Yamaha 2009 FZ6RC Manuals

Manuals and User Guides for Yamaha 2009 FZ6RC. We have 1 Yamaha 2009 FZ6RC manual available for free PDF download: Service Manual

Yamaha 2009 FZ6RC Service Manual

Yamaha 2009 FZ6RC Service Manual (420 pages)

FZ6R 2009

Brand: Yamaha | Category: Motorcycle | Size: 22.63 MB

Table of Contents

Table of Contents

7
- Symbols
  6
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
  - Important Information
    16
  - Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking the Connections
    18
    
    Removing the Quick Fastener
    19
    
    Installing the Quick Fastener
    20
  - Special Tools
    21
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  36
- Electrical Specifications
  39
- Tightening Torques
  41
- Lubrication Points and Lubricant Types
  49
  - Engine
    49
  - Chassis
    50
- Lubrication System Chart and Diagrams
  52
  - Engine Oil Lubrication Chart
    52
  - Lubrication Diagrams
    54
- Cooling System Diagrams
  66
- Cable Routing
  68
Periodic Checks and Adjustments

99
- Introduction
  101
- Periodic Maintenance
  101
- Periodic Maintenance Chart for the Emission Control System
  101
- General Maintenance and Lubrication Chart
  102
- Checking the Fuel Line
  104
- Checking the Spark Plugs
  104
- Adjusting the Valve Clearance
  105
- Adjusting the Engine Idling Speed
  107
- Synchronizing the Throttle Bodies
  108
- Checking the Air Induction System
  110
- CHECKING the CANISTER (for California Only)
  110
- Checking the Crankcase Breather Hose
  110
- Replacing the Air Filter Element
  110
- Adjusting the Clutch Cable Free Play
  111
- Adjusting the Front Disc Brake
  112
- Checking the Brake Fluid Level
  112
- Adjusting the Rear Disc Brake
  113
- Checking the Front Brake Pads
  113
- Bleeding the Hydraulic Brake System
  114
- Checking the Rear Brake Pads
  114
- Checking the Front Brake Hoses
  115
- Checking the Rear Brake Hose
  115
- Checking the Tires
  115
- Checking the Wheels
  115
- Adjusting the Drive Chain Slack
  117
- Checking the Swingarm
  117
- Checking the Wheel Bearing
  117
- Checking and Adjusting the Steering Head
  118
- Lubricating the Drive Chain
  118
- Adjusting the Handlebar Position
  119
- Adjusting the Shift Pedal
  120
- Lubricating the Levers
  120
- Lubricating the Pedal
  120
- Checking the Front Fork
  121
- Checking the Sidestand Switch
  121
- Lubricating the Rear Suspension
  121
- Lubricating the Sidestand
  121
- Adjusting the Rear Shock Absorber Assembly
  122
- Checking the Engine Oil Level
  122
- Changing the Engine Oil
  123
- Measuring the Engine Oil Pressure
  124
- Checking the Coolant Level
  125
- Checking the Cooling System
  125
- Changing the Coolant
  126
- Adjusting the Rear Brake Light Switch
  127
- Checking the Front and Rear Brake Switch
  127
- Adjusting the Throttle Cable Free Play
  128
- Checking and Lubricating the Cables
  128
- Checking and Charging the Battery
  129
- Checking the Fuses
  129
Chassis

131
- General Chassis
  
  133
- Front Wheel
  
  138
  - Removing the Front Wheel
    140
  - Checking the Front Wheel
    140
  - Adjusting the Front Wheel Static Balance
    141
  - Installing the Front Wheel
    142
- Rear Wheel
  
  143
  - Removing the Rear Wheel
    146
  - Checking the Rear Wheel
    146
  - Checking the Rear Wheel Drive Hub
    146
  - Checking and Replacing the Rear Wheel Sprocket
    146
  - Adjusting the Rear Wheel Static Balance
    147
  - Installing the Rear Wheel
    147
- Front Brake
  
  148
- Rear Brake
  
  160
  - Introduction
    165
  - Checking the Rear Brake Disc
    165
  - Replacing the Rear Brake Pads
    165
  - Removing the Rear Brake Caliper
    166
  - Disassembling the Rear Brake Caliper
    166
  - Checking the Rear Brake Caliper
    167
  - Assembling the Rear Brake Caliper
    167
  - Installing the Rear Brake Caliper
    167
  - Removing the Rear Brake Master Cylinder
    169
  - Checking the Rear Brake Master Cylinder
    169
  - Assembling the Rear Brake Master Cylinder
    169
  - Installing the Rear Brake Master Cylinder
    170
  - Handlebar
    172
  - Removing the Handlebars
    173
  - Checking the Handlebar
    173
  - Installing the Handlebar
    173
- Front Fork
  
