2004 YAMAHA FZ6 S engine coolant

TABLE OF CONTENTSSAFETY 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 ................3-2
Indicator and warning lights ............3-3
LCD tachometer .............................3-5
Multi-function display ......................3-6
Anti-theft alarm (optional) ...............3-8
Handlebar switches ........................3-9
Clutch lever ...................................3-10
Shift pedal .....................................3-10
Brake lever ...................................3-11
Brake pedal ..................................3-11
Fuel tank cap ................................3-11
Fuel ...............................................3-12
Fuel tank breather hose ................3-13
Catalytic converter ........................3-13
Seat ..............................................3-14
Storage compartment ...................3-14
Adjusting the shock absorber
assembly ...................................3-15
Sidestand ......................................3-16
Ignition circuit cut-off system ........3-17PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing panels ..... 6-5
Checking the spark plugs ............... 6-6
Engine oil and oil filter cartridge ..... 6-7
Coolant ......................................... 6-10
Replacing the air filter element ..... 6-11
Adjusting the engine idling
speed ........................................ 6-13
Adjusting the throttle cable
free play .................................... 6-14
Adjusting the valve clearance ...... 6-14
Tires ............................................. 6-14
Cast wheels .................................. 6-17
Adjusting the clutch lever
free play .................................... 6-17Adjusting the brake pedal
position ..................................... 6-18
Adjusting the rear brake light
switch ....................................... 6-19
Checking the front and rear
brake pads ................................ 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Drive chain slack .......................... 6-21
Lubricating the drive chain ........... 6-22
Checking and lubricating the
cables ....................................... 6-23
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals .............. 6-24
Checking and lubricating the
brake and clutch levers ............ 6-24
Checking and lubricating the
centerstand and sidestand ....... 6-25
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-27
Battery ......................................... 6-27
Replacing the fuses ..................... 6-28
Replacing the headlight bulb ....... 6-29
Replacing the tail/brake
light bulb ................................... 6-30
Replacing a turn signal
light bulb ................................... 6-315VXE1.book Page 1 Monday, February 9, 2004 5:39 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU32976
Multi-function display
WARNING
EWA12311
Be sure to stop the vehicle before
making any setting changes to themulti-function display.
The multi-function display is equipped
with the following:

a speedometer (which shows the
riding speed)


two tachometers, one LCD and
one digital (which show engine
r/min)


an odometer (which shows the to-
tal distance traveled)


two tripmeters (which show the
distance traveled since they were
last set to zero)


a fuel reserve tripmeter (which
shows the distance traveled since
the bottom segment of the fuel
meter started flashing)


a clock


an air intake temperature display


a fuel meter


a coolant temperature meter


a self-diagnosis device
NOTE:

Be sure to turn the key to “ON” be-
fore using the “SELECT” and “RE-
SET” buttons.


