air filter YAMAHA FZ6 NHG 2007 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 ............3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-12
Handlebar switches ......................3-13
Clutch lever ...................................3-14
Shift pedal .....................................3-14
Brake lever ...................................3-15
Brake pedal ..................................3-15
ABS ..............................................3-15
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather hose ................3-18
Catalytic converter ........................3-18
Seat ..............................................3-18
Helmet holder ...............................3-19
Storage compartment ...................3-19
Adjusting the shock absorber
assembly ...................................3-20
Sidestand ......................................3-21
Ignition circuit cut-off system ........3-22PRE-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 ..................................... 6-6
Checking the spark plugs ............... 6-6
Engine oil and oil filter cartridge ..... 6-7
Coolant ......................................... 6-10
Replacing the air filter element ..... 6-13
Adjusting the engine idling
speed ........................................ 6-15
Checking the throttle cable
free play .................................... 6-16
Valve clearance ............................ 6-16
Tires ............................................. 6-16
Cast wheels .................................. 6-19Adjusting the clutch lever
free play .................................... 6-19
Rear brake light switch ................ 6-20
Checking the front and
rear brake pads ........................ 6-20
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-22
Drive chain slack .......................... 6-22
Cleaning and lubricating
the drive chain .......................... 6-24
Checking and lubricating
the cables ................................. 6-24
Checking and lubricating
the throttle grip and cable ......... 6-25
Checking and lubricating
the brake and shift pedals ........ 6-25
Checking and lubricating
the brake and clutch levers ...... 6-26
Checking and lubricating
the sidestand ............................ 6-26
Lubricating the swingarm
pivots ........................................ 6-27
Checking the front fork ................. 6-27
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-28
Battery ......................................... 6-29
Replacing the fuses ..................... 6-30
Replacing the headlight bulb ....... 6-32
Replacing the tail/
brake light bulb ......................... 6-33U5S4E0E0.book Page 1 Wednesday, January 17, 2007 11:35 AM

DESCRIPTION
2-1
2
EAU10410
Left view1. Main fuse (page 6-30)
2. Fuse box 1 (page 6-30)
3. Battery (page 6-29)
4. Air filter element (page 6-13)
5. Idle adjusting screw (page 6-15)
6. Shock absorber assembly spring preload adjusting ring (page 3-20)
7. Owner’s tool kit (page 6-1)
8. Storage compartment (page 3-19)9. Helmet holder (page 3-19)
10.Shift pedal (page 3-14)
11.Engine oil drain bolt (page 6-7)
12.Engine oil filter cartridge (page 6-7)U5S4E0E0.book Page 1 Wednesday, January 17, 2007 11:35 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-10
3Fuel 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 the last segment on
the left starts flashing, refuel as soon as
possible.
NOTE:This fuel meter is equipped with a self-
diagnosis system. If the electrical circuit
is defective, the following cycle will be
repeated until the malfunction is cor-
rected: “E” (Empty), “F” (Full) and sym-
bol “” will flash eight times, then go offfor approximately 3 seconds. If this oc-
curs, have a Yamaha dealer check the
electrical circuit.
Coolant temperature mode
The coolant temperature display indi-
cates the temperature of the coolant.
Push the “RESET” button to switch the
coolant temperature display to the air
intake temperature display.NOTE:When the coolant temperature display
is selected, “C” is displayed for one
second, and then the coolant tempera-ture is displayed.
CAUTION:
ECA10020
Do not operate the engine if it isoverheated.
Air intake temperature mode
The air intake temperature display indi-
cates the temperature of the air drawn
into the air filter case. Push the “RE-
SET” button to switch the coolant tem-
perature display to the air intake
temperature display.NOTE:

Even if the air intake temperature
is set to be displayed, the coolant
temperature warning light comes
on when the engine overheats.
1. Fuel meter
1. Coolant temperature display
1. Air intake temperature display
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17707
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18680
NOTE:

Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
23 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
24Engine oil filter car-
tridgeReplace.√√√
25*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
26*Front and rear brake
switchesCheck operation.√√√√√ √
27Moving parts and ca-
blesLubricate.√√√√ √
28*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
29*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace the entire air induction system if necessary.√√√√ √
30*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
31*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040U5S4E0E0.book Page 4 Wednesday, January 17, 2007 11:35 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6 The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.Replace the brake hoses every four years and if cracked or damaged.
U5S4E0E0.book Page 5 Wednesday, January 17, 2007 11:35 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6 Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
EAU32852
Engine oil and oil filter car-
tridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles.
1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
64. Remove the engine oil dipstick and
wipe it clean, insert it back into the
hole (without screwing it in), and
then remove it again to check the
oil level.
NOTE:The engine oil should be between theminimum and maximum level marks.
5. If the engine oil is at or below the
minimum level mark, remove the
oil filler cap, and then add sufficient
oil of the recommended type to
raise it to the correct level.6. Insert and tighten the engine oil
dipstick, and then install and tight-
en the oil filler cap.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:
Skip steps 4–6 if the oil filter cartridge isnot being replaced.
4. Remove the oil filter cartridge with
an oil filter wrench.
1. Dipstick
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
1. Engine oil drain bolt
1. Oil filter cartridge
2. Oil filter wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:An oil filter wrench is available at aYamaha dealer.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.NOTE:Make sure that the O-ring is properlyseated.
6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.50 L (2.64 US qt) (2.20 Imp.qt)
With oil filter cartridge replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6 the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
12. Install the coolant reservoir cap.
13. Install the radiator cap, radiator
cap retainer and radiator cap re-
taining bolt.
14. Start the engine, let it idle for sev-
eral minutes, and then turn it off.
15. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap, radiator cap retainer and radi-
ator cap retaining bolt.16. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
17. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
EAU34424
Replacing the air filter element The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See page
3-18.)
2. Remove the fuel tank bolts, and
then lift the fuel tank away from the
air filter case.
3. Remove the air filter case cover by
removing the screws.
1. Radiator cap retaining bolt
2. Radiator cap
3. Radiator cap retainer
1. Bolt
U5S4E0E0.book Page 13 Wednesday, January 17, 2007 11:35 AM