  176
  - Removing the Front Fork Legs
    178
  - Disassembling the Front Fork Legs
    178
  - Checking the Front Fork Legs
    179
  - Assembling the Front Fork Legs
    180
  - Installing the Front Fork Legs
    182
- Steering Head
  
  183
  - Removing the Lower Bracket
    185
  - Checking the Steering Head
    185
  - Installing the Steering Head
    186
- Rear Shock Absorber Assembly
  
  187
- Swingarm
  
  190
  - Removing the Swingarm
    191
  - Checking the Swingarm
    191
  - Installing the Swingarm
    192
- Chain Drive
  
  193
  - Removing the Drive Chain
    194
  - Checking the Drive Chain
    194
  - Checking the Drive Sprocket
    195
  - Checking the Rear Wheel Sprocket
    195
  - Checking the Rear Wheel Drive Hub
    195
  - Installing the Drive Chain
    195
Engine

197
- Engine Removal
  
  199
  - Installing the Engine
    204
    
    Installing the Drive Chain
    205
- Camshafts
  
  206
  - Removing the Camshafts
    208
  - Checking the Camshafts
    209
  - Checking the Timing Chain and Camshaft Sprocket
    210
  - Checking the Timing Chain Guides
    210
  - Checking the Timing Chain Tensioner
    210
  - Installing the Camshafts
    211
  - Cylinder Head
    214
- Removing the Cylinder Head
  
  215
  - Checking the Cylinder Head
    215
  - Installing the Cylinder Head
    215
  - Measuring the Compression Pressure
    216
- Valves and Valve Springs
  
  218
  - Removing the Valves
    219
  - Checking the Valves and Valve Guides
    219
  - Checking the Valve Seats
    221
  - Checking the Valve Springs
    223
  - Checking the Valve Lifters
    224
  - Installing the Valves
    224
- Generator and Starter Clutch
  
  226
  - Removing the Generator
    228
  - Removing the Starter Clutch
    228
  - Checking the Starter Clutch
    228
    
    Flywheel Puller
    228
    
    Flywheel Puller Attachment
    228
  - Installing the Starter Clutch
    229
  - Installing the Generator
    229
  - Pickup Rotor
    231
- Removing the Pickup Rotor
  
  232
  - Installing the Pickup Rotor
    232
  - Camshaft Wrench
    232
- Electric Starter
  
  234
  - Checking the Starter Motor
    236
  - Assembling the Starter Motor
    237
  - Installing the Starter Motor
    237
- Oil Pump
  
  238
  - Removing the Oil Pan
    241
  - Checking the Oil Pump
    241
  - Checking the Relief Valve
    241
  - Checking the Oil Delivery Pipes
    242
  - Checking the Oil Strainer
    242
  - Checking the Oil Nozzles
    242
  - Checking the Oil Pump Drive Chain
    242
  - Assembling the Oil Pump
    242
  - Installing the Oil Pump
    243
  - Installing the Oil Strainer
    243
  - Installing the Oil Pan
    243
- Clutch
  
  245
  - Removing the Clutch
    248
  - Checking the Friction Plates
    249
  - Checking the Clutch Plates
    249
  - Checking the Clutch Springs
    250
  - Checking the Clutch Housing
    250
  - Checking the Clutch Boss
    250
  - Checking the Pressure Plate
    250
  - Checking the Clutch Push Rods
    251
  - Installing the Clutch
    251
- Shift Shaft
  
  254
  - Removing the Shift Shaft
    255
  - Checking the Shift Shaft
    255
  - Checking the Stopper Lever
    255
  - Installing the Shift Shaft
    255
- Crankcase
  
  257
  - Disassembling the Crankcase
    259
  - Checking the Crankcase
    259
  - Checking the Bearings and Oil Seals
    259
  - Assembling the Crankcase
    259
- Crankshaft
  
  262
  - Removing the Connecting Rods and Pistons
    264
  - Removing the Crankshaft Assembly
    264
  - Checking the Cylinder and Piston
    265
  - Checking the Piston Rings
    265
  - Checking the Piston Pins
    266
  - Checking the Big End Bearings
    267
  - Installing the Connecting Rod and Piston
    269
  - Checking the Crankshaft
    271
  - Checking the Crankshaft Journal Bearings
    271
  - Installing the Crankshaft
    273
- Transmission
  
