FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FZ6-N(S) 2004. 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-N(S) 2004
SUPPLEMENTARY
SERVICE MANUAL
E2003 by Yamaha Motor Co., Ltd.
First Edition, December 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTE:
WARNING
CAUTION:
EAS00002
NOTICE
This manual was produced by the Y amaha Motor Company , Ltd. primarily for use by Y amaha 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.
Y amaha 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.
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!
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 damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
12
4
8
3
5
6
7
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.
1
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”.
2
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.
3
Sub-section titles appear in smaller print than the section title.
4
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8
Jobs requiring more information (such as special tools and technical data) are described sequentially.
22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO
SPEC
ENG
FI ELEC
COOL
CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
1
to 9 indicate the subject of each
chapter.
1
General information
2
Specifications
3
Periodic checks and adjustments
4
Chassis
5
Engine
6
Cooling system
7
Fuel injection system
8
Electrical system
9
Troubleshooting
Symbols 10 to 17 indicate the following.
10
Serviceable with engine mounted
11
Filling fluid
12
Lubricant
13
Special tool
14
Tightening torque
15
Wear limit, clearance
16
Engine speed
17
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
Engine oil
19
Gear oil
20
Molybdenum-disulfide oil
21
Wheel-bearing grease
22
Lithium-soap-based grease
23
Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following.
24
Apply locking agent (LOCTITE)
25
Replace the part
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM DIAGRAMS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 18. . . . .
COWLINGS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 21. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 22. . . . . . . . . . . . . . . . . . . . . .
ENGINE
CONNECTING RODS AND PISTONS 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS 24. . . . . . . .
CHECKING THE BIG END BEARINGS (for EUR) 25. . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS (for OCE) 28. . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON
(for EUR) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON
(for OCE) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM
RADIATOR 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM
CHECKING THE SWITCHES 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM 54. . . . . . . . . . . . . . . . . . . . . . . .
SIGNALING SYSTEM 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNALING SYSTEM 59. . . . . . . . . . . . . . . . . . . . . .
FZ6-N(S) 2004 WIRING DIAGRAM
–1–
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 1B31 (EUR), 1B32 (AUS) SSS
Dimensions
Overall width
Overall height
755 mm (29.7 in)
1,085 mm (42.7 in)
SSS
SSS
Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
201 kg (443 lb)
196 kg (432 lb)
SSS
SSS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Licence light
Meter light
12V 60 W/55 W 1
12 V 5 W 1
12 V 5 W/21 W 1
12 V 10 W 4
12 V 5 W 1
EL
SSS
SSS
SSS
SSS
SSS
SSS
Starting circuit cut-off relay
Model (manufacture)
G8R-30Y-V3 (OMRON) SSS
–2–
TIGHTENING TORQUES
SPEC
See
NOTE 1
NOTE 1:
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Thread
’
Tightening torque
Item
Fastener
size
Qty
Nm mSkg ftSlb
Remarks
Connecting rod caps (for EUR) Nut M7 8 15 + 150_ 1.5 + 150_ 11 + 150_
Connecting rod caps (for OCE) Bolt M7 8 15 + 120_
1.5 + 120_
11 + 120_
CHASSIS TIGHTENING TORQUES
Thread
Tightening
Item
size
Nm mSkg ftSlb
Remarks
Radiator cover and radiator M6 8 0.8 7.2
Horn bracket and frame M6 7 0.7 5.1
Front frame and rear frame (upper) M10 41 4.1 30
Front frame and rear frame (lower) M10 41 4.1 30
T o repair , make sure to apply the liquid fixing agent to the bolt without fixing agent (90149 – 10001) and
use it.
–3–
COOLING SYSTEM DIAGRAMS
SPEC
1 Radiator
2 Oil cooler
COOLING SYSTEM DIAGRAMS
–4–
COOLING SYSTEM DIAGRAMS
SPEC
1 Water pump
2 Oil cooler
3 Radiator
–5–
COOLING SYSTEM DIAGRAMS
SPEC
1 Radiator
2 Thermostat
–6–
CABLE ROUTING
SPEC
A Clamp the right handlebar switch lead and handle-
bar. Point the tip of the clamp downward in front of
the handlebar.
B Route the branched lead behind the main switch
and immobilizer lead.
C Pass the main switch and immobilizer lead, left han-
dlebar switch lead and clutch cable in order through
the frame hole from the inner side of the vehicle.
D To the headlight and speedometer.
E Pass the right handlebar switch lead and throttle
cable, clutch cable through the meter cover hole.
F Install the clamp in the direction as shown in the il-
lustration.
