2005
FZ6-S(T)
5VX1-AE2
SUPPLEMENTARY SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the FZ6-S(T) 2005. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
FZ6-S(S) 2004 SERVICE MANUAL: 5VX1-AE1
FZ6-S(T) 2005
SUPPLEMENTARY
SERVICE MANUAL
© 2004 by Yamaha Motor Co., Ltd. First Edition, August 2004
All rights reserved.
Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
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 manual. 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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
|
|
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR |
||
|
|
SAFETY IS INVOLVED! |
||
WARNING |
Failure to follow WARNING instructions could result in severe injury or death |
|||
|
|
|||
to the motorcycle operator, a bystander or a person checking or repairing the |
||||
|
|
|||
|
|
motorcycle. |
||
|
|
A CAUTION indicates special precautions that must be taken to avoid dam- |
||
CAUTION: |
|
|||
|
age to the motorcycle. |
|||
|
|
|||
NOTE: |
A NOTE provides key information to make procedures easier or clearer. |
|||
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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter.
Refer to “SYMBOLS”.
Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described sequentially.
EAS00008
SYMBOLS
The following symbols are not relevant to every vehicle.
Symbols 
to 
indicate the subject of each chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system 
Troubleshooting
Symbols 
to 
indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed 
Electrical data
Symbols 
to 
in the exploded diagrams indicate the types of lubricants and lubrication points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
Symbols 
to 
in the exploded diagrams indicate the following.
Apply locking agent (LOCTITE®) 
Replace the part
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ELECTRICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 2 CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 2 CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . 18 CHECKING THE BIG END BEARINGS . . . . . . . . . . . . . . . . . . . . 19 INSTALLING THE CONNECTING ROD AND PISTON. . . . . . . . . 23
GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/ |
|
SPEC |
|
CHASSIS SPECIFICATIONS/ELECTRICAL SPECIFICATIONS |
|
|
|
|
|
|
|
|
|
|
|
SPECIFICATIONS |
|
|
|
GENERAL SPECIFICATIONS |
|
|
|
Item |
Standard |
Limit |
|
|
|
Model code |
5VX6 (EUR), 5VX7 (AUS) |
••• |
|
|
|
ENGINE SPECIFICATIONS
Item |
Standard |
Limit |
Piston |
|
|
Diameter D |
65.475 ~ 65.490 mm (2.5778 ~ 2.5783 in) |
••• |
Height H |
5 mm (0.20 in) |
••• |
CHASSIS SPECIFICATIONS
Item |
Standard |
Limit |
|
|
|
Drive chain |
|
|
Model (manufacturer) |
50V4 (DAIDO) |
••• |
Link quantity |
118 |
••• |
Drive chain slack |
45 ~ 55 mm (1.77 ~ 2.17 in) |
••• |
Maximum 15-link section |
••• |
239.3 mm |
|
|
(9.42 in) |
|
|
|
ELECTRICAL SPECIFICATIONS
Item |
Standard |
Limit |
|
|
|
Starting circuit cut-off relay |
|
|
Model (manufacture) |
G8R-30Y-V3 (OMRON) |
••• |
Coil resistance |
162 ~ 198 Ω |
••• |
|
|
|
1
TIGHTENING TORQUES |
|
SPEC |
|
|
|
|
|
|
|
|
|
TIGHTENING TORQUES |
|
|
|
ENGINE TIGHTENING TORQUES |
|
|
|
Item |
Fastener |
Thread |
|
Q’ty |
|
Tightening torque |
Remarks |
|||||||||
|
|
|
|
|
|
|
|
|
|
|||||||
|
size |
|
|
Nm |
|
m•kg |
|
ft•lb |
||||||||
|
|
|
|
|
|
|
|
|
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Connecting rod caps |
Bolt |
|
M7 |
|
8 |
15 + 120° |
|
1.5 + 120° |
|
11+ 120° |
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
CHASSIS TIGHTENING TORQUES |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||||
Item |
|
|
Thread |
|
|
Tightening |
|
Remarks |
||||||||
|
|
size |
|
Nm |
|
m•kg |
ft•lb |
|
||||||||
|
|
|
|
|
|
|
|
|||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|||||
Pivot shaft and frame |
|
|
M18 |
|
125 |
|
12.5 |
90 |
|
|
|
|||||
Sidestand switch nut |
|
|
M5 |
|
4 |
|
|
0.4 |
|
2.9 |
|
|
|
|||
Shift rod and shift arm bolt |
|
|
M6 |
|
10 |
|
1.0 |
|
7.2 |
|
|
|
||||
Footrest bracket and footrest cover plate |
|
M5 |
|
7 |
|
|
0.7 |
|
5.1 |
|
|
|
||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2
|
|
CABLE ROUTING |
|
SPEC |
|
|
|
|
|
|
|
|
|
|
|
|
|
CABLE ROUTING |
Clamp the right and left handlebar switch leads |
||||
|
Left handlebar switch lead |
||||
|
Main switch and immobilizer lead |
and handlebars. Point the tip of the clamp down- |
|||
|
Clutch cable |
ward in front of the handlebars. |
|||
|
Throttle cables |
Clamp the horn lead and main switch and immo- |
|||
|
Right handlebar switch lead |
bilizer lead (upper side only) 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). |
|||
Route the horn lead by the headmost side. 
Pass the throttle cables, wire harness lead, clutch cable, main switch and immobilizer lead and left handlebar switch lead in order through the frame hole from the lower side of the vehicle.
3
CABLE ROUTING |
|
SPEC |
|
|
|
|
|
|
|
|
|
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).
Pass the throttle cables through the wire guide. Route the right handlebar switch lead by the outside of the wire guide.
4
Loading...