Yamaha FZ6 – Fazer 2007-2010 workshop service Manual

Workshop service and repair manual for all variants of the Yamaha Fazer/FZ6 Fi Fuel Injection non-carburettor models this full workshop manual covers every component, service and repair procedure in full Yamaha factory specification with clear concise step by step photographs and technical drawings for the FZ6 with torque setting values throughout where required for fasteners and reassembly, below is an exhaustive list of the items covered within this set. This is the most comprehensive service manual available as used by main and independent service centres the world over.

General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline Of Fi System
Fi System
Instrument Functions
Outline Of The Abs
Abs Component Functions
Abs Operation
Abs Self-diagnosis Function
Abs Warning Light And Operation
Important Information
Preparation For Removal And Disassembly
Replacement Parts
Gaskets, Oil Seals And O-rings
Lock Washers/Plates And Cotter Pins
Bearings And Oil Seals
Circlips
Checking The Connections
Special Tools…
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points And Lubricant Types
Engine
Chassis
Lubrication System Chart And Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cooling System Diagrams
Cable Routing

Periodic Checks And
Adjustments

Chassis
General Chassis

Front Wheel
Removing The Front Wheel
Checking The Front Wheel
[D-3] Maintenance Of The Front Wheel Sensor And
Sensor Rotor
Adjusting The Front Wheel Static Balance
Installing The Front Wheel

Rear Wheel
Removing The Rear Wheel
Checking The Rear Wheel
Checking The Rear Wheel Drive Hub
Checking And Replacing The Rear Wheel Sprocket
[D-4] Maintenance Of The Rear Wheel Sensor And
Sensor Rotor
Adjusting The Rear Wheel Static Balance
Installing The Rear Wheel

Front Brake
Checking The Front Brake Discs
Replacing The Front Brake Pads
Removing The Front Brake Calipers
Disassembling The Front Brake Calipers
Checking The Front Brake Calipers
Assembling The Front Brake Calipers
Installing The Front Brake Calipers
Removing The Front Brake Master Cylinder
Checking The Front Brake Master Cylinder
Assembling The Front Brake Master Cylinder
Installing The Front Brake Master Cylinder

Rear Brake
Checking The Rear Brake Disc
Replacing The Rear Brake Pads
Removing The Rear Brake Caliper
Disassembling The Rear Brake Caliper
Checking The Rear Brake Caliper
Assembling The Rear Brake Caliper
Installing The Rear Brake Caliper
Removing The Rear Brake Master Cylinder
Checking The Rear Brake Master Cylinder
Assembling The Rear Brake Master Cylinder
Installing The Rear Brake Master Cylinder
Abs (Anti-lock Brake System)
[D-5] Maintenance Of The Hydraulic Unit
Hydraulic Unit Operation Test
[D-6-5] Trial Run
Handlebar
Removing The Handlebars
Checking The Handlebar
Installing The Handlebar

Front Fork
Removing The Front Fork Legs
Disassembling The Front Fork Legs
Checking The Front Fork Legs
Assembling The Front Fork Legs
Installing The Front Fork Legs
Steering Head
Removing The Lower Bracket
Checking The Steering Head
Installing The Steering Head

Rear Shock Absorber Assembly
Handling The Rear Shock Absorber
Disposing Of A Rear Shock Absorber
Removing The Rear Shock Absorber Assembly
Checking The Rear Shock Absorber Assembly
Installing The Rear Shock Absorber Assembly

Swingarm
Removing The Swingarm
Checking The Swingarm
Installing The Swingarm

Chain Drive
Removing The Drive Chain
Checking The Drive Chain
Checking The Drive Sprocket
Checking The Rear Wheel Sprocket
Checking The Rear Wheel Drive Hub
Installing The Drive Chain

Engine
Engine Removal
Installing The Engine

Camshafts
Removing The Camshafts
Checking The Camshafts
Checking The Timing Chain And Camshaft Sprocket
Checking The Timing Chain Guides
Checking The Timing Chain Tensioner
Installing The Camshafts

Cylinder Head
Removing The Cylinder Head
Checking The Cylinder Head
Installing The Cylinder Head
Valves And Valve Springs
Removing The Valves
Checking The Valves And Valve Guides
Checking The Valve Seats
Checking The Valve Springs
Checking The Valve Lifters
Installing The Valves

Generator And Starter Clutch
Removing The Generator
Removing The Starter Clutch
Checking The Starter Clutch
Installing The Starter Clutch
Installing The Generator

Pickup Rotor
Removing The Pickup Rotor
Installing The Pickup Rotor

Electric Starter
Checking The Starter Motor
Assembling The Starter Motor
Installing The Starter Motor

Oil Pump
Removing The Oil Pan
Checking The Oil Pump
Checking The Relief Valve
Checking The Oil Delivery Pipes
Checking The Oil Strainer

Clutch
Removing The Clutch
Checking The Friction Plates
Checking The Clutch Plates
Checking The Clutch Springs
Checking The Clutch Housing
Checking The Clutch Boss
Checking The Pressure Plate
Checking The Pull Lever Shaft And Pull Rod
Installing The Clutch

