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Yamaha FZ6RC Manuals
Manuals and User Guides for Yamaha FZ6RC. We have
1
Yamaha FZ6RC manual available for free PDF download: Service Manual
Yamaha 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
General Tightening Torque Specifications
41
Engine Tightening Torques
41
Chassis Tightening Torques
45
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
Introduction
153
Checking the Front Brake Discs
153
Replacing the Front Brake Pads
154
Removing the Front Brake Calipers
155
Disassembling the Front Brake Calipers
155
Checking the Front Brake Calipers
155
Assembling the Front Brake Calipers
156
Installing the Front Brake Calipers
156
Removing the Front Brake Master Cylinder
157
Checking the Front Brake Master Cylinder
157
Assembling the Front Brake Master Cylinder
158
Installing the Front Brake Master Cylinder
158
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
Handling the Rear Shock Absorber
188
Disposing of a Rear Shock Absorber
188
Removing the Rear Shock Absorber Assembly
188
Checking the Rear Shock Absorber Assembly
188
Installing the Rear Shock Absorber Assembly
189
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
Checking the Air Induction System
311
Installing the Air Induction System
311
Canister (for California)
312
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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