Yamaha Fazer FZ6-SAHG Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-33

FZ6-SAHG

Fuse box 1 is located behind panel D.
(See page 6-7.)

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.

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 a
fire.

1. Fuse box 2

2. ABS control unit fuse

3. ABS motor fuse
4. ABS motor spare fuse

5. Main fuse

6. Spare main fuse

1. Fuse box 1

1. Headlight fuse
2. Signaling system fuse

3. Ignition fuse

4. Radiator fan fuse
5. Backup fuse (for odometer, clock and immo-

bilizer system)

6. Fuel injection system fuse

7. Spare fuse
8. Taillight fuse

Specified fuses:

Main fuse:

30.0 A

Headlight fuse:

20.0 A

Taillight fuse:

10.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

10.0 A

Radiator fan fuse:

20.0 A

Fuel injection system fuse:

10.0 A

Backup fuse:

10.0 A

ABS control unit fuse:

FZ6-SAHG 10.0 A

ABS motor fuse:

FZ6-SAHG 30.0 A

U4S8E1E0.book Page 33 Monday, July 2, 2007 10:33 AM

Summary of Contents for Fazer FZ6-SAHG

Page 1: ...4S8 28199 E1 FZ6 SHG FZ6 SAHG OWNER S MANUAL ...

Page 2: ...d integrate type designation 9 Jun 2005 Date of issue 1 Aug 2002 Place of issue Shizuoka Japan R TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 1 2001 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC is in compliance with following norm s or documents Kind of equipment IMMOBILIZER Type designation 5SL 00 Hereby declare that the product Company YAMAHA MOTOR ELECTRONICS ...

Page 3: ...s to enjoy all advantages of your FZ6 SHG FZ6 SAHG The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your ...

Page 4: ...l If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or dea...

Page 5: ...ER S MANUAL 2007 by Yamaha Motor Co Ltd 1st edition June 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U4S8E1E0 book Page 2 Monday July 2 2007 10 33 AM ...

Page 6: ...ion chart 6 2 Removing and installing panels 6 7 Checking the spark plugs 6 9 Engine oil and oil filter cartridge 6 10 Coolant 6 12 Replacing the air filter element 6 16 Adjusting the engine idling speed 6 17 Checking the throttle cable free play 6 18 Valve clearance 6 18 Tires 6 19 Cast wheels 6 21 Adjusting the clutch lever free play 6 22 Rear brake light switch 6 22 Checking the front and rear ...

Page 7: ... 37 Front wheel FZ6 SHG 6 38 Rear wheel FZ6 SHG 6 39 Troubleshooting 6 41 Troubleshooting charts 6 42 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U4S8E1E0 book Page 2 Monday July 2 2007 10 33 AM ...

Page 8: ...ents 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 m...

Page 9: ...hield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or ...

Page 10: ...ution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit susp...

Page 11: ...d equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may...

Page 12: ...er element page 6 16 5 Idle adjusting screw page 6 17 6 Shock absorber assembly spring preload adjusting ring page 3 20 7 Owner s tool kit page 6 1 8 Helmet holder page 3 19 9 Shift pedal page 3 14 10 Engine oil drain bolt page 6 10 11 Engine oil filter cartridge page 6 10 U4S8E1E0 book Page 1 Monday July 2 2007 10 33 AM ...

Page 13: ... Rear brake fluid reservoir page 6 23 4 Engine oil filler cap page 6 10 5 Front brake fluid reservoir page 6 23 6 Radiator cap page 6 12 7 Coolant reservoir cap page 6 12 8 Coolant drain bolt page 6 13 9 Dipstick page 6 10 10 Brake pedal page 3 15 U4S8E1E0 book Page 2 Monday July 2 2007 10 33 AM ...

Page 14: ... lever page 3 14 2 Left handlebar switches page 3 13 3 Main switch steering lock page 3 2 4 Multi function meter unit page 3 8 5 Right handlebar switches page 3 13 6 Brake lever page 3 15 7 Throttle grip page 6 18 U4S8E1E0 book Page 3 Monday July 2 2007 10 33 AM ...

Page 15: ...OUR DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key ...

Page 16: ... red bow keep it in a safe place and only use it for code re registering EAU10550 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine ...

Page 17: ...itched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU10941 Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked befo...

Page 18: ...t 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 The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11423 Coolant temperature warning l...

Page 19: ...INSTRUMENT AND CONTROL FUNCTIONS 3 5 3 CAUTION ECA10020 Do not operate the engine if it is overheated U4S8E1E0 book Page 5 Monday July 2 2007 10 33 AM ...

Page 20: ... OK Go ahead with riding 117 139 C 243 283 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 42 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 42 U4S8E1E0 book Page 6 Monday July 2 2007 10 ...

Page 21: ...o cause the wheels to lock during emergen cy braking If the warning light comes on or flashes while riding have a Yamaha dealer check the brake system as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on or remains on have a Yamaha dealer check the electrical circuit EAU38620 Immobilizer system indicator light...

