Yamaha FZ6-SS User manual

CONCERNING CRATE DAMAGE:
WARNING
CAUTION:
EAA00002
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha motor-
cycle prior to delivery to the customer. Since some external parts of the motorcycle have been removed at
the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should
be noted that the assembled motorcycle should be thoroughly cleaned, inspected, and adjusted prior to
delivery to the customer.
EAA00005
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will
appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the motorcycle and/or rider.
Follow the instructions in the Dealer Warranty Handbook, Procedure Section.
Particularly important information is distinguished in this manual by the following notations.
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 damage to
the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
EAA00001
FZ6-SS
FZ6-SSC
ASSEMBLY MANUAL
E2003 by Yamaha Motor Corporation,
U.S.A. First Edition, November 2003
All rights reserved.
Any reproduction 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-11666-17-50

(1) (2)
(3) (4)
(5) (6)
(7)
(8)
EAA00008
SYMBOLS USED IN THE
ASSEMBLY MANUAL
In order to simplify descriptions in this as-
sembly manual, the following symbols are
used:
(1): Coat with lithium-soap-based grease.
(2): Tighten to 10 Nm.
(10 Nm = 1.0 mSkg, 7.2 ftSlb)
(3): Towards the front of the motorcycle
(4): Clearance required
(5): Install so that the arrow mark faces up-
ward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of op-
erations.)
B: Part name
C: Quantity of parts per motorcycle
D: Place where parts are held
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame
and/ or contained in the Styro-
foam tray (upper or lower)
*: Temporarily installed or secured
E: Size or material of parts
d / D: Diameter of part
ȏ: Length of part
e.g., 5 = 5 mm (0.2 in)

(1) (2)
(3) (4)
(5) (5)
EAA00040
PREPARATION
To assemble the motorcycle correctly, sup-
plies (e.g. oils, greases, and shop rags) and
sufficient working space are required.
Workshop
The workshop where the motorcycle is as-
sembled should be clean, spacious, and
have a level floor.
Self-protection
Protect your eyes with suitable safety
glasses or goggles when using compressed
air, when grinding or when doing any opera-
tion which may cause particles to fly off.
Protect hands and feet by wearing safety
gloves or shoes.
EAA00050
SYMBOLS USED ON
CRATE CARTON
(1) Contents of the transport package are
fragile, therefore the package must be
handled with care.
(2) Indicates correct upright position of the
transport package.
(3) Transport package must be kept away
from rain.
(4) Insertion of the forklift arms from this
side can cause damage.
(5) Lift arm inserting position.
If the forklift arms cannot be inserted under
the transport package in alignment with the
two yellow labels, adjust the arms so that
they are positioned evenly in relation to
these marks while taking care not to dam-
age the package contents.

–1–
NOTE:
NOTE:
NOTE:
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UNPACKING
1. Remove the frame cover (1).
To remove the frame cover, cut the vinyl
bands around the cover using a cutter or
scissors.
2. Remove the carton boxes (2) and (3).
Remove the front wheel (4).
3. Remove the packing frame bolts (5) and
upper handlebar holders (6).
4. Remove the bolts (7).
5. Remove the packing frames (8). (Lift up
and then move to the side.)
Remove the bolts while holding the frame.
Before starting the assembly, check for
damaged or missing parts. Check both the
parts contained in the carton boxes and on
the motorcycle for damage, scratches, and
other defects.

–2–
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PARTS LOCATION
(1) Carton box 1.
(2) Carton box 2.
(3) Front tire.

–3–
7EAA00080
(1) Carton box 1
1. Screws and special nuts (windshield)
2. Upper handlebar holders
3. Rivets
4. Screws
5. Bolts
6. Plugs
7. Nuts
8. Screws
9. Washers
10.Screws
11. Nuts
12.Bands
13.Inner panels
14.Windshield trims
15.Rear view mirrors
16.Windshield
17.Front fender
18.Owner’s manual
(2) Carton box 2
1. Handlebar
2. Gnip end (right)
3. Bolts (upper handlebar holders)
4. Front brake master cylinder bracket
5. Bolts (front brake master cylinder brack-
et)
6. Screws (left handlebar switch)
7. Collars
(3) Front tire

