SERVICE MANUAL

FZ6RY(C)

2009

36P-28197-10

LIT-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

G This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

G 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.

G 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”.

G Sub-section titles appear in smaller print than the section title “2”.

G To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section “3”.

G Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-

bly step “4”.

G Symbols indicate parts to be lubricated or replaced “5”.

Refer to “SYMBOLS”.

G A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc “6”.

G 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

E

New

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

3 4

5

6

7 8

9 10

11 12

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/

cm², 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:

G a speedometer

G a tachometer

G an odometer

G two tripmeters (which show the distance trav-

eled since they were last set to zero)

G a fuel reserve tripmeter (which shows the dis-

tance traveled since the left segment of the fuel

meter started flashing)

G a clock

G a fuel meter

G a coolant temperature display

G a self-diagnosis device

TIP

G Be sure to turn the key to “ON” before using the

“SELECT” and “RESET” buttons.

G 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

8 7 6

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