For the U.K. only: To switch the
speedometer and odometer/trip-
meter displays between kilometers
and miles, press the “SELECT”button for at least two seconds.Odometer, tripmeter and digital ta-
chometer modes
Pushing the “SELECT” button switches
the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP 1” and “TRIP 2” (“TRIP F”) and
the tachometer “E” in the following or-
der:
ODO → TRIP 1 → TRIP 2 → (TRIP F)
→ E → ODO
When the fuel amount in the fuel tank
decreases to 3.6 L (0.95 US gal) (0.79
Imp.gal), the bottom segment of the
fuel meter will start flashing, and the
odometer display will automatically
change to the fuel reserve tripmeter
mode “TRIP F” and start counting the
distance traveled from that point. In that
case, pushing the “SELECT” button
switches the display between the vari-
ous tripmeter and odometer modes in
the following order:
TRIP F → E → ODO → TRIP 1 → TRIP
2 → TRIP F
To reset a tripmeter, select it by push-
ing the “SELECT” button, and then
push the “RESET” button for at least
one second. If you do not reset the fuel
reserve tripmeter manually, it will reset
1. Speedometer
2. Fuel meter
3. Coolant temperature meter
4.“SELECT” button
5.“RESET” button
6. Clock/air intake temperature display
7. Odometer/tripmeters/digital tachometer5VXE1.book Page 6 Monday, February 9, 2004 5:39 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-7
3 itself automatically and the display will
return to the prior mode after refueling
and traveling 5 km (3 mi).
Clock
To switch the air intake temperature
display to the clock, first set the display
to the odometer or tachometer mode,
and then push the “RESET” button for
at least two seconds.
NOTE:The clock is automatically displayedwhen the key is turned to “OFF”.
To set the clock:1. Push the “SELECT” button and
“RESET” button together for at
least two seconds.
2. When the hour digits start flashing,
push the “RESET” button to set the
hours.
3. Push the “SELECT” button, and
the minute digits will start flashing.
4. Push the “RESET” button to set
the minutes.
5. Push the “SELECT” button and
then release it to start the clock.Air intake temperature mode
The temperature displayed may vary
from the outside temperature depend-
ing on engine conditions. To switch the
clock to the air intake temperature
mode, first set the display to the odom-
eter or tachometer mode, and then
push the “RESET” button for at least
two seconds.
Fuel meter
The fuel meter indicates the amount of
fuel in the fuel tank. The display seg-
ments of the fuel meter disappear to-
wards “E” (Empty) as the fuel level
decreases. When only one segment is
left near “E”, refuel as soon as possible.
NOTE:This fuel meter is equipped with a self-
diagnosis system. If the electrical circuit
is defective, the display segments will
flash. If this occurs, have a Yamahadealer check the electrical circuit.
Coolant temperature meter
With the key in the “ON” position, the
coolant temperature meter indicates
the temperature of the coolant. Whenthe key is turned to “ON”, all of the dis-
play segments of the coolant tempera-
ture meter will appear one after the
other and then disappear in order to
test the electrical circuit. The coolant
temperature varies with changes in the
weather and engine load. If the top seg-
ment flashes, stop the vehicle and let
the engine cool. (See page 6-37.)
CAUTION:
ECA10020
Do not operate the engine if it isoverheated.
Self-diagnosis devices
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
engine trouble warning light will come
on, and then the multi-function display
will indicate a two-digit error code (e.g.,
12, 13, 14).
This model is also equipped with a self-
diagnosis device for the immobilizer
system.
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INSTRUMENT AND CONTROL FUNCTIONS
3-8
3If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code (e.g., 51, 52, 53).
NOTE:If the multi-function display indicates er-
ror code 52 (all segments of the coolant
temperature meter will come on, except
the top segment, which will flash), this
could be caused by transponder inter-
ference. If this error appears, try the fol-lowing.
1. Use the code re-registering key to
start the engine.
NOTE:Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the enginefrom starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
If the multi-function display indicates
any error code, note the code number,
and then have a Yamaha dealer check
the vehicle.CAUTION:
ECA11590
If the display indicates an error
code, the vehicle should be checked
as soon as possible in order to avoidengine damage.
EAU12330
Anti-theft alarm (optional) This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
1. Error code display5VXE1.book Page 8 Monday, February 9, 2004 5:39 PM

PRE-OPERATION CHECKS
4-2
4
EAU15601
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-12
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-19, 6-20
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-18, 6-19, 6-20
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-17
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
14*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
15 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
16*Sidestand switchCheck operation.√√√√√ √
17*Front forkCheck operation and for oil leakage.√√√√
18*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
19*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
20 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
21Engine oil filter car-
tridgeReplace.√√√
22*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 102030405VXE1.book Page 3 Monday, February 9, 2004 5:39 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20143
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Remove the seat. (See page
3-14.)
3. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.
4. If the coolant is at or below the
minimum level mark, open the
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.
CAUTION:
ECA10470


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.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
1. Maximum level mark
2. Minimum level mark
1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.27 L (0.29 US qt) (0.24 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.NOTE:

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page6-37 for further instructions.
EAU33030
Changing the coolant
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
EAU32881
Replacing the air filter element The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See page
3-14.)
2. Remove panels A and B. (See
page 6-5.)
3. Remove the fuel tank bolts, and
then lift the fuel tank away from the
air filter case.
4. Remove the air filter case cover by
removing the screws.1. Bolt
5VXE1.book Page 11 Monday, February 9, 2004 5:39 PM