Yamaha FZ6RC User manual

SERVICE MANUAL
FZ6RY(C)
2009
36P-28197-10LIT-11616-22-77

EAS20050
FZ6RY(C)
SERVICE MANUAL
©2008 by Yamaha Motor Corporation, U.S.A.
First edition, December 2008
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-11616-22-77

EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. 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 vehi-
cle 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 vehi-
cle 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 sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
●
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.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid pos-
sible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EAS20090
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 and each chapter is divided into sections. The current section title
is shown at the top of each page “1”.
●
Sub-section titles appear in smaller print than the section title “2”.
●
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
●
Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-
bly step “4”.
●
Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
●
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.
●
Jobs requiring more information (such as special tools and technical data) are described sequentially
“7”.
5
3
4
6
1
2
7

EAS20100
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
G
M
BF
B
T
R
.
.
LS
M
S
LT
ENew
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Engine oil
Gear oil
Molybdenum disulfide oil
Brake fluid
Wheel bearing grease
Lithium-soap-based grease
Molybdenum disulfide grease
Silicone grease
Apply locking agent (LOCTITE®).
Replace the part with a new one.
SYMBOL DEFINITION SYMBOL DEFINITION

GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND
ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
COOLING SYSTEM
6
FUEL SYSTEM
7
ELECTRICAL SYSTEM
8
TROUBLESHOOTING
9
EAS20110
TABLE OF CONTENTS

1
2
3
4
5
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION ...........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER....................................................1-1
MODEL LABEL ........................................................................................1-1
FEATURES ....................................................................................................1-2
OUTLINE OF FI SYSTEM........................................................................1-2
FI SYSTEM ..............................................................................................1-3
INSTRUMENT FUNCTIONS....................................................................1-4
IMPORTANT INFORMATION ........................................................................1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-7
REPLACEMENT PARTS .........................................................................1-7
GASKETS, OIL SEALS AND O-RINGS ...................................................1-7
LOCK WASHERS/PLATES AND COTTER PINS....................................1-7
BEARINGS AND OIL SEALS...................................................................1-8
CIRCLIPS.................................................................................................1-8
CHECKING THE CONNECTIONS.................................................................1-9
REMOVING THE QUICK FASTENER .....................................................1-10
INSTALLING THE QUICK FASTENER....................................................1-11
SPECIAL TOOLS...........................................................................................1-12

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
1
1

FEATURES
1-2
EAS20170
FEATURES
EAS4B51038
OUTLINE OF FI SYSTEM
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. In a 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 chamber. Despite the same
volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as
acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the
use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be
achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for engines to deliver more performance and cleaner exhaust gases increase, it
becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system in place
of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the
engine at all times by using a microprocessor that regulates the fuel injection volume according to the
engine operating conditions detected by various sensors.
Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better
fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has
been placed under computer control together with the FI system in order to realize cleaner exhaust gas-
es.
1
2
345 6 78910 1112
18 17 16 15 14 13
1. Ignition coil
2. Engine trouble warning light
3. Air filter case
4. Intake air pressure sensor
5. Intake air temperature sensor
6. Fuel tank
7. Fuel pump
8. Fuel hose
9. Battery
10. ECU (engine control unit)
11. Lean angle sensor
12. Relay unit
13. Catalyst
14. Fuel injector
15. Coolant temperature sensor
16. Crankshaft position sensor
17. Throttle position sensor
18. Spark plug

FEATURES
1-3
EAS4B51039
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel
pump) maintains the fuel pressure that is applied to the fuel injector at 245 – 255 kPa (2.45 – 2.55 kgf/
cm
2
, 35.5 – 37.0 psi) higher than the intake manifold pressure. Accordingly, when the energizing signal
from the ECU (engine control unit) energizes the fuel injector, the fuel passage opens, causing the fuel
to be injected into the intake manifold only during the time the passage remains open. Therefore, the
longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel
that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection dura-
tion), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU (engine control unit). Signals
that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor,
intake air temperature sensor and coolant temperature sensor enable the ECU (engine control unit) to
determine the injection duration. The injection timing is determined through the signals from the crank-
shaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at
all times in accordance with the driving conditions.
Illustration is for reference only.
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. ECU (engine control unit)
5. Catalyst
6. Coolant temperature sensor
7. Crankshaft position sensor
8. Intake air pressure sensor
9. Throttle body
10. Intake air temperature sensor
11. Air filter case
12. Throttle position sensor
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
EAS20S1001
INSTRUMENT FUNCTIONS
Multi-function meter unit
WARNING
EWA20S1001
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The multi-function meter unit is equipped with
the following:
●
a speedometer
●
a tachometer
●
an odometer
●
two tripmeters (which show the distance trav-
eled since they were last set to zero)
●
a fuel reserve tripmeter (which shows the dis-
tance traveled since the left segment of the fuel
meter started flashing)
●
a clock
●
a fuel meter
●
a coolant temperature display
●
a self-diagnosis device
TIP
●
Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” buttons.
●
To switch the speedometer and odometer/trip-
meter displays between kilometers and miles,
press the “SELECT” button for at least one
second.
Tachometer
The electric tachometer allows the rider to mon-
itor the engine speed and keep it within the ideal
power range.
When the key is turned to “ON”, the tachometer
needle will sweep once across the r/min range
and then return to zero r/min in order to test the
electrical circuit.
NOTICE
ECA20S1006
Do not operate the engine in the tachometer
red zone.
Red zone:11666 r/min and above
Clock
The clock displays when the key is turned to
“ON”. In addition, the clock can be displayed for
10 seconds by pushing the “SELECT” button
when the main switch is in the “OFF” or “LOCK”
position.
To set the clock
1. Turn the key to “ON”.
2. Push the “SELECT” button and “RESET” but-
ton together for at least two seconds.
3. When the hour digits start flashing, push the
“RESET” button to set the hours.
1. Fuel meter
2. Coolant temperature display
3. Speedometer
4. Tachometer
5. Odometer/tripmeter/fuel reserve tripmeter
6. “SELECT” button
7. “RESET” button
8. Clock
876 5
1 2 3 4
1. Tachometer
2. Tachometer red zone
1. Clock
1
2
1

