maintenance YAMAHA FZ6 S 2007 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2007, Model line: FZ6 S, Model: YAMAHA FZ6 S 2007Pages: 92, PDF Size: 4.62 MB
Page 6 of 92
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 ......................3-6
Anti-theft alarm (optional) .............3-10
Handlebar switches ......................3-10
Clutch lever ...................................3-11
Shift pedal .....................................3-12
Brake lever ...................................3-12
Brake pedal ..................................3-12
ABS ..............................................3-13
Fuel tank cap ................................3-13
Fuel ...............................................3-14
Fuel tank breather hose ................3-15
Catalytic converter ........................3-15
Seat ..............................................3-16
Helmet holder ...............................3-16
Storage compartment ...................3-17
Adjusting the shock absorber
assembly ...................................3-17
Sidestand ......................................3-18Ignition circuit cut-off system ........ 3-19
PRE-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 panels ..... 6-6
Checking the spark plugs ............... 6-7
Engine oil and oil filter cartridge ..... 6-8
Coolant ......................................... 6-11
Replacing the air filter element ..... 6-14
Adjusting the engine idling
speed ........................................ 6-16
Checking the throttle cable free
play ........................................... 6-16
Valve clearance ............................ 6-17
Tires ............................................. 6-17
Cast wheels .................................. 6-20Adjusting the clutch lever free
play ........................................... 6-20
Rear brake light switch ................ 6-21
Checking the front and rear brake
pads .......................................... 6-21
Checking the brake fluid level ...... 6-22
Changing the brake fluid .............. 6-23
Drive chain slack .......................... 6-23
Cleaning and lubricating the drive
chain ......................................... 6-24
Checking and lubricating
the cables ................................. 6-25
Checking and lubricating
the throttle grip and cable ......... 6-25
Checking and lubricating the brake
and shift pedals ........................ 6-26
Checking and lubricating the brake
and clutch levers ...................... 6-26
Checking and lubricating the
centerstand and sidestand ....... 6-27
Lubricating the swingarm
pivots ........................................ 6-27
Checking the front fork ................. 6-28
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-29
Battery ......................................... 6-29
Replacing the fuses ..................... 6-31
Replacing the headlight bulb ....... 6-32
Replacing the tail/brake light
bulb ........................................... 6-34U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM
Page 8 of 92
1-1
1
SAFETY INFORMATION
EAU10281
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE USE
AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE EX-
PERTISE OF THE OPERATOR. EV-
ERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTOR-
CYCLE.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUALAND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed to car-
ry the operator and a passenger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
Make sure that you are qualified
and that you only lend your
motorcycle to other qualified op-
erators.
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
U4P5E1E0.book Page 1 Monday, September 11, 2006 1:33 PM
Page 29 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-15
3 or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13411
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.
EAU13441
Catalytic converter This vehicle is equipped with catalytic
converters in the exhaust system.
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.
1. Fuel tank breather hose
2. Original position (paint mark)
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Page 42 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17520
Owner’s tool kit The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
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Page 43 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
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
6-3
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*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 10203040U4P5E1E0.book Page 3 Monday, September 11, 2006 1:33 PM
Page 45 of 92
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.
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.
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
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6Every 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU18771
Removing and installing pan-
els 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
6-7
6
EAU33020
Panel C
To remove the panel1. Remove the seat. (See page
3-16.)
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.
EAU19642
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 operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer 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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