2008 YAMAHA FZ6 NHG brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
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.
EAU40260
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.


Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
U5S5E1E0.book Page 21 Friday, June 22, 2007 1:03 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.


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.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.Drive chain slack:
45.0–55.0 mm (1.77–2.17 in)
U5S5E1E0.book Page 22 Friday, June 22, 2007 1:03 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU23111
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU44270
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.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU23141
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.
EAU23200
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.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease (all-
purpose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U5S5E1E0.book Page 26 Friday, June 22, 2007 1:03 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAUM1650
Lubricating the swingarm piv-
ots The swingarm pivots must be lubricat-
ed at the intervals specified in the peri-
odic maintenance and lubrication chart.
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 main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
Recommended lubricant:
Lithium-soap-based grease
U5S5E1E0.book Page 27 Friday, June 22, 2007 1:03 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6 5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the bolts.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
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 counter-
clockwise.
WARNING
EWA12301
Do not touch the muffler bracket un-til the exhaust system has cooled.
3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise 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.
1. Tail/brake light bulb socket
2. Muffler bracket cover
U5S5E1E0.book Page 33 Friday, June 22, 2007 1:03 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU44790
Front wheel (FZ6-NHG)
WARNING
EWA14840
For the ABS model, have a Yamahadealer remove and install the wheel.
EAU24490
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.2. Lift the front wheel off the ground
according to the procedure on
page 6-35.
3. Remove the brake caliper on each
side by removing the bolts.
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
4. Pull the wheel axle out, and then
remove the wheel.
EAU43370
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Install the brake calipers by install-
ing the bolts.NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brakediscs.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
1. Wheel axle
2. Front wheel axle pinch bolt
1. Brake caliper
2. Brake caliper bolt
U5S5E1E0.book Page 36 Friday, June 22, 2007 1:03 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6 6. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU44800
Rear wheel (FZ6-NHG)
WARNING
EWA14840
For the ABS model, have a Yamahadealer remove and install the wheel.
EAU43380
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-35.
3. Remove the axle nut.
4. Loosen the locknut and drive chain
adjusting bolt on each side of the
swingarm.5. While supporting the brake caliper
and slightly lifting the wheel, pull
the wheel axle out.
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)
1. Locknut
2. Drive chain slack adjusting bolt
3. Axle nut
U5S5E1E0.book Page 37 Friday, June 22, 2007 1:03 PM