Yamaha FZ6-ST Manuel

FZ6-ST

5VX-28197-11

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-18-43

FZ6-STC

FZ6-ST/ FZ6-STC

SUPPLEMENTARY

SERVICE MANUAL

Corporation, U.S.A.

First edition, August 2004

or unauthorized use without the written

permission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/ N LIT-11616-18-43

EAS00010

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)

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers 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 ve-

hicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. 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.

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 deal-

ers and will appear in future editions of this manual where applicable.

TE:

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS00040

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 dam-

age to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ENGINE

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . 18

REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . 19

CHECKING THE BIG END BEARINGS. . . . . . . . . . . . . . . . . . . . . 20

INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . 24

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Model code 5VX8 (USA except for CAL)

5VX9 (CAL)

•••

Item Standard Limit

Piston

Diameter D 65.475 ~ 65.490 mm (2.5778 ~ 2.5783

in)

•••

Height H 5 mm (0.20 in) •••

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)

Item Standard Limit

Ignition system

T.C.I. unit model (manufacturer) F8T812 (MITSUBISHI) (USA) •••

F8T813 (MITSUBISHI) (CAL) •••

Starting circuit cut-off relay

Model (manufacture) G8R-30Y-V3 (OMRON) •••

Coil resistance 162 ~ 198 Ω•••

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/

CHASSIS SPECIFICATIONS/ELECTRICAL SPECIFICATIONS

SPEC

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

Item Fastener Thread

size Q’ty Tightening torque Remarks

Nm m•kg ft•lb

Connecting rod caps Bolt M7 8 15+120°

1.5+120°

11+120°

Item Thread

size

Tightening torque Remarks

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

TIGHTENING TORQUES

SPEC

CABLE ROUTING

Left handlebar switch lead

Main switch lead

Clutch cable

Throttle cables

Right handlebar switch lead

Clamp the right and left handlebar switch leads

and handlebars. Point the tip of the clamp

downward in front of the handlebars.

Clamp the horn lead and main switch 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 inner side of the vehicle.

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 out-

side of the wire guide.

CABLE ROUTING

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