Page 22: ... bright ness control mode NOTE Be sure to turn the key to ON be fore using the SELECT and RE SET buttons For the U K only To switch the speedometer and odometer trip meter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turne...

Page 23: ...TRIP A and TRIP B in the following order TRIP A TRIP B ODO TRIP A When the fuel amount in the fuel tank decreases to 3 6 L 0 95 US gal 0 79 Imp gal the left segment of the fuel meter will start flashing and the odom eter display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch ...

Page 24: ...mperature 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 is overheated Air intake temperature mode The air intake t...

Page 25: ...e NOTE If the display indicates error code 52 this could be caused by transponder in terference If this error code appears try the following 1 Use the code re registering key to start the engine 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 ...

Page 26: ...ON and then re lease the SELECT button after five seconds 4 Push the RESET button to select the desired brightness level 5 Push the SELECT button to con firm the selected brightness level The display will return to the odom eter or tripmeter mode EAU12331 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 infor...

Page 27: ...switch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAU...

Page 28: ...an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch...

Page 29: ...s The Yamaha ABS Anti lock Brake System features a dual electronic con trol system which acts on the front and rear brakes independently The ABS is monitored by an ECU Electronic Con trol Unit which will have recourse to manual braking if a malfunction occurs WARNING EWA10090 The ABS performs best on long braking distances On certain rough or gravel roads the braking distance may be longer with th...

Page 30: ...it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into position with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the ca...

Page 31: ...ic parts EAU13320 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or prem...

Page 32: ...CA10700 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 idle too long EAU32980 Seat To remove the seat 1 Insert the key int...

Page 33: ...ince the helmet may hit objects causing loss of con trol and possibly an accident EAU42910 Storage compartment This storage compartment is designed to hold a genuine Yamaha CYCLELOK Other locks may not fit When placing a CYCLELOK in the stor age compartment securely fasten it with the strap When the CYCLELOK is not in the storage compartment be sure to secure the strap to prevent los ing it WARNIN...

Page 34: ...ve the seat See page 3 18 2 To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting ring in direction b NOTE Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit ...

Page 35: ... 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 of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidesta...

Page 36: ...revents 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 EWA10260 The vehicle must be placed on the centerstand during this in spect...

Page 37: ...ter 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 ...

Page 38: ...equences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not ...

Page 39: ...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 23 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reser...

Page 40: ... 6 19 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightene...

Page 41: ...d 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 22 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA16050 The following warning lights and in dicator light should come on for a few seconds then go off Oil le...

Page 42: ...t flashes or remains on after starting the ABS may be defective and the brake system reverts to conven tional braking If this occurs have a Yamaha dealer check the system as soon as possible The immobilizer system indica tor light should come on when the key is turned to ON and then go off after a few seconds If the indicator light does not come on or does not go off or if it flashes and the displ...

Page 43: ...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 rea...

Page 44: ...ng the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CA...

Page 45: ...liar with mainte nance work have a Yamaha dealer do 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 18 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 ...

Page 46: ...ls NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 24000 mi 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check o...

Page 47: ...ack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Every 800 km 500 mi and after washing the motorcycle or riding in the rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 12000 mi 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 B...

Page 48: ... 23 Shock absorber as sembly Check operation and shock ab sorber for oil leakage 24 Fuel injection Adjust engine idling speed and synchronization 25 Engine oil Change Check oil level and vehicle for oil leakage 26 Engine oil filter car tridge Replace 27 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 28 Front and rear brake switches Check operation NO ITEM C...

Page 49: ...rs and change the brake fluid 29 Moving parts and cables Lubricate 30 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 31 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace the entire air induction system if necessary 32 Muffler and exhaust pipe Check t...

Page 50: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 6 6 Replace the brake hoses every four years and if cracked or damaged U4S8E1E0 book Page 6 Monday July 2 2007 10 33 AM ...

Page 51: ... to be removed and installed EAU42661 Panels A and B To remove one of the panels 1 Remove the bolts 2 Pull the front cowling away from the vehicle as shown and then re move the panel To install the panel Insert the projections on the panel into the slots in the front cowling as shown and then install the bolts 1 Panel A 2 Panel B 3 Panel C 1 Panel D 1 Bolt 1 Front cowling 2 Panel A U4S8E1E0 book P...

Page 52: ...he original posi tion and then install the bolts 2 Install panels A and B EAU33020 Panel D To remove the panel 1 Remove the seat See page 3 18 2 Remove the bolt and then pull the panel off as shown To install the panel 1 Place the panel in the original posi tion and then install the bolt 2 Install the seat 1 Projection 2 Slot 1 Panel C 2 Bolt 1 Panel D 2 Bolt U4S8E1E0 book Page 8 Monday July 2 200...

Page 53: ...ngine 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 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 surfac...

Page 54: ...pe 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 the minimum 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 ...

Page 55: ...n 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 1 Engine oil drain bolt 1 Engine oil filter cartridge 2 Oil filter w...

Page 56: ...e a Yamaha dealer check 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 EAU40151 To check the coolant level The coolant level should be checked as follows before each r...