FEATURES
1-5
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button and then release
it to start the clock.
Odometer and tripmeter modes
Push the “SELECT” button to switch the display
between the odometer mode “ODO” and the
tripmeter modes “TRIP A” and “TRIP B” in the
following order:
TRIP A → TRIP B → ODO → TRIP A
When the fuel amount in the fuel tank decreases
to 3.2 L (0.85 US gal, 0.70 Imp.gal), the left seg-
ment of the fuel meter will start flashing, and the
odometer display will automatically change to
the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that
point. In that case, push the “SELECT” button to
switch the display between the various tripmeter
and odometer modes in the following order:
F-TRIP → TRIP A → TRIP B → ODO → F-TRIP
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second. If you do not reset
the fuel reserve tripmeter manually, it will reset
itself automatically and the display will return to
the prior mode after refueling and traveling 5 km
(3 mi).
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear towards “E” (Empty) as the fuel level
decreases. When the last segment on the left
starts flashing, refuel as soon as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in the electrical
circuit, the following cycle is repeated until the
malfunction is corrected: fuel level segments
and symbol “ ” flash eight times, then go off for
approximately 3 seconds. If this occurs, check
the electrical circuit. Refer to “SIGNALING
SYSTEM” on page 8-19.
Coolant temperature mode
The coolant temperature display indicates the
temperature of the coolant.
NOTICE
ECA20S1007
Do not continue to operate the engine if it is
overheating.
1. Odometer/tripmeter/fuel reserve tripmeter
1
1. Fuel meter
1. Coolant temperature display
1
1

FEATURES
1-6
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light will come on
and the display will indicate an error code.
If the display indicates any error codes, note the
code number, and then check the vehicle.
NOTICE
ECA20S1008
If the display indicates an error code, the ve-
hicle should be checked as soon as possible
in order to avoid engine damage.
1. Error code display
1

IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-12.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease

IMPORTANT INFORMATION
1-8
EAS20230
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
NOTICE
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

CHECKING THE CONNECTIONS
1-9
EAS20250
CHECKING THE CONNECTIONS
NOTICE
ECA20S1001
Electronic parts are very sensitive. Handle
with care and do not give impact.
NOTICE
ECA20S1002
●
Mankind has static electricity. It`s voltage
is very high and electronic parts are very
sensitive.
●
It is possible that inner small components
of electronic parts are destroyed by static
electricity.
●
Do not touch and do not make them dirty.
NOTICE
ECA20S1003
●
When you disconnect electronic parts from
the wire harness, always turn off the main
switch.
●
If you disconnect above condition, it may
damage the electronic parts.
TIP
When you check the electric system of a motor-
cycle, check the battery voltage before. Mini-
mum 11V is requested to check each
component function.
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
●
Lead
●
Coupler
●
Connector
2. Check:
●
Lead
●
Coupler
●
Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
●
All connections
Loose connection → Connect properly.

CHECKING THE CONNECTIONS
1-10
TIP
If the pin “1” on the terminal is flattened, bend it
up.
TIP
If the contact seems not good, pull the terminal
by hand and check its condition.
4. Connect:
●
Lead
●
Coupler
●
Connector
TIP
Make sure all connections are tight.
5. Check:
●
Continuity
(with the pocket tester)
TIP
●
If there is no continuity, clean the terminals.
●
When checking the wire harness, perform
steps (1) to (3).
●
As a quick remedy, use a contact revitalizer
available at most part stores.
TIP
When you check the voltage or electrical conti-
nuity, insert the measuring probe from back side
as you can insert from back side.
EAS21840
REMOVING THE QUICK FASTENER
TIP
To remove the quick fastener, push its center
with a screwdriver, then pull the fastener out.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Probe
2. Coupler
1
2

CHECKING THE CONNECTIONS
1-11
EAS21850
INSTALLING THE QUICK FASTENER
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the cover and push the pin “a”
in with screwdriver. Make sure that the pin is
flush with the fastener’s head.