OWNER’S MANUAL FZ6-NHG FZ6-NAHG 5S5-28199-E1
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM EAU26944 YAMAHA MOTOR ELECTRONICS CO., LTD. 1450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan DECLARATION of CONFORMITY We Company: YAMAHA MOTOR ELECTRONICS CO., LTD. Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the FZ6-NHG/FZ6-NAHG, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FZ6-NHG/FZ6-NAHG.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM IMPORTANT MANUAL INFORMATION EAU10151 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.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM IMPORTANT MANUAL INFORMATION EAU10200 FZ6-NHG/FZ6-NAHG OWNER’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.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Immobilizer system .........................3-1 Main switch/steering lock ................
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM TABLE OF CONTENTS Replacing a turn signal light bulb ...........................................6-34 Replacing the license plate light bulb ...........................................6-34 Replacing the auxiliary light bulb ...........................................6-35 Supporting the motorcycle ............6-35 Front wheel (FZ6-NHG).................6-36 Rear wheel (FZ6-NHG) .................6-37 Troubleshooting ............................
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM SAFETY INFORMATION EAU10281 1 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.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM SAFETY INFORMATION ● ● 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.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: FZ6-NAHG 191 kg (421 lb) FZ6-NHG 196 kg (432 lb) 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.
U5S5E1E0.book Page 4 Friday, June 22, 2007 1:03 PM SAFETY INFORMATION ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Helmet holder (page 3-19) 10.Shift pedal (page 3-14) 11.Engine oil drain bolt (page 6-7) 12.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10974 Immobilizer system 1. Code re-registering key (red bow) 2. Standard keys (black bow) This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS ● Keep other immobilizer system keys away from the main switch as they may cause signal interference. EAU10471 Main switch/steering lock 3 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. NOTE: Be sure to use the standard key (black bow) for regular use of the vehicle.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS To lock the steering To unlock the steering 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 “ ”. ECA11020 1. Push. 2. Turn. 1. Turn the handlebars all the way to the left. 2.
U5S5E1E0.book Page 4 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11003 Indicator and warning lights EAU11060 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. 3 ● This model is also equipped with a self-diagnosis device for the oil level detection circuit.
U5S5E1E0.book Page 5 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10020 CAUTION: Do not operate the engine if it is overheated.
U5S5E1E0.book Page 6 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS Coolant temperature Display Conditions What to do Under 39 °C (Under 103 °F) Message “Lo” is displayed. OK. Go ahead with riding. 40–116 °C (104–242 °F) Temperature is displayed. 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.
U5S5E1E0.book Page 7 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11530 Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. (See page 3-8 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”.
U5S5E1E0.book Page 8 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU39426 Multi-function meter unit ● ● ● ● 3 1. Coolant temperature display/air intake temperature display 2. Speedometer 3. Tachometer 4. Odometer/tripmeter/fuel reserve tripmeter 5. “SELECT” button 6. “RESET” button 7. Clock 8. Fuel meter EWA12421 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit.
U5S5E1E0.book Page 9 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS Clock 4. Push the “SELECT” button, and the minute digits will start flashing. 5. Push the “RESET” button to set the minutes. 6. Push the “SELECT” button and then release it to start the clock. Odometer and tripmeter modes 1. Clock 2. Speedometer The clock displays when the key is turned to “ON”.
U5S5E1E0.book Page 10 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS Fuel meter go off for approximately 3 seconds. If this occurs, have a Yamaha dealer check the electrical circuit. ECA10020 CAUTION: Do not operate the engine if it is overheated. Coolant temperature mode Air intake temperature mode 3 1. 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.
U5S5E1E0.book Page 11 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the air intake temperature was displayed prior to turning the key to “OFF”. When the air intake temperature display is selected, “A” is displayed for one second, and then the air intake temperature is displayed.
U5S5E1E0.book Page 12 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS LCD and tachometer brightness control mode 4. Push the “RESET” button to select the desired brightness level. 5. Push the “SELECT” button to confirm the selected brightness level. The display will return to the odometer or tripmeter mode. 3 1. 2. 3. 4.
U5S5E1E0.book Page 13 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12347 Handlebar switches position. To cancel the turn signal lights, push the switch in after it has returned to the center position. Right Left EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 1. Engine stop switch “ 2. Start switch “ ” 1. 2. 3. 4. 5.