1 Left handlebar switch lead
2 Main switch and immobilizer lead
3 Clutch cable
4 Throttle cables
5 Right handlebar switch lead
6 Handlebar
CABLE ROUTING
–7–
CABLE ROUTING
SPEC
1 Right handlebar switch lead
2 Throttle cables
3 Horn lead
4 Wire harness
5 Rear brake light switch lead
6 Neutral switch lead
7 Fuel tank breather hose
8 Crankshaft position sensor lead
9 Meter lead and left handlebar lead
A Pass the right handlebar switch lead through the
hole on the right side of the frame.
Route it under the inside of the throttle cable and
wire harness.
B Pass the throttle cable through the hole located on
the right side of the frame.
Route the throttle cable above the wire harness.
C Route the horn lead inner side of the coolant reser-
voir tank hose.
D Clamp the horn lead and radiator hose (the external
side only). Horn lead should be positioned inside of
the hose. Install the clamp in the direction pointing
its detent pawl to the downside.
E Route the right handlebar switch lead under the
bracket 2.
F Route the coolant reservoir tank hose under the
cover 2. Route the radiator hose (outside) inner
side.
G Route the radiator hoses (2 pieces) under the cover
2.
H Route the crank shaft position sensor lead inner
side of the radiator hose.
–8–
N Install the right handlebar switch lead coupler
through the hole of the bracket 2 from the downside.
O Route the starter motor lead by the inner side of the
air cut-off valve hose.
P Pass the ignition coil leads #1 and #4 through inner
side of the air cut-off valve hose, and then between
the frame and bracket 2.
Q To the sub-wire harness.
I Pull down the mark-painted sections of the fuel tank
breather hose, fuel tank drain hose and coolant reservoir tank breather hose to be lower than the clamp
position of the muffler stay . Any order to take out the
fuel tank breather hose and fuel tank drain hose can
be accepted.
J Pass the fuel tank breather hose, fuel tank drain
hose, coolant reservoir tank breather hose and
brake right switch lead through the guide of the stay
assembly 2.
K Clamp the tail brake light switch lead together with
the brake fluid reservoir hose.
L Pass the neutral switch lead between the engine
and coolant reservoir tank bracket.
M To the starter motor.
CABLE ROUTING
SPEC
–9–
CABLE ROUTING
SPEC
16 Rear turn signal light lead (right)
17 Rear turn signal light lead (left)
18 Speed sensor lead
19 Side stand switch lead
20 Oil level switch lead
21 A.C. magneto lead
22 Throttle cable (return side)
23 Throttle cable (pull side)
24 Radiator fan motor lead
25 Oil level gauge lead
26 Sidestand switch lead
27 A. C. magneto lead
28 Speed sensor lead
1 Left handlebar switch lead
2 Main switch and immobilizer lead
3 Meter lead and left handlebar switch lead
4 Clutch cable
5 Battery negative lead coupler
6 Starter relay lead
7 Battery negative lead
8 Fuel tank drain hose
9 Rectifier/regulator
10 Turn signal relay
11 Radiator fan motor relay
12 Dimmer relay
13 Starting circuit cut-off relay
14 Clamp
15 License plate light lead
–10–
A To the headlight bulb.
B Route it inside (in the width direction of the vehicle)
of the left handlebar switch lead.
C To the auxiliary light socket.
D To the meter.
E Line up the left handlebar switch lead coupler and
fan motor lead coupler behind the head pipe.
F To the immobilizer.
G To the main switch.
H Place three couplers on the flange of the cover.
I To the fuel pump.
J Clamp four wire leads. There should be no exces-
sive slack on the wire leads.
K To the engine.
L To the fuel tank.
M Either installation position can be accepted, but
make sure that the leads are not crossed.
N Clamp the rear turn signal lead and license plate
light lead to the frame. Hook the clamp to the bracket. Pull out the lead sufficiently to the frame side and
route it along with the side of the back stay . Cut the
tip of the clamp to be between 1 and 5 mm (0.04 and
0.20 in) upward.
O Clamp the rear turn signal lead and license plate
light lead to the frame. Cut the tip of the clamp to be
between 1 and 5 mm (0.04 and 0.20 in).
P Gap between the lead and muffler should be 10 mm
(0.39 in) or more.
Q Coupler should not run on the relay assembly.
R To the tail/brake light.
S To the license plate light.
T To the rear turn signal light. (right)
U To the rear turn signal light. (left)
CABLE ROUTING
SPEC
–11–
V Pass the fuel tank drain hose through the clamp lo-
cated under the coolant reservoir tank.
W Route it behind the starter motor lead.
