2009-2015 Yamaha FZ6R Motorcycle Service Manual

Description

This Official 2009-2015 Yamaha FZ600R Motorcycle Factory Service Manual provides service, repair, and maintenance information for the:

2009 Yamaha FZ6R motorcycles
2010 Yamaha FZ6R motorcycles
2011 Yamaha FZ6R motorcycles
2012 Yamaha FZ6R motorcycles
2013 Yamaha FZ6R motorcycles
2014 Yamaha FZ6R motorcycles
2015 Yamaha FZ6R motorcycles

Table of Contents

General Information
Specifications
Periodic Checks And Adjustments
Chassis
Engine
Cooling System
Fuel System
Electrical System
Troubleshooting

Index of Topics

Chapter 1: General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline Of Fi System
Fi System
Instrument Functions
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
Removing The Quick Fastener
Installing The Quick Fastener
Special Tools

Chapter 2:
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

Chapter 3: Periodic Checks And Adjustments
Periodic Maintenance
Introduction
Periodic Maintenance Chart For The Emission Control
System
General Maintenance And Lubrication Chart
Checking The Fuel Line
Checking The Spark Plugs
Adjusting The Valve Clearance
Adjusting The Engine Idling Speed
Synchronizing The Throttle Bodies
Checking The Canister (for California Only)
Checking The Air Induction System
Checking The Crankcase Breather Hose
Replacing The Air Filter Element
Adjusting The Clutch Cable Free Play
Checking The Brake Fluid Level
Adjusting The Front Disc Brake
Checking The Front Brake Pads
Adjusting The Rear Disc Brake
Checking The Rear Brake Pads
Bleeding The Hydraulic Brake System
Checking The Front Brake Hoses
Checking The Rear Brake Hose
Checking The Wheels
Checking The Tires
Checking The Wheel Bearing
Checking The Swingarm
Adjusting The Drive Chain Slack
Lubricating The Drive Chain
Checking And Adjusting The Steering Head
Adjusting The Handlebar Position
Lubricating The Levers
Lubricating The Pedal
Adjusting The Shift Pedal
Lubricating The Sidestand
Checking The Sidestand Switch
Checking The Front Fork
Lubricating The Rear Suspension
Adjusting The Rear Shock Absorber Assembly
Checking The Engine Oil Level
Changing The Engine Oil
Measuring The Engine Oil Pressure
Checking The Coolant Level
Checking The Cooling System
Changing The Coolant
Checking The Front And Rear Brake Switch
Adjusting The Rear Brake Light Switch
Checking And Lubricating The Cables
Adjusting The Throttle Cable Free Play
Checking And Charging The Battery
Checking The Fuses
Adjusting The Headlight Beams
Replacing The Headlight Bulbs

Chapter 4: Chassis
General Chassis
Front Wheel
Removing The Front Wheel
Checking The Front Wheel
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
Adjusting The Rear Wheel Static Balance
Installing The Rear Wheel
Front Brake
Introduction
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
Introduction
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
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
Chapter 5: Engine
Engine Removal
Installing The Engine
Installing The Drive Chain
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
Measuring The Compression Pressure
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
Checking The Oil Nozzles
Checking The Oil Pump Drive Chain
Assembling The Oil Pump
Installing The Oil Pump
Installing The Oil Strainer
Installing The Oil Pan
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 Clutch Push Rods
Installing The Clutch
Shift Shaft
Removing The 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
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
Assembling The Main Axle And Drive Axle
Installing The Transmission

Chapter 6:  Cooling System
Radiator
Checking The Radiator
Installing The Radiator
Oil Cooler
Checking The Oil Cooler
Installing The Oil Cooler
Thermostat
Checking The Thermostat
Installing The Thermostat Assembly
Water Pump
Disassembling The Water Pump
Checking The Water Pump
Assembling The Water Pump
Installing The Water Pump

Chapter 7: 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 Throttle Body Joints
Checking The Fuel Injectors
Installing The Injectors
Checking The Injector Pressure
Checking And Cleaning The Throttle Bodies
Checking The Fuel Pressure
Adjusting The Throttle Position Sensor
Air Induction System
Checking The Air Induction System
Installing The Air Induction System
Canister (for California)

Chapter 8: Electrical System
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-off System Operation

Chapter 9: Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Signaling System
Circuit Diagram
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Injection System
Circuit Diagram
Ecu Self-diagnostic Function
Fail-safe Actions (substitute Characteristics
Operation Control)
Trouble Shooting Chart
Diagnostic Mode
Troubleshooting Details
Other Diagnostic Monitoring Codes
Fuel Pump System
Circuit Diagram
Troubleshooting
Electrical Components
Checking The Switches
Checking The Bulbs And Bulb Sockets
Checking The Fuses
Checking And Charging The Battery
Checking The Relays
Checking The Turn Signal Relay
Checking The Relay Unit (diode)
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