–4–
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SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

–5–
1 Handlebar holders 2 V
2 Hexagon head bolt 4 V d = 8 (0.31), ȏ= 30 (1.18)
3 Plug 4 V
4 Handlebar 1 C
1 Screw 1 d = 5 (0.20), ȏ= 45 (1.77)
2 Screw 1 d = 5 (0.20), ȏ= 20 (0.79)
3 Grip end 1 V
1 Front tire 1 S
2 Collar 2 V
3 Axle 1
4 Hexagon head bolt 1
CAUTION:
WARNING
WARNING
NOTE:
CAUTION:
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1. HANDLEBAR
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
C: Align the punch mark on the
handlebar with the top of the
lower handlebar holders.
D: Tighten the bolts to specifica-
tion.
Bolt:
23 Nm (2.3 mSkg, 17 ftSlb)
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2. THROTTLE GRIP
A: Align the projection on the han-
dlebar switch with the hole in
the handlebar.
B: Tighten the bolt to specifica-
tion.
Bolt:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)
C: Check the throttle grip for
smooth action.
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to “CABLE ROUTING”.
D: Tighten the grip end.
Grip end:
26 Nm (2.6 mSkg, 19 ftSlb)
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EAA00108
3. FRONT WHEEL
A: Clean the brake discs.
B: Clean the front wheel axle.
C: Clean the collar.
D:
Take care not to get grease on
the brake discs or inner surface
of the brake pads. If you do so,
clean using a rag dampened
with a solvent. Foreign material
on the braking surface may
cause impaired braking action.
E: Lift the front wheel and install
the front wheel axle. Be sure
the arrow on the tire is pointed
in the rotating direction.
Do not depress the brake lever
when the calipers are off the brake
discs.
F: Tighten the wheel axle to speci-
fication.
Wheel axle:
72 Nm (7.2 mSkg, 52 ftSlb)
Before tightening the wheel axle
pinch bolt, stroke the front forks
several times to make sure of
proper fork operation.
G: Tighten the wheel axle pinch
bolt to specification.
Wheel axle pinch bolt:
23 Nm (2.3 mSkg, 17 ftSlb)

–6–
1 Front fender 1 S
2 Bolt 2 V d = 6 (0.24), ȏ= 22 (0.87)
3 Bolt 2 V d = 6 (0.24), ȏ= 25 (0.98)
4 Collar 2 V d = 6 (0.24)
1 Bolt 1 V d = 5 (0.20), ȏ= 45 (1.77)
2 Bolt 1 V d = 5 (0.20), ȏ= 30 (1.18)
1 Bracket 1 V
2 Hexagon head bolt 2 V d = 6 (0.24), ȏ= 20 (0.79)
3 Master cylinder 1
4Brake light switch connector 2
CAUTION:
WARNING
WARNING
WARNING
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EAA00110
4. FRONT FENDER
A: Tighten the front fender bolts to
specification.
Bolt:
6 Nm (0.6 mSkg, 4.3 ftSlb)
B:
Make sure the brake hose is
routed outside of the front fend-
er.
Be careful not to scratch the
front fender with the front fork
outer tube.
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to “CABLE ROUTING”.
C: Clamp the front brake hose.
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5. FRONT BRAKE MASTER
CYLINDER
A: Lubricate the pivoting parts of
the brake lever.
Recommended lubricants:
Yamaha cable lube or motor
oil
B: Make sure that the “UP” mark
with the bracket is pointed up-
ward.
C: Align the punch mark on the
handlebar with the gap of the
master cylinder bracket.
D: Tighten the bolts in stages and
maintain an equal gap on each
side of the bracket to specifica-
tion.
Bolt:
10 Nm (1.0 mSkg, 7.2 ftSlb)
E: Connect the front brake light
switch connector.
F: Check the brake lever for
smooth action.
Proper cable and hose routing
is essential to assure safe mo-
torcycle operation.
Refer to “CABLE ROUTING”.
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EAA00123
6. HANDLEBAR SWITCH
A: Align the projection on the left
handlebar switch with the hole
in the handlebar.
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to “CABLE ROUTING”.
B: Tighten the bolts to specifica-
tion.
Bolt:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)