Yamaha FZ6-ST Manual

FZ6-ST
5VX-28197-11
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-18-43
FZ6-STC

FZ6-ST/ FZ6-STC
SUPPLEMENTARY
SERVICE MANUAL
© 2004 by Yamaha Motor
Corporation, U.S.A.
First edition, August 2004
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-11616-18-43
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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FZ6-ST/FZ6-STC. For complete service information procedures it is necessary to use this Supple-
mentary Service Manual together with the following manual.
FZ6-SS/FZ6-SSC SERVICE MANUAL: LIT-11616-17-50 (5VX-28197-10)

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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
N
O
TE:
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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 dam-
age to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described
sequentially.

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SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols to indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
Symbols to indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols to in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
Symbols to in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE®)
Replace the part

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 2
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 2
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . 19
CHECKING THE BIG END BEARINGS. . . . . . . . . . . . . . . . . . . . . 20
INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . 24

SPEC
1
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Model code 5VX8 (USA except for CAL)
5VX9 (CAL)
•••
•••
Item Standard Limit
Piston
Diameter D 65.475 ~ 65.490 mm (2.5778 ~ 2.5783
in)
•••
Height H 5 mm (0.20 in) •••
Item Standard Limit
Drive chain
Model (manufacturer) 50V4 (DAIDO) •••
Link quantity 118 •••
Drive chain slack 45 ~ 55 mm (1.77 ~ 2.17 in) •••
Maximum 15-link section ••• 239.3 mm
(9.42 in)
Item Standard Limit
Ignition system
T.C.I. unit model (manufacturer) F8T812 (MITSUBISHI) (USA) •••
F8T813 (MITSUBISHI) (CAL) •••
Starting circuit cut-off relay
Model (manufacture) G8R-30Y-V3 (OMRON) •••
Coil resistance 162 ~ 198 Ω•••
GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/
CHASSIS SPECIFICATIONS/ELECTRICAL SPECIFICATIONS

SPEC
2
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Item Fastener Thread
size Q’ty Tightening torque Remarks
Nm m•kg ft•lb
Connecting rod caps Bolt M7 8 15+120°
1.5+120° 11+120°
Item Thread
size
Tightening torque Remarks
Nm m•kg ft•lb
Pivot shaft and frame M18 125 12.5 90
Sidestand switch nut M5 4 0.4 2.9
Shift rod and shift arm bolt M6 10 1.0 7.2
Footrest bracket and footrest cover plate M5 7 0.7 5.1
TIGHTENING TORQUES

SPEC
3
CABLE ROUTING
Left handlebar switch lead
Main switch lead
Clutch cable
Throttle cables
Right handlebar switch lead
Clamp the right and left handlebar switch leads
and handlebars. Point the tip of the clamp
downward in front of the handlebars.
Clamp the horn lead and main switch lead
(upper side only) 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).
Route the horn lead by the headmost side.
Pass the throttle cables, wire harness lead,
clutch cable, main switch and immobilizer lead
and left handlebar switch lead in order through
the frame hole from the inner side of the vehicle.
CABLE ROUTING

SPEC
4
Point the lead, which comes from the terminal,
to the front side of the vehicle body. There
should be no slack of leads between the band
and terminals.
Clamp the brake hose 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).
Pass the throttle cables through the wire guide.
Route the right handlebar switch lead by the out-
side of the wire guide.
CABLE ROUTING