Page 57: ...otected 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 of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot NOTE The radiator fan is automatically switched on or off according to the coolant temperature in th...

Page 58: ...side down 7 Install the coolant reservoir and its reservoir cover by placing them in the original position and then in stalling the bolts 8 Remove the coolant drain bolt to drain the cooling system 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the coolant drain bolt and then tighten it to the specified torque NOTE Check the washer fo...

Page 59: ...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 St...

Page 60: ... ECA12880 When removing the air filter case cover be careful not to allow foreign objects to drop into the air intake manifold 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 oth...

Page 61: ...l position as shown 9 Install the panels 10 Install the seat EAU34301 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment Check the engine idling speed and if necessary adjust it to specification by turning t...

Page 62: ...p Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Engine idling sp...

Page 63: ...eration of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest items close to the center of the motorcycle and distribute the weight ev...

Page 64: ...tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed be...

Page 65: ...peration of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been change...

Page 66: ...urn the adjusting bolt in direction b NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU36501 Rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If nec...

Page 67: ...rake If a brake pad has worn to the point that a wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the brake pads as a set EAU40260 Checking the br...

Page 68: ...r the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock and dirt may clog the ABS hydrau lic unit valves Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake flui...

Page 69: ...ng bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engin...

Page 70: ...nd riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants fo...

Page 71: ...tion and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake an...

Page 72: ...ever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease U4S8E1E0 book Page 28 Monday July 2 2007 10 33 AM ...

Page 73: ...chart EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 P...

Page 74: ...g must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yam...

Page 75: ...yte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any conta...

Page 76: ...ored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 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 speci...

Page 77: ...y a fire 1 Fuse box 2 2 ABS control unit fuse 3 ABS motor fuse 4 ABS motor spare fuse 5 Main fuse 6 Spare main fuse 1 Fuse box 1 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan fuse 5 Backup fuse for odometer clock and immo bilizer system 6 Fuel injection system fuse 7 Spare fuse 8 Taillight fuse Specified fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A S...

Page 78: ...llows 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 cooled down 3 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA...

Page 79: ...s Do not use a headlight bulb of a wattage 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 EAU32822 Replacing the tail brake light bulb 1 Remove the seat See page 3 18 2 Remove the socket together with the bulb by turning it counter clockwise WARNING EWA12301 Do not touch the muffler bracket un til ...

Page 80: ...ulb 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...

Page 81: ... auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove panel C See page 6 7 2 Remove the auxiliary light socket together with the bulb by pulling 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 bulb by pushing it in 6 Install the panel 1 License plate light bulb 2 Licen...

Page 82: ...not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut 4 Pull the wheel axle out and then remove the wheel EAU42670 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Install the brake calipers by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing ...

Page 83: ...or cycle so that there is no danger of 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 bolt on each side of the swingarm 5 While supporting the brake caliper and slightly lifting the wheel pull the wheel axle out Tightening torques Wheel axle 72 Nm 7 2 m kgf 52 ft lbf Front wheel axle pinch bolt 1...

Page 84: ...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 slot in the brake caliper bracket is fit over the retain er on the swingarm 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 25 3 Inst...

Page 85: ...resent 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...

Page 86: ...n 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 sta...

Page 87: ...e hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check ...

Page 88: ...muffler outlets with plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel ax...

Page 89: ...or hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sp...

Page 90: ... any excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26201 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10...

Page 91: ...o ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires fr...

Page 92: ...h oil filter cartridge replacement 2 80 L 2 96 US qt 2 46 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 00 L 2 11 US qt 1 76 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 19 4 L 5 13 US gal 4 27 Imp gal Fuel r...

Page 93: ...nt 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition FZ6 SAHG 90 185 kg 198 408 lb FZ6 SHG 90 190 kg 198 419 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 5...

Page 94: ...ight 12 V 5 0 W 2 License plate light 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED ABS warning light FZ6 SAHG LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Sign...

Page 95: ...entification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your ...

Page 96: ...label is affixed to the frame under the seat See page 3 18 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U4S8E1E0 book Page 2 Monday July 2 2007 10 33 AM ...

Page 97: ...ndlebar switches 3 13 Hazard switch 3 14 Headlight bulb replacing 6 34 Helmet holder 3 19 High beam indicator light 3 4 Horn switch 3 13 I Identification numbers 9 1 Ignition circuit cut off system 3 22 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 4 K Key identification number 9 1 L License plate light bulb replacing 6 36 M Main switch steering lock ...

Page 98: ...tor lights 3 4 Turn signal light bulb replacing 6 36 Turn signal switch 3 13 V Valve clearance 6 18 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheel front FZ6 SHG 6 38 Wheel rear FZ6 SHG 6 39 Wheels 6 21 U4S8E1E0 book Page 2 Monday July 2 2007 10 33 AM ...

Page 99: ...U4S8E1E0 book Page 3 Monday July 2 2007 10 33 AM ...

Page 100: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 07 0 5 1 CR E ...

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Yamaha Fazer FZ6-SAHG, Owner'S Manual

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