  274
  - Removing the Transmission
    279
  - Checking the Shift Forks
    279
  - Checking the Shift Drum Assembly
    279
  - Checking the Transmission
    280
  - Assembling the Main Axle and Drive Axle
    280
  - Installing the Transmission
    281
Cooling System

283
- Radiator
  
  284
  - Checking the Radiator
    286
  - Installing the Radiator
    286
- Oil Cooler
  
  287
  - Checking the Oil Cooler
    288
  - Installing the Oil Cooler
    288
- Thermostat
  
  289
  - Checking the Thermostat
    290
  - Installing the Thermostat Assembly
    290
- Water Pump
  
  292
  - Disassembling the Water Pump
    294
  - Checking the Water Pump
    294
  - Assembling the Water Pump
    294
  - Installing the Water Pump
    295
Fuel System

297
- Fuel Tank
  
  298
  - Checking the Fuel Pump Body
    299
  - Checking the Fuel Pump Operation
    299
  - Installing the Fuel Pump
    299
  - Removing the Fuel Pump
    299
  - Removing the Fuel Tank
    299
  - Installing the Fuel Tank
    300
- Throttle Bodies
  
  302
  - Checking the Throttle Body Joints
    302
  - Checking the Fuel Injectors
    304
  - Installing the Injectors
    304
  - Checking the Injector Pressure
    304
  - Checking and Cleaning the Throttle Bodies
    305
  - Checking the Fuel Pressure
    306
  - Adjusting the Throttle Position Sensor
    307
- Air Induction System
  
  308
Electrical System

313
- Ignition System
  
  316
  - Circuit Diagram
    316
  - Troubleshooting
    318
- Electric Starting System
  
  320
  - Circuit Diagram
    320
  - Starting Circuit Cut-Off System Operation
    322
  - Troubleshooting
    324
- Charging System
  
  326
  - Circuit Diagram
    326
  - Troubleshooting
    328
- Lighting System
  
  330
  - Circuit Diagram
    330
  - Troubleshooting
    332
- Signaling System
  
  334
  - Circuit Diagram
    334
  - Troubleshooting
    336
- Cooling System
  
  340
  - Circuit Diagram
    340
  - Troubleshooting
    342
- Fuel Injection System
  
  344
  - Circuit Diagram
    344
  - Ecu Self-Diagnostic Function
    346
  - Fail-Safe Actions (Substitute Characteristics Operation Control)
    346
  - Trouble Shooting Chart
    348
  - Diagnostic Mode
    349
  - Troubleshooting Details
    350
  - Other Diagnostic Monitoring Codes
    380
- Fuel Pump System
  
  382
  - Circuit Diagram
    382
  - Troubleshooting
    384
- Electrical Components
  
  386
  - Checking the Switches
    390
  - Checking the Bulbs and Bulb Sockets
    393
  - Checking the Fuses
    394
  - Checking and Charging the Battery
    395
  - Checking the Relays
    398
  - Checking the Turn Signal Relay
    399
  - Checking the Relay Unit (Diode)
    400
  - Checking the Ignition Spark Gap
    400
  - Checking the Spark Plug Caps
    401
  - Checking the Ignition Coil
    401
  - Checking the Crankshaft Position Sensor
    402
  - Checking the Lean Angle Sensor
    402
  - Checking the Starter Motor Operation
    403
  - Checking the Stator Coil
    403
  - Checking the Rectifier/Regulator
    404
  - Checking the Horn
    404
  - Checking the Engine Oil Level Switch
    404
  - Checking the Air Induction System Solenoid
    405
  - Checking the Fuel Sender
    405
  - Checking the Speed Sensor
    406
  - Checking the Radiator Fan Motor
    406
  - Checking the Coolant Temperature Sensor
    407
  - Checking the Throttle Position Sensor
    407
  - Checking the Intake Air Pressure Sensor
    408
  - Checking the Intake Air Temperature Sensor
    408
Troubleshooting

411
- General Information
  411
- General Information
  412
- Incorrect Engine Idling Speed
  412
- Starting Failures
  412
- Troubleshooting
  412
- Faulty Clutch
  413
- Faulty Gear Shifting
  413
- Jumps out of Gear
  413
- Overheating
  413
- Poor Medium-And-High-Speed Performance
  413
- Shift Pedal Does Not Move
  413
- Faulty Front Fork Legs
  414
- Faulty Lighting or Signaling System
  414
- Overcooling
  414
- Poor Braking Performance
  414
- Unstable Handling
  414

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