Pump
Checking the Relief Valve
Checking the Oil Delivery Pipes
Checking the Oil Strainer
Checking the Oil Nozzles
Assembling the Oil Pump
Installing the Oil Pump
Installing the Oil Strainer
Installing the Oil Pan
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Pull Lever Shaft and Pull Rod
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Crankcase
Disassembling the Crankcase
Checking the Crankcase
Checking the Bearings and Oil Seals
Checking the Oil Pump Drive Chain
Assembling the Crankcase
Crankshaft
Removing the Connecting Rods and Pistons
Removing the Crankshaft Assembly
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pins
Checking the Big End Bearings
Installing the Connecting Rod and Piston
Checking the Crankshaft
Checking the Crankshaft Journal Bearings
Installing the Crankshaft
Transmission
Removing the Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Installing the Transmission
Cooling System
Checking the Radiator
Installing the Radiator
Oil Cooler
Checking the Oil Cooler
Installing the Oil Cooler
Thermostat
Checking the Thermostat
Installing the Thermostat Assembly
Water Pump
Disassembling the Water Pump
Checking the Water Pump
Assembling the Water Pump
Installing the Water Pump
Fuel System
Fuel Tank
Checking the Fuel Pump Body
Checking the Fuel Pump Operation
Installing the Fuel Pump
Removing the Fuel Pump
Removing the Fuel Tank
Installing the Fuel Tank
Throttle Bodies
Checking the Injectors
Checking the Throttle Bodies
Checking the Fuel Pressure
Adjusting the Throttle Position Sensor
Air Induction System
Checking the Air Induction System
Installing the Air Induction System
Electrical System
General Information
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-Off System Operation
Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Signaling System
Circuit Diagram
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Injection System
Circuit Diagram
Ecu Self-Diagnostic Function
Fail-Safe Actions (Substitute Characteristics Operation Control)
Troubleshooting Method
Diagnostic Mode
Troubleshooting Details
Fuel Pump System
Circuit Diagram
Troubleshooting
Immobilizer System
Circuit Diagram
General Information
Part Replacement and Key Code Registration Requirements
Troubleshooting
Self-Diagnosis Fault Code Indication
Abs (Anti-Lock Brake System)
Abs Components Chart
Abs Connector Location Chart
Abs Ecu and Abs Motor Relay
[D-1] Maintenance of the Abs Ecu
[D-2] Maintenance of the Abs Motor Relay
Abs Troubleshooting Outline
Basic Instruction for Troubleshooting
Basic Process for Troubleshooting
[A] Abs Malfunction Check Using the Abs Warning Light
[B] Detailed Abs Malfunction Check
[B-1] the Abs Warning Light Does Not Come on
[B-2] the Abs Warning Light Remains on
[B-3] the Abs Warning Light Flashes
[B-4] Malfunction Check by the Abs Self Diagnosis (Past Malfunction)
[B-5] Malfunction Check by the Abs Self Diagnosis (Present Malfunction)
[C] Determining the Cause and Location of the Malfunction
[C-1] Only the Abs Warning Light Does Not Come on When the Main Switch Is Set to "On
[C-2] Abs Warning Light and All Other Indicators Do Not Come on
[C-3] Abs Warning Light Flashes
[C-4] Abs Warning Light Flashes Every 0.5 Second
[C-5] Diagnosis by the Malfunction Code
[D-6-4] Deleting the Malfunction Code
[D-6-6] Delete Function Test
Specifications
[D-6] Final Check
Electrical Components
Checking the Switches
Checking the Bulbs and Bulb Sockets
Checking the Leds
Checking the Fuses
Checking and Charging the Battery
Checking the Relays
Checking the Abs Motor Relay
Checking the Solenoid Valves and Motor
Checking the Turn Signal/Hazard Relay
Checking the Relay Unit (Diode)
Checking the Spark Plug Caps
Checking the Ignition Coils
Checking the Crankshaft Position Sensor
Checking the Lean Angle Sensor
Checking the Wheel Sensor
Checking the Startor Motor Operation
Checking the Stator Coil
Checking the Rectifier/Regulator
Checking the Horn
Checking the Engine Oil Level Gauge
Checking the Fuel Sender
Checking the Speed Sensor
Checking the Radiator Fan Motor
Checking the Coolant Temperature Sensor
Checking the Throttle Position Sensor
Checking the Fuel Pump
Checking the Air Induction System Solenoid
Checking the Intake Air Pressure Sensor
Checking the Intake Air Temperature Sensor
Troubleshooting
Wiring Diagram
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2007
FZ6-N/S
FZ6-NA/SA
FZ6-NHG(W)
FZ6-SHG(W)
FZ6-NAHG/SAHG
SERVICE MANUAL
4S8-28197-E0
Table of
Contents
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Chapters
Table of Contents
7
Specifications
45
Periodic Checks and Adjustments
131
Chassis
171
Engine
259
Cooling System
343
Fuel System
357
Electrical System
371
Table of Contents
Troubleshooting
TROUBLESHOOTING
376
TROUBLESHOOTING
381
TROUBLESHOOTING
386
TROUBLESHOOTING
390
TROUBLESHOOTING
394
TROUBLESHOOTING
402
TROUBLESHOOTING METHOD
409
TROUBLESHOOTING DETAILS
416
TROUBLESHOOTING
432
TROUBLESHOOTING
440
[D-1] MAINTENANCE OF THE ABS ECU
451
BASIC INSTRUCTION FOR TROUBLESHOOTING
452
BASIC PROCESS FOR TROUBLESHOOTING
454
TROUBLESHOOTING
505
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This manual is also suitable for:
2007 fz6-sa
2007 fz6-s
2007 fz6-nhgw
2007 fz6-n
2007 fz6-shg
2007 fz6-shgw
...
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2007 fz6-nahg
2007 fz6-sahg
2007 fz6-nhg
Fz6-n/s 2007
Fz6-nhg(w) 2007
Fz6-shg(w) 2007
Fz6-na/sa 2007
Fz6-nahg/sahg 2007
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