check engine YAMAHA FZ6 N 2005 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
LCD tachometer .............................3-5
Multi-function display ......................3-5
Anti-theft alarm (optional) ...............3-8
Handlebar switches ........................3-8
Clutch lever ...................................3-10
Shift pedal .....................................3-10
Brake lever ...................................3-10
Brake pedal ..................................3-11
Fuel tank cap ................................3-11
Fuel ...............................................3-12
Fuel tank breather hose ................3-13
Catalytic converter ........................3-13
Seat ..............................................3-13
Storage compartment ...................3-14
Adjusting the shock absorber
assembly ...................................3-15
Sidestand ......................................3-16
Ignition circuit cut-off system ........3-16PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing the
panel ........................................... 6-5
Checking the spark plugs ............... 6-5
Engine oil and oil filter cartridge ..... 6-6
Coolant ........................................... 6-9
Replacing the air filter element ..... 6-11
Adjusting the engine idling
speed ........................................ 6-12
Adjusting the throttle cable free
play ........................................... 6-13
Adjusting the valve clearance ...... 6-13
Tires ............................................. 6-13
Cast wheels .................................. 6-16Adjusting the clutch lever free
play ........................................... 6-16
Adjusting the rear brake light
switch ....................................... 6-17
Checking the front and rear
brake pads ................................ 6-17
Checking the brake fluid level ...... 6-18
Changing the brake fluid .............. 6-19
Drive chain slack .......................... 6-19
Lubricating the drive chain ........... 6-21
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake and shift pedals .............. 6-22
Checking and lubricating the
brake and clutch levers ............ 6-23
Checking and lubricating the
sidestand .................................. 6-23
Lubricating the swingarm
pivots ........................................ 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-26
Replacing the fuses ..................... 6-27
Replacing the headlight bulb ....... 6-28
Replacing the tail/brake light
bulb ........................................... 6-29U1B3E1E0.book Page 1 Thursday, July 8, 2004 11:49 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11250
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.NOTE:

Even if the oil level is sufficient, the
warning light may flicker when
riding on a slope or during sudden
acceleration or deceleration, but
this is not a malfunction.


This model is also equipped with a
self-diagnosis device for the oil
level detection circuit. If the oil lev-
el detection circuit is defective, the
following cycle will be repeated un-
til the malfunction is corrected: Theoil level warning light will flash ten
times, then go off for 2.5 seconds.
If this occurs, have a Yamaha
dealer check the vehicle.
EAU11530
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system. (See page 3-5 for an
explanation of the self-diagnosis de-
vice.)
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU26871
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
NOTE:This model is also equipped with a self-
diagnosis device for the immobilizer
system. If the immobilizer system is de-
fective, the indicator will start flashing
and the multi-function meter will display
an error code when the key is turned to
“ON”. (See “Self-diagnosis device” onpage 3-5 for details.)
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INSTRUMENT AND CONTROL FUNCTIONS
3-7
3 Air intake temperature mode
The temperature displayed may vary
from the outside temperature depend-
ing on engine conditions. To switch the
clock to the air intake temperature
mode, first set the display to the odom-
eter or tachometer mode, and then
push the “RESET” button for at least
two seconds.
Fuel meter
The fuel meter indicates the amount of
fuel in the fuel tank. The display seg-
ments of the fuel meter disappear to-
wards “E” (Empty) as the fuel level
decreases. When only one segment is
left near “E”, refuel as soon as possible.
NOTE:This fuel meter is equipped with a self-
diagnosis system. If the electrical circuit
is defective, the display segments will
flash. If this occurs, have a Yamahadealer check the electrical circuit.
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. Whenthe key is turned to “ON”, all of the dis-
play segments of the coolant tempera-
ture meter will appear one after the
other and then disappear in order to
test the electrical circuit. The coolant
temperature varies with changes in the
weather and engine load. If the top seg-
ment flashes, stop the vehicle and let
the engine cool. (See page 6-36.)
CAUTION:
ECA10020
Do not operate the engine if it isoverheated.
Self-diagnosis devices
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
engine trouble warning light will come
on, and then the multi-function display
will indicate a two-digit error code (e.g.,
12, 13, 14).
This model is also equipped with a self-
diagnosis device for the immobilizer
system.If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code (e.g., 51, 52, 53).
NOTE:If the multi-function display indicates er-
ror code 52 (all segments of the coolant
temperature meter will come on, except
the top segment, which will flash), this
could be caused by transponder inter-
ference. If this error appears, try the fol-lowing.
1. Use the code re-registering key to
start the engine.1. Error code display
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INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
NOTE:Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the enginefrom starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
If the multi-function display indicates
any error code, note the code number,
and then have a Yamaha dealer check
the vehicle.CAUTION:
ECA11590
If the display indicates an error
code, the vehicle should be checked
as soon as possible in order to avoidengine damage.
EAU12330
Anti-theft alarm (optional) This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
EAU12343
Handlebar switches Left1. Pass switch “”
2. Dimmer switch “/”
3. Turn signal switch “/”
4. Horn switch “”
5. Hazard switch “”
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INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
EAU13410
Fuel tank breather hose Before operating the motorcycle:

Check the fuel tank breather hose
connection.


Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.


Make sure that the end of the fuel
tank breather hose is not blocked,
and clean it if necessary.
EAU13430
Catalytic converter This model is equipped with a catalytic
converter in the exhaust chamber.
WARNING
EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-ing any maintenance work.CAUTION:
ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.

Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.


Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.


Do not allow the engine to idletoo long.
EAU32980
Seat To remove the seat
1. Insert the key into the seat lock,
and then turn it counterclockwise.
2. While holding the key in that posi-
tion, lift the rear of the seat up, and
then pull the seat off.
To install the seat
1. Insert the projection on the front of
the seat into the seat holder as
shown.
1. Fuel tank breather hose
2. White mark
1. Seat lock
2. Unlock.
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
EAU15300
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.NOTE:The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation ofthe ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly as describedbelow and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
EAU15311
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.


It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.WARNING
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-fore riding.
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INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NONOTE:
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PRE-OPERATION CHECKS
4-2
4
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-12
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-6
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-9
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-17, 6-18
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-17, 6-18
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-16
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OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU32951
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the sid-
estand up.WARNING
EWA10290


Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-16.


Never ride with the sidestanddown.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:
ECA12741
The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light


Engine trouble warning light


Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-
tral position.NOTE:When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
3. Start the engine by pushing the
start switch.NOTE:If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any oneattempt.
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OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU16810
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17091
0–1000 km (0–600 mi)
Avoid prolonged operation above 7000
r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 8400
r/min.
CAUTION:
ECA10301
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10310


Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
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