Yamaha FZ6-NHG Owner'S Manual Download Page 80

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PERIODIC MAINTENANCE AND ADJUSTMENT

6-36

2. Lift the front wheel off the ground

according to the procedure on
page 6-35.

3. Remove the brake caliper on each

side by removing the bolts.

NOTICE:

Do not apply the brake

after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.

[ECA11051]

4. Pull the wheel axle out, and then

remove the wheel.

EAU43371

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.

TIP

Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.

4. Lower the front wheel so that it is

on the ground, and then put the
sidestand down.

5. Tighten the wheel axle, the front

wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.

6. Push down hard on the handlebar

several times to check for proper
fork operation.

EAU44800

Rear wheel (FZ6-NHG)

WARNING

EWA14840

For the ABS model, have a Yamaha
dealer remove and install the wheel.

EAU43381

To remove the rear wheel

WARNING

EWA10821

To avoid injury, securely support the
vehicle so there is no danger of it
falling over.

1. Loosen the axle nut.
2. Lift the rear wheel off the ground

according to the procedure on
page 6-35.

3. Remove the axle nut.
4. Loosen the locknut and drive chain

adjusting bolt on each side of the
swingarm.

1. Brake caliper
2. Brake caliper 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, 13 ft·lbf)

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

U5S5E2E0.book Page 36 Monday, August 4, 2008 2:07 PM

Summary of Contents for FZ6-NHG

Page 1: ...DIC183 FZ6 NHG FZ6 NAHG OWNER S MANUAL Read this manual carefully before operating this vehicle 5S5 28199 E2 ...

Page 2: ...sion record No Contents Date To change contact person and 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 de...

Page 3: ...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 Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the mos...

Page 4: ...bey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U5S5E2E0 book Page 1 ...

Page 5: ...R S MANUAL 2008 by Yamaha Motor Co Ltd 1st edition July 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5S5E2E0 book Page 2 Monday August 4 2008 2 07 PM ...

Page 6: ...aintenance and lubrication chart 6 2 Removing and installing the panel 6 7 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 19 Adjusting the clutch lever free play 6 20 Rear brake light switch 6 20 Che...

Page 7: ...ulb 6 34 Supporting the motorcycle 6 35 Front wheel FZ6 NHG 6 35 Rear wheel FZ6 NHG 6 36 Troubleshooting 6 38 Troubleshooting charts 6 40 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 U5S5E2E0 book Page 2 Monday August 4 2008 2 07 PM ...

Page 8: ...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...

Page 9: ...d 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 Always wear protective clothing that covers your legs ankles and feet The eng...

Page 10: ...s evenly as possi ble on both sides of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres ...

Page 11: ...ork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may beco...

Page 12: ...6 14 5 Idle adjusting screw page 6 16 6 Shock absorber assembly spring preload adjusting ring page 3 21 7 Owner s tool kit page 6 1 8 Storage compartment page 3 20 9 Helmet holder page 3 20 10 Shift pedal page 3 14 11 Engine oil drain bolt page 6 8 12 Engine oil filter cartridge page 6 8 U5S5E2E0 book Page 1 Monday August 4 2008 2 07 PM ...

Page 13: ...eservoir page 6 21 3 Engine oil filler cap page 6 8 4 Front brake fluid reservoir page 6 21 5 Radiator cap page 6 11 6 Coolant reservoir page 6 11 7 Coolant drain bolt page 6 12 8 Engine oil dipstick page 6 8 9 Brake pedal page 3 15 U5S5E2E0 book Page 2 Monday August 4 2008 2 07 PM ...

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 Throttle grip page 6 16 7 Brake lever page 3 15 U5S5E2E0 book Page 3 Monday August 4 2008 2 07 PM ...

Page 15: ...UR 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 a...

Page 16: ... it for code re registering EAU38530 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary light come on and the engine can be start ed The key cannot be removed TIP The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are...

Page 17: ...the key in and then turn it to OFF while still pushing it EAU34341 Parking The steering is locked and the taillight license plate light and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to NOTICE ECA11020 Do not use the parking position for an ...

Page 18: ...alfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If a problem is detected in the oil level detection circuit the following cycle will be repeated until 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 EAU11425 Coolant temperature warn...

Page 19: ... en gine if it is overheating TIP For radiator fan equipped vehi cles the radiator fan s automati cally switch on or off according to the coolant temperature in the ra diator If the engine overheats see page 6 40 for further instructions U5S5E2E0 book Page 5 Monday August 4 2008 2 07 PM ...

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 40 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 40 U5S5E2E0 book Page 6 Monday August 4 2008 2 ...

Page 21: ...areful not to 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 EAU38621 Immobilizer system ind...

