2005 YAMAHA FZ6 S oil filter
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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 ......................3-5
Anti-theft alarm (optional) ...............3-8
Handlebar switches ........................3-8
Clutch lever ...................................3-10
Shift pedal .....................................3-10
Brake lever ...................................3-10
Brake pedal ..................................3-11
Fuel tank cap ................................3-11
Fuel ...............................................3-12
Fuel tank breather hose ................3-13
Catalytic converter ........................3-13
Seat ..............................................3-13
Storage compartment ...................3-14
Adjusting the shock absorber
assembly ...................................3-15
Sidestand ......................................3-16
Ignition circuit cut-off system ........3-16PRE-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 ..... 6-12
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 rear brake light
switch ....................................... 6-18
Checking the front and rear
brake pads ................................ 6-18
Checking the brake fluid level ...... 6-19
Changing the brake fluid .............. 6-20
Drive chain slack .......................... 6-20
Lubricating the drive chain ........... 6-22
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-23
Checking and lubricating the
brake and shift pedals .............. 6-23
Checking and lubricating the
brake and clutch levers ............ 6-24
Checking and lubricating the
centerstand and sidestand ....... 6-24
Lubricating the swingarm
pivots ........................................ 6-25
Checking the front fork ................. 6-25
Checking the steering .................. 6-26
Checking the wheel bearings ....... 6-26
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 ........................................... 6-31U5VXE2E0.book Page 1 Wednesday, July 7, 2004 11:32 AM
Page 12 of 90
DESCRIPTION
2-1
2
EAU10410
Left view1. Main fuse (page 6-28)
2. Battery (page 6-27)
3. Air filter element (page 6-12)
4. Idle adjusting screw (page 6-13)
5. Shock absorber assembly spring preload adjusting ring (page 3-15)
6. Owner’s tool kit (page 6-1)
7. Shift pedal (page 3-10)
8. Engine oil drain bolt (page 6-7)9. Engine oil filter cartridge (page 6-7)U5VXE2E0.book Page 1 Wednesday, July 7, 2004 11:32 AM
Page 37 of 90
OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU16810
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17091
0–1000 km (0–600 mi)
Avoid prolonged operation above 7000
r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 8400
r/min.
CAUTION:
ECA10301
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
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Page 41 of 90
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 Drive chainCheck chain slack, alignment and condition.
Adjust and lubricate chain with a special O-ring chain lu-
bricant thoroughly. Every 800 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
22Engine oil filter car-
tridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
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Page 45 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6 Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
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 speci-fied torque as soon as possible.CAUTION:
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twistit back and forth while pushing it in.
EAU32852
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles.
1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)
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Page 46 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
64. 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.
NOTE:The engine oil should be between theminimum and maximum level marks.
5. If the engine oil is at or below the
minimum level mark, remove the
oil filler cap, and then add sufficient
oil of the recommended type to
raise it to the correct level.6. Insert and tighten the engine oil
dipstick, and then install and tight-
en the oil filler cap.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:
Skip steps 4–6 if the oil filter cartridge isnot being replaced.
4. Remove the oil filter cartridge with
an oil filter wrench.
1. Dipstick
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
1. Engine oil drain bolt
1. Engine oil filter cartridge
2. Oil filter wrench
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Page 47 of 90
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:An oil filter wrench is available at aYamaha dealer.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.NOTE:Make sure that the O-ring is properlyseated.
6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.7. 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.
1. O-ring
1. Torque wrench
Tightening 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)
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Page 81 of 90
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
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