U5S5E1E0.book Page 14 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU44710 The engine trouble warning light and ABS warning light (ABS model only) will come on when the key is turned to “ON” and the start switch is pushed, but this does not indicate a malfunction. EAU12820 EAU12870 Clutch lever Shift pedal 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.
U5S5E1E0.book Page 15 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU26822 Brake lever EAU12941 Brake pedal EAU26792 ABS (for ABS models) The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The Yamaha ABS (Anti-lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently.
U5S5E1E0.book Page 16 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS ● 3 This ABS has a test mode which allows the owner to experience the pulsating at the brake lever or brake pedal when the ABS is operating. However, special tools are required, so please consult your Yamaha dealer when performing this test. EAU13072 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.
U5S5E1E0.book Page 17 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13220 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13320 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole and to fill the tank to the bottom of the filler tube as shown.
U5S5E1E0.book Page 18 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13412 Fuel tank breather hose EAU13442 Catalytic converters EAU32980 Seat This vehicle is equipped with catalytic converters in the exhaust system. EWA10860 WARNING 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. 3 ECA10700 1.
U5S5E1E0.book Page 19 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14281 Helmet holder EAU42910 Storage compartment 3 1. Projection 2. Seat holder 2. Push the rear of the seat down to lock it in place. 3. Remove the key. NOTE: Make sure that the seat is properly secured before riding. 1. Helmet holder 2. Unlock. To open the helmet holder, insert the key into the lock, and then turn the key as shown.
U5S5E1E0.book Page 20 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS ● Do not exceed the maximum load of FZ6-NAHG 191 kg (421 lb) FZ6-NHG 196 kg (432 lb) for the vehicle. EAU36462 Adjusting the shock absorber assembly NOTE: ● Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. ● Use the special wrench included in the owner’s tool kit to make the adjustment. 3 1. Spring preload adjusting ring 2. Special wrench 3.
U5S5E1E0.book Page 21 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the gas cylinder. ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure.
U5S5E1E0.book Page 22 Friday, June 22, 2007 1:03 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15312 Ignition circuit cut-off system 3 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. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
U5S5E1E0.book Page 23 Friday, June 22, 2007 1:03 PM 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? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM PRE-OPERATION CHECKS EAU15593 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.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM PRE-OPERATION CHECKS EAU15605 Pre-operation check list 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. 6-7 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM 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. 6-16, 6-25 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.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU44720 Starting the engine EWA10270 WARNING ● ● ● 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.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM OPERATION AND IMPORTANT RIDING POINTS serve the battery. Do not crank the engine more than 10 seconds on any one attempt. ● ECA16040 CAUTION: ● 5 ● ● If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM OPERATION AND IMPORTANT RIDING POINTS ECA10260 CAUTION: ● ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U5S5E1E0.book Page 4 Friday, June 22, 2007 1:03 PM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17212 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: ● 5 ● Keep the engine speed out of the tachometer red zone.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17520 Owner’s tool kit 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 inspection, adjustment, and lubrication are explained on the following pages.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU1770A Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a mileage-based maintenance, is performed instead. ● From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING NO. ITEM 8 * Brake hoses CHECK OR MAINTENANCE JOB 1000 km (600 mi) • Check for cracks or damage. 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) √ √ √ √ • Replace. • Check runout and for damage. √ √ √ √ 10 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary.
U5S5E1E0.book Page 4 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING NO. 6 ITEM CHECK OR MAINTENANCE JOB 1000 km (600 mi) 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) ANNUAL CHECK 17 Brake pedal pivot shaft • Lubricate with lithium-soap-based grease. √ √ √ √ √ 18 Clutch lever pivot shaft • Lubricate with lithium-soap-based grease.
U5S5E1E0.book Page 5 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING NO. 29 ITEM Moving parts and cables Throttle grip hous30 * ing and cable CHECK OR MAINTENANCE JOB 1000 km (600 mi) ANNUAL CHECK 10000 km (6000 mi) 20000 km (12000 mi) 30000 km (18000 mi) 40000 km (24000 mi) • Lubricate. √ √ √ √ √ • Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable.
U5S5E1E0.book Page 6 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18751 EAU19642 Removing and installing the panel Checking the spark plugs The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Panel A 2. Bolt To install the panel 1. Place the panel in the original position, and then install the bolt. 6 1.
U5S5E1E0.book Page 7 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. EAU32853 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.
U5S5E1E0.book Page 8 Friday, June 22, 2007 1:03 PM 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. 1. Engine oil filler cap 1. Engine oil drain bolt 6. Insert and tighten the engine oil dipstick, and then install and tighten the oil filler cap. 6 1. Dipstick 2. Maximum level mark 3.
