2004 YAMAHA FZ6 S clutch

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine iscold!NOTE:The engine is warm when it quickly re-sponds to the throttle.
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel, and then slightly raise it.
CAUTION:
ECA10260


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 dis-
tances. The transmission is
properly lubricated 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 theshock of forced shifting.
EAU16751
Recommended shift points (for
Switzerland only)
The recommended shift points during
acceleration are shown in the table be-
low.
1. Shift pedal
2. Neutral position
5VXE1.book Page 2 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17701
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
5VXE1.book Page 2 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
67. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
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
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately 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 theoil level is sufficient.CAUTION:
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
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)
5VXE1.book Page 9 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively 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 pres-
sure according to the operatingconditions.
EAU21960
Cast wheels To maximize the performance, durabil-
ity, and safe operation 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 or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU22080
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
To increase the clutch lever free play,
turn the adjusting bolt in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).1. Clutch lever free play adjusting bolt
2. Clutch lever free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
NOTE:If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internalclutch mechanism.
EAU22250
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 25.8 mm
(1.02 in) below the bottom of the foot-
rest bracket as shown. Periodically
check the brake pedal position and, if
necessary, have a Yamaha dealer ad-
just it.
WARNING
EWA10690
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air inthe hydraulic system will diminish
the braking performance, which may
result in loss of control and an acci-
dent.
1. Distance between brake pedal and footrest
5VXE1.book Page 18 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
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 (all-pur-
pose grease)
5VXE1.book Page 24 Monday, February 9, 2004 5:39 PM

SPECIFICATIONS
8-1
8
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)Engine:Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 4-cylinder
Displacement:
600.0 cm³ (36.61 cu.in)
Bore × stroke:
65.5 × 44.5 mm (2.58 × 1.75 in)
Compression ratio:
12.20 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine 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)Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.27 L (0.29 US qt) (0.24 Imp.qt)
Radiator capacity (including all routes):
2.00 L (2.11 US qt) (1.76 Imp.qt)Air filter:Air filter element:
Oil-coated paper element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
19.4 L (5.13 US gal) (4.27 Imp.gal)
Fuel reserve amount:
3.6 L (0.95 US gal) (0.79 Imp.gal)Electronic fuel injection:Manufacturer:
MIKUNI
Model:
36EIDW x 2Spark plug(s):Manufacturer/model:
NGK/CR9EK
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
86/44 (1.955)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
46/16 (2.875)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
5VXE1.book Page 1 Monday, February 9, 2004 5:39 PM

INDEX
AAir filter element, replacing ................... 6-11
Anti-theft alarm (optional) ....................... 3-8
Auxiliary light bulb, replacing ................ 6-32BBattery .................................................. 6-27
Brake and clutch levers, checking
and lubricating .................................... 6-24
Brake and shift pedals, checking
and lubricating .................................... 6-24
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever ........................................... 3-11
Brake pedal .......................................... 3-11
Brake pedal position, adjusting............. 6-18CCables, checking and lubricating .......... 6-23
Care ........................................................ 7-1
Catalytic converter ................................ 3-13
Centerstand and sidestand,
checking and lubricating ..................... 6-25
Clutch lever........................................... 3-10
Clutch lever free play, adjusting ........... 6-17
Coolant ................................................. 6-10DDimmer switch ........................................ 3-9
Drive chain, lubricating ......................... 6-22
Drive chain slack .................................. 6-21EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-13
Engine oil and oil filter cartridge ............. 6-7
Engine stop switch.................................. 3-9
Engine trouble warning light ................... 3-4
FFront and rear brake pads,
checking .............................................. 6-19
Front fork, checking...............................6-25
Fuel ....................................................... 3-12
Fuel consumption, tips for reducing ........ 5-3
Fuel tank breather hose ........................ 3-13
Fuel tank cap......................................... 3-11
Fuses, replacing .................................... 6-28HHandlebar switches ................................. 3-9
Hazard switch........................................ 3-10
Headlight bulb, replacing....................... 6-29
High beam indicator light......................... 3-4
Horn switch ............................................. 3-9IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-17
Immobilizer system .................................3-1
Immobilizer system indicator light ........... 3-4
Indicator and warning lights .................... 3-3KKey identification number ........................ 9-1LLCD tachometer ...................................... 3-5
License plate light bulb, replacing ......... 6-31MMain switch/steering lock ........................ 3-2
Model label .............................................. 9-2
Multi-function display...............................3-6NNeutral indicator light .............................. 3-3OOil level warning light .............................. 3-4
PPanels, removing and installing .............. 6-5
Parking.................................................... 5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-9
Periodic maintenance and lubrication
chart...................................................... 6-2
Pre-operation check list .......................... 4-2RRear brake light switch, adjusting ......... 6-19SSafety information ................................... 1-1
Seat ...................................................... 3-14
Shifting .................................................... 5-2
Shift pedal ............................................. 3-10
Shock absorber assembly, adjusting .... 3-15
Sidestand .............................................. 3-16
Spark plugs, checking............................. 6-6
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ............................................. 3-9
Steering, checking ................................ 6-26
Storage ................................................... 7-3
Storage compartment ........................... 3-14TTail/brake light bulb, replacing .............. 6-30
Throttle cable free play, adjusting ......... 6-14
Throttle grip and cable, checking
and lubricating .................................... 6-23
Tires ...................................................... 6-14
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-36
Troubleshooting charts ......................... 6-37
Turn signal indicator lights ...................... 3-3
5VXE1.book Page 1 Monday, February 9, 2004 5:39 PM