Shift Shaft
Checking The Shift Shaft
Checking The Stopper Lever
Installing The Shift Shaft

Crankcase
Disassembling The Crankcase
Checking The Crankcase
Checking The Bearings And Oil Seals
Checking The Oil Pump Drive Chain
Assembling The Crankcase

Crankshaft
Removing The Connecting Rods And Pistons
Removing The Crankshaft Assembly
Checking The Cylinder And Piston
Checking The Piston Rings
Checking The Piston Pins
Checking The Big End Bearings
Installing The Connecting Rod And Piston
Checking The Crankshaft
Checking The Crankshaft Journal Bearings
Installing The Crankshaft

Transmission
Removing The Transmission
Checking The Shift Forks
Checking The Shift Drum Assembly
Checking The Transmission
Installing The Transmission

Cooling System
Checking The Radiator
Installing The Radiator
Checking The Oil Cooler
Installing The Oil Cooler
Checking The Thermostat
Installing The Thermostat Assembly
Disassembling The Water Pump
Checking The Water Pump
Assembling The Water Pump
Installing The Water

Fuel System
Fuel Tank
Removing The Fuel Tank
Removing The Fuel Pump
Checking The Fuel Pump Body
Checking The Fuel Pump Operation
Installing The Fuel Pump
Installing The Fuel Tank

Throttle Bodies
Checking The Injectors
Checking The Throttle Bodies
Checking The Fuel Pressure
Adjusting The Throttle Position Sensor
Air Induction System
Checking The Air Induction

Electrical System
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-off System Operation
Troubleshooting
Charging System
Circuit Diagram

Troubleshooting
Lighting System
Signaling System
Circuit Diagram
Cooling System
Circuit Diagram
Fuel Injection System

Ecu Self-diagnostic Function
Fail-safe Actions (Substitute Characteristics Operation Control)
Troubleshooting Method

Diagnostic Mode
Troubleshooting Details
Fuel Pump System
Circuit Diagram
Immobilizer System
Circuit Diagram
General Information
Part Replacement And Key Code Registration Requirements

Self-diagnosis Fault Code Indication
Abs (Anti-lock Brake System)
Abs Circuit Diagram
Abs Components Chart
Abs Connector Location Chart
Abs Ecu And Abs Motor Relay
[D-1] Maintenance Of The Abs Ecu
[D-2] Maintenance Of The Abs Motor Relay

Abs Troubleshooting Outline
Basic Instruction For Troubleshooting
Basic Process For Troubleshooting
[A] Abs Malfunction Check Using The Abs Warning
Light
[B] Detailed Abs Malfunction Check
[B-1] The Abs Warning Light Does Not Come On
[B-2] The Abs Warning Light Remains On
[B-3] The Abs Warning Light Flashes
[B-4] Malfunction Check By The Abs Self Diagnosis
(Past Malfunction)
[B-5] Malfunction Check By The Abs Self Diagnosis
(Present Malfunction)
[C] Determining The Cause And Location Of
The Malfunction
[C-1] Only The Abs Warning Light Does Not
Come On When The Main Switch Is Set To “On”
[C-2] Abs Warning Light And All Other Indicators
Do Not Come On
[C-3] Abs Warning Light Flashes
[C-4] Abs Warning Light Flashes Every 0.5 Second
[C-5] Diagnosis By The Malfunction Code
[D-6-4] Deleting The Malfunction Code
[D-6-6] Delete Function Test
[D-6] Final Check

Electrical Components
Checking The Switches
Checking The Bulbs And Bulb Sockets
Checking The LEDs
Checking The Fuses
Checking And Charging The Battery
Checking The Relays
Checking The Abs Motor Relay
Checking The Solenoid Valves And Motor
Checking The Turn Signal/Hazard Relay
Checking The Relay Unit (Diode)
Checking The Spark Plug Caps
Checking The Ignition Coils
Checking The Crankshaft Position Sensor
Checking The Lean Angle Sensor
Checking The Wheel Sensor
Checking The Starter Motor Operation
Checking The Stator Coil
Checking The Rectifier/Regulator
Checking The Horn
Checking The Engine Oil Level Gauge
Checking The Fuel Sender
Checking The Speed Sensor
Checking The Radiator Fan Motor
Checking The Coolant Temperature Sensor
Checking The Throttle Position Sensor
Checking The Fuel Pump
Checking The Air Induction System Solenoid
Checking The Intake Air Pressure Sensor
Checking The Intake Air Temperature Sensor

Troubleshooting
General Information
Starting Failures
Incorrect Engine Idling Speed
Poor Medium-and-high-speed Performance
Faulty Gear Shifting
Shift Pedal Does Not Move
Jumps Out Of Gear
Faulty Clutch
Overheating
Overcooling
Poor Braking Performance
Faulty Front Fork Legs
Unstable Handling
Faulty Lighting Or Signaling System
Troubleshooting At The Abs Warning Light

Full Colour Wiring Diagrams For All Variants