Page 22: ...emperature display an air intake temperature display a self diagnosis device an LCD and tachometer bright ness control mode TIP 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...

Page 23: ...ay between the odometer mode ODO and the tripmeter modes 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 odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from t...

Page 24: ...nt temperature display indi cates the temperature of the coolant TIP When the coolant temperature display is selected C is displayed for one second and then the coolant tempera ture is displayed NOTICE ECA10021 Do not continue to operate the en gine if it is overheating Air intake temperature mode The air intake temperature display indi cates the temperature of the air drawn into the air filter ca...

Page 25: ...r code TIP 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 TIP 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 whi...

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: ...witch 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 EAU12711 Start switch Push this switch to crank the engine with the starter See page 5 1 for start ing instructions prior to starting the en gine EAU44710 The engine tr...

Page 28: ...820 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 switch which is part of the igni tion circuit cut off system See page 3 22 EAU12870 Shift pedal T...

Page 29: ...models 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 wi...

Page 30: ...ise 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 TIP The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly c...

Page 31: ... soft cloth since fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoli...

Page 32: ...AU13445 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system WARNING EWA10862 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust syste...

Page 33: ...rn it counterclockwise 2 While holding the key in that posi tion lift the rear of the seat up and then pull the seat off To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown 2 Push the rear of the seat down to lock it in place 3 Remove the key TIP Make sure that the seat is properly se cured before riding 1 Seat lock 2 Unlock 1 Projection 2 Seat holder...

Page 34: ...partment 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 WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do not exceed the ma...

Page 35: ...d in the owner s tool kit to make the adjustment 3 Install the seat WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This m...

Page 36: ...een designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU44892 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lo...

Page 37: ...0 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 The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch swit...

Page 38: ...ha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 8 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check coolin...

Page 39: ...le free play and lubricate cable and grip housing 6 16 6 25 Control cables Make sure that operation is smooth Lubricate if necessary 6 25 Drive chain Check chain slack Adjust if necessary Check chain condition Lubricate if necessary 6 23 6 24 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 17 6 19 Brake and shift pedals Make sure tha...

Page 40: ... tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 3 22 ITEM CHECKS PAGE U5S5E2E0 book Page 3 Monday August 4 2008 2 07 PM ...

Page 41: ...nt the engine from starting even though the engine will crank when pushing the start switch EAU44724 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sid estand up See page 3 22 for more informa tion 1 Turn t...

Page 42: ...el and the vehicle for oil leak age If necessary add engine oil and then check the warning light again If the coolant temperature warn ing light flickers or remains on after starting immediately stop the engine and then check the coolant level and the vehicle for coolant leakage If necessary add coolant and then check the warning light again If the engine trouble warning light flashes or remains o...

Page 43: ...icated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16810 Tips for reducing fuel con sumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel ...

Page 44: ... be changed and the oil filter car tridge or element replaced ECA10302 1000 1600 km 600 1000 mi Avoid prolonged operation above 8400 r min 1600 km 1000 mi and beyond The vehicle can now be operated nor mally NOTICE ECA10310 Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle E...

Page 45: ...cle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See pa...

Page 46: ... 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 ope...

Page 47: ...ck 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 Br...

Page 48: ...k 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 CHECK OR ...

Page 49: ... 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 the...

Page 50: ...PERIODIC MAINTENANCE AND ADJUSTMENT 6 6 6 Replace the brake hoses every four years and if cracked or damaged U5S5E2E0 book Page 6 Monday August 4 2008 2 07 PM ...

Page 51: ...ts 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 spar...

Page 52: ...il 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 A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several...

Page 53: ...l 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 TIP Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 ...

Page 54: ... then install and tighten the oil filler cap TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down NOTICE 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 1 O ring 1 Torque w...

Page 55: ...d 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 EAU20092 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion TIP The coolant level must be checked on a co...

Page 56: ...as been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10472 EAU42611 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Place a container under the engine to collect the used coolant 3 Remove the radiator cap retaining bolt ra...

Page 57: ... for damage and re place it if necessary 11 Pour the specified amount of the recommended coolant into the ra diator and reservoir 12 Install the coolant reservoir cap 13 Install the radiator cap radiator cap retainer and radiator cap re taining bolt 1 Coolant reservoir cap 2 Coolant reservoir 1 Coolant reservoir cover 2 Bolt 1 Coolant drain bolt Tightening torque Coolant drain bolt 10 Nm 1 0 m kgf...

Page 58: ... engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system EAU34425 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...

Page 59: ...in its original position Make sure that the fuel hoses are properly connected and routed and are not pinched Be sure to place the hoses in their original position WARNING Be fore placing the fuel tank in the original position make sure that all hoses i e fuel hose fuel tank breather hose fuel tank overflow hose are not dam aged that they are properly con nected and routed and that they are not pin...

