OWNER’S MANUAL FZ6-SS(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.10-2.
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U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZ6-S(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZ6-SS(C) OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, September 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM TABLE OF CONTENTS Replacing the license plate light bulb ...........................................6-34 Front wheel ...................................6-35 Rear wheel ...................................6-36 Troubleshooting ............................6-38 Troubleshooting charts .................6-39 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ..............
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM SAFETY INFORMATION EAU10280 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM SAFETY INFORMATION 1 ● ● turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 189 kg (417 lb) (CAL) 190 kg (419 lb) (U49). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
U5VX10E0.book Page 4 Thursday, October 16, 2003 8:38 AM SAFETY INFORMATION 1 Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
U5VX10E0.book Page 5 Thursday, October 16, 2003 8:38 AM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U5VX10E0.book Page 6 Thursday, October 16, 2003 8:38 AM SAFETY INFORMATION 1 4 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 1 5JW-00 2 5 WARNING Improper loading can cause loss of control. Read owner’s manual for proper loading.
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U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10660 OFF All electrical systems are off. The key can be removed. To unlock the steering EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. 3 1. Push. 2.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11001 Indicator and warning lights 3 1. 2. 3. 4. 5. Oil level warning light “ ” Engine trouble warning light “ ” Neutral indicator light “ ” High beam indicator light “ ” Turn signal indicator lights “ ” and “ ” EAU11030 Turn signal indicator lights “ ” and “ ” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU32922 LCD tachometer ECA10031 EAU33670 Multi-function display CAUTION: Do not operate the engine in the tachometer red zone. Red zone: 14000 r/min and above EWA12311 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 3 1. LCD tachometer 2.
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U5VX10E0.book Page 5 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS Air intake temperature display The temperature displayed may vary from the outside temperature depending on engine conditions. Pushing the “RESET” button for at least two seconds switches the clock display to the air intake temperature display. Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear towards “E” (Empty) as the fuel level decreases.
U5VX10E0.book Page 6 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12342 Handlebar switches Left EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. ECA10050 CAUTION: See page 5-1 for starting instructions prior to starting the engine. EAU12460 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”.
U5VX10E0.book Page 7 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12870 Shift pedal EAU26822 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever.
U5VX10E0.book Page 8 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13070 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel tank cap EWA11090 WARNING 3 Make sure that the fuel tank cap is properly closed before riding. 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
U5VX10E0.book Page 9 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
U5VX10E0.book Page 10 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13430 Catalytic converter This model is equipped with a catalytic converter in the exhaust chamber. EWA10860 WARNING 3 EAU32980 Seat To remove the seat 1. Insert the key into the seat lock, and then turn it counterclockwise. The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. 1. Projection 2.
U5VX10E0.book Page 11 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14451 Storage compartment When washing the vehicle, be careful not to let any water enter the storage compartment. EAU14830 Adjusting the shock absorber assembly 3 1. Storage compartment 1. Spring preload adjusting ring 2. Special wrench 3. Position indicator The storage compartment is located under the seat. (See page 3-10.
U5VX10E0.book Page 12 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS crease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b). NOTE: Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber.
U5VX10E0.book Page 13 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U5VX10E0.book Page 14 Thursday, October 16, 2003 8:38 AM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-9 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-10 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Wheels and tires • • • • Check for damage.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU16370 Starting the engine EWA10270 WARNING ● ● 5 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM OPERATION AND IMPORTANT RIDING POINTS ECA11130 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U5VX10E0.book Page 4 Thursday, October 16, 2003 8:38 AM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17211 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EWA10310 WARNING ● ECA10310 CAUTION: ● ● Keep the engine speed out of the tachometer red zone.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel and vacuum hoses for cracks or damage. • Replace if necessary.
U5VX10E0.book Page 4 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 General maintenance and lubrication chart INITIAL No. 1 * ITEM Air filter element ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ • Check condition and damage. √ √ • Replace if necessary. 2 * Clutch • Check operation.
U5VX10E0.book Page 5 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack/alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 11 * Steering bearings • Check bearing assembly for looseness.
U5VX10E0.book Page 6 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 17 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 18 * Shock absorber assembly • Check operation and for oil leakage.
U5VX10E0.book Page 7 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17630 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid.
U5VX10E0.book Page 8 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel C EAU32862 Panels A and B To remove one of the panels Remove the bolts and the quick fastener, and then pull the panel off as shown. 1. Panel A 2.
