Checking The Front And Rear Brake Calipers

Recommended brake component replacement schedule Every two years and whenever the brake is disassembled brake caliper pistons Rust scratches wear Replace the brake caliper pistons. brake caliper cylinders (2) Scratches wear Replace the brake caliper assembly. brake caliper body (3) Cracks damage Replace the brake caliper assembly. brake fluid delivery passages (brake caliper body) Obstruction Blow out with compressed air.

Replacing The Front Brake Pads

The following procedure applies to both brake calipers. When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. side reflector bracket (left side only) (2) brake hose holder (3) brake caliper (4) brake pad shims (onto the brake pads) 3. Measure brake pad wear limit Out of specification pads as a set. Brake pad wear limit 0.8 mm (0.03 in) Brake pad wear limit 0.8 mm (0.03 in) brake pad shims (onto the brake pads) Always install new brake...

Cable Routing

Xvs 650 Neutral Switch

Left handlebar switch lead Main switch lead Clutch cable Throttle cables Right handlebar switch lead A Clamp the right and left handlebar switch leads and handlebars. Point the tip of the clamp downward in front of the handlebars. 0 Clamp the horn lead and main switch lead 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 . O Route the horn lead by the headmost side. 0 Pass the throttle cables, wire...

Lower ring nut final tightening torque 18 Nm 18 mkg 13 fWb

Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD in chapter 4. f. Install the upper ring nut . g. Finger tighten the upper ring nut , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.

Measuring The Compression Pressure

The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. Out of specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE. 2. Start the engine, warm it up for several minutes, and then turn it off. rider seat Refer to SEAT. front cowling inner panel letf and right Refer to COWLINGS. Refer to AIR FILTER CASE. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Refer to BATTERY BOX AND BATTERY BOX BRACKET.

Note

Fz6 Steering Nut Wrench

Place the motorcycle on a suitable stand so that the front wheel is elevated. Grasp the bottom of the front fork legs and gently rock the front fork. Binding looseness Adjust the steering head. Refer to HANDLEBAR and STEERING HEAD in chapter 4. a. Remove the lock washer the upper ring nut 2, and the rubber washer 3. b. Loosen the lower ring nut and then tighten it to specification with a steering nut wrench

Adjusting The Rear Brake

Check brake pedal position distance from the top of the rider footrest to the top of the brake pedal Out of specification Adjust. Brake pedal position below the top of the rider footrest 25.8 mm 1.02 in b. Turn the adjusting bolt in direction or until the specified brake pedal position is obtained.

General Tightening Torque Specifications

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. A...

Checking The Engine Oil Level

How Check Oil Level Motorcycle

Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure the motorcycle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. The engine oil level should be between the minimum level mark and maximum level mark . Below the minimum level mark Add the recommended engine oil to the proper level. AT 5 C 40 F or higher A Yamalube 4 20W40 or SAE 20W40 type SE motor oil AT 15 C 60 F or lower B Yamalube 4 10W30 or SAE 10W30 type SE...

Engine Specifications

Standard compression pressure at sea level Liquid-cooled, 4-stroke, DOHC 600 cm3 36.61 cu.in Forward-inclined parallel 4-cylinder 65.5 x 44.5 mm 2.58 x 1.75 in 12.2 1 1,250 - 1,350 r min 29 kPa 218 mmHg, 8.6 inHg 1,550 kPa 15.50 kg cm2,15.50 bar, 220.46 psi at 400 r min Recommended fuel Fuel tank capacity Total including reserve Reserve only 19.4 L 4.25 lmp gal, 5.1 US gal 3.6 L 0.79 lmp gal, 0.9 US gal Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge...

Yamaha Fz8 Carbon

Make sure all of the cables and wires are properly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie loosely around the end of the handlebar as shown. c. Hook a spring gauge 2 onto the plastic locking tie. d. Hold the spring gauge at a 90o angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run.

Removing The Fuel Tank

Extract the fuel in the fuel tank through the fuel tank cap with a pump. Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remaining in it. Before removing the hoses, place a few rags in the area under where it will be removed. Do not set the fuel tank down so that the installation surface of the fuel pump is directly under the tank. Be sure to lean the fuel tank in an upright position. REMOVING THE FUEL PUMP 1. Remove...

Ym01253

These tools are used to remove or install the valve assemblies. Middle driven shaft bearing driver 90890-04058 YM-4058 Mechanical seal installer 90890-04078 YM-33221 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal.

Outline Of Fi System

Fuel Injection Yamaha Fz6

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume...

Adjusting The Valve Clearance Synchronizing The Throttle Bodies

Vacuum Gauge 90890 03094

For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE Place the motorcycle on a suitable stand. front cowling inner panel left and right Refer to COWLINGS Refer to AIR FILTER CASE. vacuum gauge onto the synchronizing hose 2 Refer to AIR FILTER CASE....

Checking The Exhaust System

Yamaha Pipe Joint

The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove radiator Refer to RADIATOR in chapter 6. 20 Nm 2.0 m kg, 15 fWb Catalyst joint bolt 20 Nm 2.0 m kg, 15 fWb Muffler joint bolt 7 Muffler and muffler stay 8 20 Nm 2.0 m kg, 15 fWb Exhaust pipe and exhaust pipe stay 9 20 Nm 2.0 m kg, 15 fWb Catalyst pipe and catalyst pipe stay 10 4. Install radiator Refer to RADIATOR in chapter 6.

Eas00897

Yamaha Fz6 Air Intake

The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake temperature sensor and coolant temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance...