maintenance YAMAHA FZ6 S 2004 Owner's Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals.
CAUTION:
ECA10630


Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (constant-volt-
age) battery charger is required.
Using a conventional battery
charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charg-
er, have a Yamaha dealercharge your battery.
EAU32840
Replacing the fuses The main fuse box is located under the
fuel tank.
The fuse box is located behind panel C.
(See page 6-5.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.1. Main fuse
2. Spare fuse
1. Fuse box
1. Headlight fuse
2. Signaling system fuse
3. Ignition fuse
4. Radiator fan fuse
5. Backup fuse (for odometer, clock and
immobilizer system)
6. Electronic fuel injection fuse
7. Spare fuse
8. Parking lighting fuse
5VXE1.book Page 28 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU23740
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.
2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
3. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.CAUTION:
ECA10650
Take care not to damage the follow-
ing parts:
Specified fuses:
Main fuse:
30.0 A
Headlight fuse:
20.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Radiator fan fuse:
20.0 A
Electronic fuel injection fuse:
10.0 A
Backup fuse:
10.0 A
Parking lighting fuse:
10.0 A
1. Headlight bulb cover
2. Headlight coupler
1. Headlight bulb holder
5VXE1.book Page 29 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6


Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.


Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of awattage higher than specified.4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU32820
Replacing the tail/brake light
bulb 1. Remove the seat. (See page
3-14.)
WARNING
EWA12300
Do not touch the bracket until the ex-haust system has cooled.
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
1. Do not touch the glass part of the bulb.
1. Tail/brake light bulb socket
2. Muffler bracket
5VXE1.book Page 30 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
64. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with the
bulb) by turning it clockwise.
6. Install the seat.
EAU24201
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.CAUTION:
ECA11190
Do not overtighten the screw, other-wise the lens may break.
EAU24310
Replacing the license plate
light bulb 1. Remove the license plate light unit
by removing the screws.
2. Remove the socket (together with
the bulb) by pulling it out.
1. Screw
1. Screw
1. License plate light bulb
2. License plate light unit
5VXE1.book Page 31 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 3. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by pushing it in.
6. Install the license plate light unit by
installing the screws.
EAU32830
Replacing an auxiliary light
bulb This model is equipped with two auxil-
iary lights. If an auxiliary light bulb burns
out, replace it as follows.
1. Remove panel B (if replacing the
left auxiliary light bulb) or panel A
(if replacing the right auxiliary light
bulb). (See page 6-5.)
2. Remove the auxiliary light socket
(together with the coupler) by pull-
ing it out.
3. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.5. Install the auxiliary light socket (to-
gether with the coupler) by push-
ing it in.1. Auxiliary light bulb
2. Auxiliary light bulb socket
5VXE1.book Page 32 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU24360
Front wheel
EAU24470
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Place the motorcycle on the cen-
terstand.
2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.3. Remove the brake hose holder on
each side by removing the bolts.
4. Remove the brake caliper on each
side by removing the bolts.
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
5. Pull the wheel axle out, and then
remove the wheel.
EAU24860
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts.NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brakediscs.
5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
1. Wheel axle
2. Front wheel axle pinch bolt
1. Brake hose holder
2. Brake caliper
3. Bolt
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf, 52 ft·lbf)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kgf, 14 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
5VXE1.book Page 33 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 7. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU32872
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.
2. Place the motorcycle on the cen-
terstand.
3. Remove the axle nut.
4. Loosen the locknut and drive chain
adjusting nut on each side of the
swingarm.5. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
1. Axle nut
2. Drive chain slack adjusting nut
3. Locknut
5VXE1.book Page 34 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the rear wheel.
6. While supporting the brake caliper
and slightly lifting the wheel, pull
the wheel axle out.NOTE:A rubber mallet may be useful to tap thewheel axle out.
7. Remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU32940
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the right-hand side.NOTE:

Make sure that the retainer on the
swingarm is inserted into the slot in
the brake caliper bracket.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
1. Wheel axle
2. Drive chain slack adjusting nut
3. Locknut
4. Brake caliper bracket
5. Brake caliper
1. Retainer
2. SlotTightening torque:
Axle nut:
120 Nm (12.0 m·kgf, 87 ft·lbf)
5VXE1.book Page 35 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU25870
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
5VXE1.book Page 36 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU25911
Troubleshooting charts Starting problems or poor engine performance
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
5VXE1.book Page 37 Monday, February 9, 2004 5:39 PM