U5VX10E0.book Page 9 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19651 Checking the spark plugs 1. Panel C 2. Bolt 6 To install the panel 1. Place the panel in the original position, and then install the bolt. 2. Install the seat. The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer.
U5VX10E0.book Page 10 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19680 NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. Canister (for California only) EAU32850 Engine oil and oil filter cartridge The engine oil level should be checked before each ride.
U5VX10E0.book Page 11 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Remove the engine oil dipstick and wipe it clean, insert it back into the hole (without screwing it in), and then remove it again to check the oil level. 6 1. Dipstick 2. Maximum level mark 3. Minimum level mark NOTE: The engine oil should be between the minimum and maximum level marks. 5.
U5VX10E0.book Page 12 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.50 L (2.64 US qt) (2.20 Imp.qt) With oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt) NOTE: An oil filter wrench is available at a Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. ECA11620 CAUTION: 1.
U5VX10E0.book Page 13 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. ECA10400 CAUTION: If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. 10. Turn the engine off, and then check the oil level and correct it if necessary.
U5VX10E0.book Page 14 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Coolant reservoir cap 5. Add coolant or distilled water to raise the coolant to the specified level, close the coolant reservoir cap, and then install the seat. Coolant reservoir capacity (up to the maximum level mark): 0.27 L (0.29 US qt) (0.24 Imp.qt) ECA10470 CAUTION: ● ● If coolant is not available, use distilled water or soft tap water instead.
U5VX10E0.book Page 15 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32882 ECA10480 Replacing the air filter element The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-10.) 2. Remove panels A and B. (See page 6-8.) 3.
U5VX10E0.book Page 16 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● Be sure to place the fuel tank breather hose and the fuel tank overflow hose in the original position. EAU21380 Adjusting the throttle cable free play EAU21400 Adjusting the valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise.
U5VX10E0.book Page 17 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21750 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING ● 6 ● The tire air pressure must be checked and adjusted on cold tires (i.e.
U5VX10E0.book Page 18 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tire inspection EWA10580 WARNING ● ● 1. Tire sidewall 2. Tire wear indicator 3. Tire tread depth Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. It is dangerous to ride with a worn-out tire.
U5VX10E0.book Page 19 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR Front tire: Size: 120/70 ZR17M/C (58W) Manufacturer/model: BRIDGESTONE/BT020F GG DUNLOP/D252F Rear tire: Size: 180/55 ZR17M/C (73W) Manufacturer/model: BRIDGESTONE/BT020R GG DUNLOP/D252 FRONT and REAR: Tire air valve: TR412 Valve core: #9000A (original) ● ● “broken in”.
U5VX10E0.book Page 20 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22010 Accessories and replacement parts any consequences caused by the use of items which have not been approved by Yamaha. EAU22080 Adjusting the clutch lever free play EWA10620 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
U5VX10E0.book Page 21 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22251 NOTE: If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. Adjusting the brake pedal position 1. Distance between brake pedal and footrest 6 The top of the brake pedal should be positioned approximately 25.8 mm (1.02 in) below the bottom of the footrest bracket as shown.
U5VX10E0.book Page 22 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front and rear brake pads indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Rear brake pads EAU22270 Adjusting the rear brake light switch EAU22390 EAU22500 EAU22420 Front brake pads 1. Rear brake light switch 2.
U5VX10E0.book Page 23 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22580 Checking the brake fluid level Front brake 1. Minimum level mark Rear brake 6 Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
U5VX10E0.book Page 24 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22730 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years.
U5VX10E0.book Page 25 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23021 Tightening torque: Axle nut: 120 Nm (12.0 m·kgf, 87 ft·lbf) Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. ECA10581 1. 2. 3. 4.
U5VX10E0.book Page 26 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11110 CAUTION: Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings.
U5VX10E0.book Page 27 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 Checking and lubricating the brake and shift pedals EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the brake and clutch levers Brake lever Clutch lever 6 The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U5VX10E0.book Page 28 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23210 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the centerstand and sidestand 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 maintenance and lubrication chart.
U5VX10E0.book Page 29 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
U5VX10E0.book Page 30 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAU23440 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. This model is equipped with a sealedtype (MF) battery, which does not require any maintenance.
U5VX10E0.book Page 31 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR 4. After installation, make sure that the battery leads are properly connected to the battery terminals. ECA10630 EAU32841 Replacing the fuses The main fuse box is located under the fuel tank. CAUTION: ● ● 6 Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required.