U5S5E1E0.book Page 9 Friday, June 22, 2007 1:03 PM 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. 1. Torque wrench Tightening torque: Oil filter cartridge: 17 Nm (1.
U5S5E1E0.book Page 10 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient.
U5S5E1E0.book Page 11 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Add coolant to the maximum level mark, and then install the reservoir cap. Coolant reservoir capacity (up to the maximum level mark): 0.25 L (0.26 US qt) (0.22 Imp.qt) ECA10471 CAUTION: ● ● ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.
U5S5E1E0.book Page 12 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Coolant reservoir cover 2. Bolt 6 6. Drain the coolant from the coolant reservoir by turning it upside down. 7. Install the coolant reservoir and its reservoir cover by placing them in the original position, and then installing the bolts. 8. Remove the coolant drain bolt to drain the cooling system. 1. Coolant drain bolt 9.
U5S5E1E0.book Page 13 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. 12. Install the coolant reservoir cap. 13. Install the radiator cap, radiator cap retainer and radiator cap retaining bolt. 16. Check the coolant level in the reservoir. If necessary, remove the coolant reservoir cap, add coolant to the maximum level mark, and then install the cap. 17.
U5S5E1E0.book Page 14 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA12880 EWA12462 CAUTION: WARNING ● When removing the air filter case cover, be careful not to allow foreign objects to drop into the air intake manifold. 1. Air filter element 2. Air intake manifold ● 5. Insert a new air filter element into the air filter case. ECA10480 Before placing the fuel tank in the original position, make sure that all hoses (i.e.
U5S5E1E0.book Page 15 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA12471 WARNING Be sure to place the hoses in their original position as shown. 1. Original position (paint mark) 8. 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.
U5S5E1E0.book Page 16 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21382 Checking the throttle cable free play EAU21401 EAU21771 Valve clearance Tires 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.
U5S5E1E0.book Page 17 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 225 kPa (33 psi) (2.25 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) FZ6-NAHG 90–191 kg (198–421 lb) FZ6-NHG 90–196 kg (198–432 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 225 kPa (33 psi) (2.25 kgf/cm²) Rear: 250 kPa (36 psi) (2.
U5S5E1E0.book Page 18 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10470 WARNING ● ● 6 Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the vehicle with excessively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheel and brake related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
U5S5E1E0.book Page 19 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● “broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions.
U5S5E1E0.book Page 20 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU36501 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. Rear brake light switch The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect.
U5S5E1E0.book Page 21 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR the point that a wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set. EAU40260 Checking the brake fluid level Front brake EAU22500 Rear brake pads 1. Minimum level mark Rear brake 1. Lining thickness 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.
U5S5E1E0.book Page 22 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● fluid and may result in vapor lock, and dirt may clog the ABS hydraulic unit valves. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
U5S5E1E0.book Page 23 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment. 3. Tighten the locknuts, then the axle nut to their specified torques. Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle nut: 120 Nm (12.0 m·kgf, 85 ft·lbf) 1. Drive chain slack 4. If the drive chain slack is incorrect, adjust it as follows.
U5S5E1E0.book Page 24 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23022 Cleaning and 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.
U5S5E1E0.book Page 25 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23111 Checking and lubricating the throttle grip and cable EAU44270 Checking and lubricating the brake and shift pedals Recommended lubricant: Lithium-soap-based grease (all-purpose grease) The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
U5S5E1E0.book Page 26 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23141 Checking and lubricating the brake and clutch levers Brake lever EAU23200 Recommended lubricants: Brake lever: Silicone grease Clutch lever: Lithium-soap-based grease (allpurpose grease) Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.
U5S5E1E0.book Page 27 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 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.
U5S5E1E0.book Page 28 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings 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.
U5S5E1E0.book Page 29 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU34372 Battery FZ6-NHG 1. Positive battery lead (red) 2. Negative battery lead (black) FZ6-NAHG The battery is located under the fuel tank. (See page 6-13.) This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.
U5S5E1E0.book Page 30 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. After installation, make sure that the battery leads are properly connected to the battery terminals. ECA10630 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. Using a conventional battery charger will damage the battery.
U5S5E1E0.book Page 31 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. 5. Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse (for odometer, clock and immobilizer system) 6. Fuel injection system fuse 7. Spare fuse 8. Taillight fuse 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. 3.