Page 60: ...n crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21382 Checking the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check th...

Page 61: ...rol The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause a...

Page 62: ...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 EWA10481 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle may be different which could lead to an accident Always make sure that the valve ca...

Page 63: ...eration 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 changed...

Page 64: ...ease the clutch lever free play turn the adjusting bolt in direction b TIP 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 EAU36502 Rear brake light switch The rear brake light which is activated by the brake pedal should come on just before braking takes effect If neces sary have...

Page 65: ... 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 brake ...

Page 66: ... 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 fluid...

Page 67: ... tighten the drive chain turn the drive chain slack adjusting bolt on each side of the swingarm in direc tion a To loosen the drive chain turn the adjusting bolt on each side of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To pre...

Page 68: ...d riding in the rain 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap propriate solvents ECA11121 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubri cants for the drive...

Page 69: ...ll cause the in ner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EWA10721 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 and...

Page 70: ...ver 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 U5S5E2E0 book Page 26 Monday August 4 2008 2 07 PM ...

Page 71: ...ic maintenance and lubrication chart EAU23272 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 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an uprigh...

Page 72: ...ff the ground See page 6 35 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 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 Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be ch...

Page 73: ...ek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 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 ...

Page 74: ... 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 NOTICE ECA16530 Always keep the battery charged Storing a discharged battery can cause permanent battery damage EAU44701 Replacing the fuses The main fuse and fuse box 2 ABS model only are located under the fuel tank See page 6 14 FZ6 NHG...

Page 75: ...adlight 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 headligh...

Page 76: ...ulb 4 Place a new headlight bulb into po sition and then secure it with the bulb holder 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the bolts 7 Have a Yamaha dealer adjust the headlight beam if necessary 1 Do not touch the glass part of the bulb 1 Bolt 1 Headlight bulb cover 2 Headlight coupler 1 Headlight bulb holder 2 Headlight bulb...

Page 77: ... stops 5 Install the socket together with the bulb by turning it clockwise 6 Install the seat EAU24204 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the burnt out 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...

Page 78: ...U34405 Replacing the auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit by re moving the bolts on each side 2 Remove the auxiliary light socket together with the bulb by turning it counterclockwise 3 Remove the burnt out 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...

Page 79: ...ck un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU44790 Front wheel FZ6 NHG WARNING ...

Page 80: ... the sidestand down 5 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 6 Push down hard on the handlebar several times to check for proper fork operation EAU44800 Rear wheel FZ6 NHG WARNING EWA14840 For the ABS model have a Yamaha dealer remove and install the wheel EAU43381 To remove the rear wheel WARNING EWA10821 To avoid injury securel...

Page 81: ...emove and install the rear wheel 7 Remove the wheel NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU32943 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 1 Locknut 2 Drive chain slack adjusting bolt 3 Axle nut 1 Loc...

Page 82: ...e 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 ...

Page 83: ...RIODIC MAINTENANCE AND ADJUSTMENT 6 39 6 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U5S5E2E0 book Page 39 Monday August 4 2008 2 07 PM ...

Page 84: ...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 eng...

Page 85: ... hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap TIP 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 th...

Page 86: ...utlets 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 axles Alway...

Page 87: ...and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for 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 combina...

Page 88: ...stic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26202 Storage Short term Always ...

Page 89: ...rk plugs and then install the spark plugs and the spark plug caps 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 f...

Page 90: ... With 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 Fu...

Page 91: ...t 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi Loading condition FZ6 NAHG 90 191 kg 198 421 lb FZ6 NHG 90 196 kg 198 432 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi High speed riding Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 kgf cm 36 psi 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 50...

Page 92: ... 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 NAHG LED Immobilizer system indicator light LED Fuses Main fuse 30 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A ...

Page 93: ...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 TIP The vehicle identification number is used to identify your motorcycle and may be used to register your m...

Page 94: ...label is affixed to the frame under the seat See page 3 19 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 U5S5E2E0 book Page 2 Monday August 4 2008 2 07 PM ...

Page 95: ...ht bulb replacing 6 31 Helmet holder 3 20 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 34 M Main switch steering lock 3 2 Matte color caution 7 1 Model label 9 2 Mult...

Page 96: ...3 4 Turn signal light bulb replacing 6 33 Turn signal switch 3 13 V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheel front FZ6 NHG 6 35 Wheel rear FZ6 NHG 6 36 Wheels 6 19 U5S5E2E0 book Page 2 Monday August 4 2008 2 07 PM ...

Page 97: ...U5S5E2E0 book Page 3 Monday August 4 2008 2 07 PM ...

Page 98: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2008 08 0 4 1 CR E DIC183 ...

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Yamaha FZ6-NHG, Owner'S Manual

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