YAMAHA FZ6 S 2005 Service Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13 Drive chainCheck chain slack, alignment and condition.
Adjust and lubricate chain with a special O-ring chain lu-
bricant thoroughly. Every 800 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
22Engine oil filter car-
tridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18670
NOTE:

The air filter needs more frequent service if you are 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.
23*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
24*Front and rear brake
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace the entire air induction system if necessary.√√√√ √
28*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18771
Removing and installing
panels The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.
EAU32863
Panels A and B
To remove one of the panelsRemove the bolts and the quick fasten-
er screw, and then pull the panel off as
shown.
To install the panel
Place the panel in the original position,
and then install the quick fastener
screw and the bolts.
1. Panel A
2. Panel B
1. Panel C
1. Panel A
2. Bolt
3. Quick fastener screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU33020
Panel C
To remove the panel1. Remove the seat. (See page
3-13.)
2. Remove the bolt, and then pull the
panel off as shown.
To install the panel1. Place the panel in the original posi-
tion, and then install the bolt.2. Install the seat.
EAU19651
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be defective. Do
not attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Panel C
2. Bolt
Specified spark plug:
NGK/CR9EK
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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.CAUTION:
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twistit back and forth while pushing it in.
EAU32852
Engine oil and oil filter
cartridge 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, 12.5 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. Engine 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
6-10
6
NOTE:After the engine is started, the engine
oil level warning light should go off if theoil level is sufficient.CAUTION:
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU34352
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove the
seat. (See page 3-13.)
4. Remove the fuel tank bolts, and
then lift the fuel tank away from the
coolant reservoir cap. (See page
6-12.)
5. Open the coolant reservoir cap.
1. Maximum level mark
2. Minimum level mark
3. Coolant reservoir
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6 6. Add coolant or distilled water to
raise the coolant to the specified
level, close the coolant reservoir
cap, and then place the fuel tank in
the original position and install the
bolts.
7. Install the seat.
CAUTION:
ECA10470


If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.NOTE:

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page6-37 for further instructions.
EAU33030
Changing the coolant
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.27 L (0.29 US qt) (0.24 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU32884
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
3-13.)
2. Remove panels A and B. (See
page 6-5.)
3. Remove the fuel tank bolts, and
then lift the fuel tank away from the
air filter case.
4. Remove the air filter case cover by
removing the screws.5. Pull the air filter element out.
6. Insert a new air filter element into
the air filter case.
CAUTION:
ECA10480


Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
7. Install the air filter case cover by in-
stalling the screws.
8. Place the fuel tank in the original
position and install the bolts.WARNING
EWA12461


Before placing the fuel tank in
the original position, make sure
that the fuel hose is not dam-
aged. If the fuel hose is dam-
aged, do not start the engine but
have a Yamaha dealer replace
the hose, otherwise fuel may
leak.


Make sure that the fuel tank hos-
es are properly connected androuted, and not pinched.
1. Bolt
1. Screw
2. Air filter case cover
1. Air filter element
2. Air filter case
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