U5VX10E0.book Page 32 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23740 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 Electronic fuel injection fuse: 10.0 A Backup fuse: 10.0 A Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1.
U5VX10E0.book Page 33 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.
U5VX10E0.book Page 34 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24201 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. EAU24310 Replacing the license plate light bulb 1. Remove the license plate light unit by removing the screws. 1. Tail/brake light bulb socket 2. Muffler bracket 4. Remove the defective bulb by pushing it in and turning it counterclockwise. 5.
U5VX10E0.book Page 35 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the defective bulb by pulling it out. 4. Insert a new bulb into the socket. 5. Install the socket (together with the bulb) by pushing it in. 6. Install the license plate light unit by installing the screws. EAU24360 Front wheel EAU33680 To remove the front wheel EWA10820 WARNING ● ● 6 3. Remove the brake hose holder and reflector on each side by removing the bolts. 4.
U5VX10E0.book Page 36 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU33690 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle. 3. Lower the front wheel so that it is on the ground. 4. Install the brake calipers by installing the bolts. 7. Push down hard on the handlebar several times to check for proper fork operation.
U5VX10E0.book Page 37 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11070 NOTE: The drive chain does not need to be disassembled in order to remove and install the rear wheel. 6. While supporting the brake caliper and slightly lifting the wheel, pull the wheel axle out. Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. EAU32940 To install the rear wheel 1.
U5VX10E0.book Page 38 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Troubleshooting 1. Retainer 2. Slot 2. Install the drive chain onto the rear sprocket, and then adjust the drive chain slack. (See page 6-24.) 3. Install the axle nut, and then lower the rear wheel so that it is on the ground. 4. Tighten the axle nut to the specified torque. Tightening torque: Axle nut: 120 Nm (12.
U5VX10E0.book Page 39 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
U5VX10E0.book Page 40 Thursday, October 16, 2003 8:38 AM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26040 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, 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.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM MOTORCYCLE CARE AND STORAGE ECA10800 CAUTION: ● ● ● Apply spray oil and wax sparingly and make sure to wipe off 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.
U5VX10E0.book Page 4 Thursday, October 16, 2003 8:38 AM MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/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. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 6.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM SPECIFICATIONS Dimensions: Overall length: 2095 mm (82.5 in) Overall width: 750 mm (29.5 in) Overall height: 1215 mm (47.8 in) Seat height: 795 mm (31.3 in) Wheelbase: 1440 mm (56.7 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 2800 mm (110.2 in) Weight: With oil and fuel: 207.0 kg (456 lb) (U49) 208.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM SPECIFICATIONS 2nd: 37/19 (1.947) 3rd: 28/18 (1.556) 4th: 32/24 (1.333) 5th: 25/21 (1.190) 6th: 26/24 (1.083) Chassis: Frame type: Diamond Caster angle: 25.0 ° Trail: 97.5 mm (3.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM SPECIFICATIONS Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: Model: GT12B-4 Voltage, capacity: 12 V, 10.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: 8 Headlight: 12 V, 60 W/55.0 W × 1 Headlight: 12 V, 55.0 W × 1 Tail/brake light: 12 V, 5.0/21.0 W × 1 Front turn signal/position light: 12 V, 21 W/5.0 W × 2 Rear turn signal light: 12 V, 21.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION EAU26540 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U5VX10E0.book Page 3 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U5VX10E0.book Page 5 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U5VX10E0.book Page 7 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U5VX10E0.book Page 9 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U5VX10E0.book Page 10 Thursday, October 16, 2003 8:38 AM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
U5VX10E0.book Page 1 Thursday, October 16, 2003 8:38 AM INDEX A F Accessories and replacement parts ..... 6-20 Air filter element, replacing ................... 6-15 B Battery .................................................. 6-30 Brake and clutch levers, checking and lubricating .................................... 6-27 Brake and shift pedals, checking and lubricating .................................... 6-27 Brake fluid, changing ............................ 6-24 Brake fluid level, checking .........
U5VX10E0.book Page 2 Thursday, October 16, 2003 8:38 AM INDEX Turn signal indicator lights ...................... 3-2 Turn signal light bulb, replacing ............ 6-34 Turn signal switch ................................... 3-6 V Valve clearance, adjusting .................... 6-16 Vehicle identification number .................. 9-1 W Warranty, extended................................. 9-9 Warranty, limited ..................................... 9-7 Wheel bearings, checking.....................
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OWNER’S MANUAL FZ6-SS(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.10-2.