U5S5E1E0.book Page 32 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU34380 EWA10790 Replacing the headlight bulb WARNING This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the bolts on each side. Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 1. Headlight bulb cover 2.
U5S5E1E0.book Page 33 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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 counterclockwise. 4. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 5. Install the socket (together with the bulb) by turning it clockwise. 6. Install the seat. 1. Do not touch the glass part of the bulb. 5.
U5S5E1E0.book Page 34 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24202 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. License plate light bulb 2. License plate light bulb socket 6 1. Screw 2. Turn signal light lens 1. Screw 2. License plate light unit 2.
U5S5E1E0.book Page 35 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU34403 Replacing the auxiliary light bulb If the auxiliary light bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the bolts on each side. 2. Remove the auxiliary light socket (together with the bulb) by turning it counterclockwise. 1. Auxiliary light bulb 2. Auxiliary light bulb socket 3. Remove the defective bulb by pulling it out. 4. Insert a new bulb into the socket. 5.
U5S5E1E0.book Page 36 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU44790 ECA11050 Front wheel (FZ6-NHG) CAUTION: EWA14840 Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut. WARNING For the ABS model, have a Yamaha dealer remove and install the wheel. 4. Pull the wheel axle out, and then remove the wheel.
U5S5E1E0.book Page 37 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU44800 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) 6. Push down hard on the handlebar several times to check for proper fork operation. Rear wheel (FZ6-NHG) EWA14840 WARNING For the ABS model, have a Yamaha dealer remove and install the wheel.
U5S5E1E0.book Page 38 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: ● Make sure that the slot in the brake caliper bracket is fit over the retainer on the swingarm. ● Make sure that there is enough space between the brake pads before installing the wheel. 1. 2. 3. 4. 5. 6 Locknut Drive chain slack adjusting bolt Wheel axle Brake caliper bracket Brake caliper NOTE: A rubber mallet may be useful to tap the wheel axle out. 6.
U5S5E1E0.book Page 39 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Tightening torque: Axle nut: 120 Nm (12.0 m·kgf, 85 ft·lbf) Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U5S5E1E0.book Page 40 Friday, June 22, 2007 1:03 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU42360 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. Check the fuel level in the fuel tank.
U5S5E1E0.book Page 41 Friday, June 22, 2007 1:03 PM 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.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 CAUTION: Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM MOTORCYCLE CARE AND STORAGE ● ● contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM MOTORCYCLE CARE AND STORAGE 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it.
U5S5E1E0.book Page 4 Friday, June 22, 2007 1:03 PM MOTORCYCLE CARE AND STORAGE 3. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM SPECIFICATIONS Dimensions: Overall length: 2095 mm (82.5 in) Overall width: 755 mm (29.7 in) Overall height: 1085 mm (42.7 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: FZ6-NAHG 206.0 kg (454 lb) FZ6-NHG 201.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM SPECIFICATIONS Gear ratio: 1st: 37/13 (2.846) 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: 25.00 ° Trail: 97.5 mm (3.
U5S5E1E0.book Page 3 Friday, June 22, 2007 1:03 PM SPECIFICATIONS Wheel travel: 130.0 mm (5.12 in) Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: AC magneto Battery: Model: GT12B-4 Voltage, capacity: 12 V, 10.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: 8 Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 5.0 W/21.0 W × 1 Front turn signal light: 12 V, 10.0 W × 2 Rear turn signal light: 12 V, 10.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 2. Code re-registering key (red bow) 3. Standard keys (black bow) 1.
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM CONSUMER INFORMATION EAU26540 Model label 1. Model label The model 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.
U5S5E1E0.book Page 1 Friday, June 22, 2007 1:03 PM INDEX A F ABS (for ABS models) .......................... 3-15 ABS warning light (for ABS models)....... 3-7 Air filter element, replacing ................... 6-13 Anti-theft alarm (optional) ..................... 3-12 Auxiliary light bulb, replacing ................ 6-35 B Battery .................................................. 6-29 Brake and clutch levers, checking and lubricating.....................
U5S5E1E0.book Page 2 Friday, June 22, 2007 1:03 PM INDEX Troubleshooting .................................... 6-39 Troubleshooting charts ......................... 6-40 Turn signal indicator lights ...................... 3-4 Turn signal light bulb, replacing ............ 6-34 Turn signal switch ................................. 3-13 V Valve clearance .................................... 6-16 Vehicle identification number .................. 9-1 W Wheel bearings, checking.....................
U5S5E1E0.
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007.07-0.