X Point the bend-R section of the throttle cable (pull
side) to the inner side horizontally . It is also possible
to visually check the bend-R section.
Y Point the tip of the clamp to the inner side of the ve-
hicle body.
Z Make sure to pass the neutral switch lead through
the hole of the flap.
AA Clamp the seat lock wire to the frame as shown in
the illustration. Secure the clamp to the weld of
the cross member with the frame. Position the
binding section in front of the vehicle body and cut
the tip to be between 1 and 5 mm (0.04 and 0.20
in).
CABLE ROUTING
SPEC
–12–
14 Seat lock cable
15 Rectifier/regulator
16 E.C.U
17 Fuel tank drain hose
18 Cover
19 Starter relay lead
20 Battery negative lead
21 Battery negative lead coupler
22 Handlebar switch lead
23 Clutch cable
24 Cover 2
25 Spark plug lead
26 Air cut-off valve hose
1 Right handlebar switch lead
2 Throttle cables
3 Battery positive lead
4 Coolant reservoir tank hose
5 Battery cover
6 Connecter cover
7 Fuel tank breather hose
8 Brake fluid reservoir hose
9 Lean angle cut-off switch
10 Fuse box
11 Rear turn signal light lead (right)
12 License plate light lead
13 Rear turn signal light lead (left)
CABLE ROUTING
SPEC
–13–
CABLE ROUTING
SPEC
A To the meter.
B Either right or left side arrangement for the left han-
dlebar switch lead coupler and radiator fan motor
coupler can be accepted.
C Point the L-shape terminal to the front side of the ve-
hicle.
D Hook the starter motor lead to the alternate pawls
on the battery cover.
E To the crankshaft position sensor.
F Route the crank shaft position sensor lead above
the starter motor leads.
G Clamp the starter motor lead and crank shaft posi-
tion sensor lead. Point the projected part of the tip to
the inner side of the vehicle.
H Pass the radiator hose, coolant reservoir hose, wire
harness and starter motor lead in order through the
lower side of the vehicle.
I Set the 4-pin coupler in the connector cover after
wiring it.
J To the sidestand switch.
K To the speed sensor.
L To the A.C. magneto.
M To the oil level gauge.
N To the rear brake/light switch.
O To the neutral switch.
P Push the wire harness in the groove of the mud
guard.
Q Point the opening section of the clamp upward.
R To the rear turn signal. (right)
S To the rear turn signal. (left)
T To the license plate light.
U To the tail/brake light.
V Insert the enwinding clamp of the wire harness into
the hole of the rear frame.
–14–
AG Pass the spark plug leads #1 and #4 through the
slit of the cover 2.
AH Pass the spark plug lead #2 through the inner
hole of the cover 2.
AI Pass the spark plug lead #3 through the outer
hole of the cover 2.
AJ Route the spark plug lead #4 behind the air cut-off
valve hose.
AK Point the spark plug caps of #1 to #4 to the direc-
tion as shown in the illustration.
AL Route the spark plug lead #3 under the air cut-off
valve hose.
AM Route the spark plug lead #2 behind the air cut-off
valve hose.
AN Route the spark plug lead #4 by the front side of
the spark plug leads #2 and #3.
CABLE ROUTING
SPEC
W Attach the rectifier regulator lead to the clamp of the
rectifier bracket.
X To the engine ground.
Y To the fuel injection.
Z To the fuel pump.
AA Route the clutch cable under the fuel injection
lead.
AB Pass the clutch cables through the clamp, and
then install the clamp to the cover. Position of the
clamp is forward of the cable stopper.
AC To the main switch.
AD To the immobilizer.
AE Route the starter relay lead outside of the main
switch and immobilizer lead.
AF Press the battery negative lead into the space be-
tween the ribs of the frame.
–15–
CABLE ROUTING
SPEC
AO Route the spark plug leads #2 and #3 behind the
air cut-off valve hose.
–16–
CABLE ROUTING
SPEC
a Fuel piping connector attachment directions. (fuel
pump side)
1. It is inserted until it makes a click sound the connector, and it checks that a connector does not fall out. It
takes care that a foreign substance does not enter
into a seal portion. (Working groves should not be
used at the time of work.)
E It prevents that this portion falls out.
2. The clamp is attached from the bottom after the
work of “1”.
It checks being completely equipped with , and
section.
A B
C
1 Fuel pump assembly
2 Fuel tank breather hose
3 Fuel tank drain hose
4 Fuel hose
5 Clip
6 Clamp
A Air opening.
B Install the O-ring with its lip pointed upward.
C Fuel tank breather hose has a white point mark.
D Point the knob of clip front side
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