2007 YAMAHA FZ6 SHG brake fluid

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
Multi-function meter unit .................3-6
Anti-theft alarm (optional) .............3-11
Handlebar switches ......................3-11
Clutch lever ...................................3-12
Shift pedal .....................................3-13
Brake lever ...................................3-13
Brake pedal ..................................3-13
Fuel tank cap ................................3-14
Fuel ...............................................3-14
Fuel tank breather hose ................3-15
Catalytic converter ........................3-16
Seat ..............................................3-16
Helmet holder ...............................3-17
Storage compartment ...................3-17
Adjusting the shock absorber
assembly ...................................3-18
Sidestand ......................................3-19
Ignition circuit cut-off system ........3-19PRE-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 ..... 6-6
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge ..... 6-9
Coolant ......................................... 6-11
Replacing the air filter element ..... 6-15
Adjusting the engine idling
speed ........................................ 6-16
Checking the throttle cable free
play ........................................... 6-17
Valve clearance ............................ 6-17
Tires ............................................. 6-17
Cast wheels .................................. 6-20
Adjusting the clutch lever free
play ........................................... 6-20Rear brake light switch ................ 6-21
Checking the front and rear brake
pads .......................................... 6-21
Checking the brake fluid level ...... 6-22
Changing the brake fluid .............. 6-23
Drive chain slack .......................... 6-23
Cleaning and lubricating the drive
chain ......................................... 6-25
Checking and lubricating the
cables ....................................... 6-25
Checking and lubricating the
throttle grip and cable ............... 6-26
Checking and lubricating the
brake and shift pedals .............. 6-26
Checking and lubricating the
brake and clutch levers ............ 6-27
Checking and lubricating the
centerstand and sidestand ....... 6-27
Lubricating the swingarm
pivots ........................................ 6-28
Checking the front fork ................. 6-28
Checking the steering .................. 6-29
Checking the wheel bearings ....... 6-29
Battery ......................................... 6-30
Replacing the fuses ..................... 6-31
Replacing the headlight bulb ....... 6-32
Replacing the tail/brake light
bulb ........................................... 6-33
Replacing a turn signal light
bulb ........................................... 6-34U4S8E0E0.book Page 1 Tuesday, August 1, 2006 3:16 PM

DESCRIPTION
2-2
2
EAU10420
Right view1. Fuse box (page 6-31)
2. Storage compartment (page 3-17)
3. Rear brake fluid reservoir (page 6-22)
4. Engine oil filler cap (page 6-9)
5. Front brake fluid reservoir (page 6-22)
6. Radiator cap (page 6-11)
7. Coolant reservoir cap (page 6-11)
8. Coolant drain bolt (page 6-12)9. Dipstick (page 6-9)
10.Brake pedal (page 3-13)
U4S8E0E0.book Page 2 Tuesday, August 1, 2006 3:16 PM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-14
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-11
Front 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.6-21, 6-22
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.6-21, 6-22
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-20
U4S8E0E0.book Page 2 Tuesday, August 1, 2006 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
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.√√√√
U4S8E0E0.book Page 2 Tuesday, August 1, 2006 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18680
NOTE:

Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
23*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
24*Front and rear brake
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace the entire air induction system if necessary.√√√√ √
28*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
U4S8E0E0.book Page 4 Tuesday, August 1, 2006 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
U4S8E0E0.book Page 5 Tuesday, August 1, 2006 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6 the point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU22500
Rear brake pads
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 (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU22580
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.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.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
U4S8E0E0.book Page 22 Tuesday, August 1, 2006 3:16 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders 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.


Brake hoses: Replace every four
years.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22792
To check the drive chain slack
1. Place the motorcycle on the cen-
terstand.
2. Shift the transmission into the neu-
tral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.1. Drive chain slack
U4S8E0E0.book Page 23 Tuesday, August 1, 2006 3:16 PM