2008 YAMAHA FZ6 SHG brake pads

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 ............3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-12
Handlebar switches ......................3-13
Clutch lever ...................................3-14
Shift pedal .....................................3-14
Brake lever ...................................3-15
Brake pedal ..................................3-15
ABS (for ABS models) ..................3-15
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather hose ................3-18
Catalytic converters ......................3-18
Seat ..............................................3-18
Helmet holder ...............................3-19
Storage compartment ...................3-19
Adjusting the shock absorber
assembly ...................................3-20
Sidestand ......................................3-21
Ignition circuit cut-off system ........3-22PRE-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 ..... 6-7
Checking the spark plugs ............... 6-9
Engine oil and oil filter cartridge ... 6-10
Coolant ......................................... 6-12
Replacing the air filter element ..... 6-16
Adjusting the engine idling
speed ........................................ 6-17
Checking the throttle cable free
play ........................................... 6-18
Valve clearance ............................ 6-18
Tires ............................................. 6-19
Cast wheels .................................. 6-21
Adjusting the clutch lever free
play ........................................... 6-22Rear brake light switch ................ 6-22
Checking the front and rear brake
pads .......................................... 6-23
Checking the brake fluid level ...... 6-23
Changing the brake fluid .............. 6-24
Drive chain slack .......................... 6-25
Cleaning and lubricating the drive
chain ......................................... 6-26
Checking and lubricating the
cables ....................................... 6-27
Checking and lubricating the
throttle grip and cable ............... 6-27
Checking and lubricating the
brake and shift pedals .............. 6-27
Checking and lubricating the
brake and clutch levers ............ 6-28
Checking and lubricating the
centerstand and sidestand ....... 6-29
Lubricating the swingarm
pivots ........................................ 6-29
Checking the front fork ................. 6-29
Checking the steering .................. 6-30
Checking the wheel bearings ....... 6-31
Battery ......................................... 6-31
Replacing the fuses ..................... 6-32
Replacing a headlight bulb .......... 6-34
Replacing the tail/brake light
bulb ........................................... 6-35
Replacing a turn signal light
bulb ........................................... 6-36U4S8E1E0.book Page 1 Monday, July 2, 2007 10:33 AM

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.3-17
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-12
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.6-23, 6-23
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.6-23, 6-23
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-22
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU1770A
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.


From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).


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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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 (24000 mi)
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
U4S8E1E0.book Page 2 Monday, July 2, 2007 10:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36890
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn tothe 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.
1. Brake pad wear indicator
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
U4S8E1E0.book Page 23 Monday, July 2, 2007 10:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6Before 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 thefluid 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.
Recommended brake fluid:
DOT 4
U4S8E1E0.book Page 24 Monday, July 2, 2007 10:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EAU44790
Front wheel (FZ6-SHG)
WARNING
EWA14840
For the ABS model, have a Yamahadealer remove and install the wheel.
EAU42640
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. Place the vehicle on the center-
stand.
2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.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.
EAU42670
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. Take the vehicle off the center-
stand so that the front wheel 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
U4S8E1E0.book Page 38 Monday, July 2, 2007 10:33 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
NOTE:A rubber mallet may be useful to tap thewheel axle out.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the rear wheel.
7. Remove the wheel.CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU32941
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the right-hand side.
NOTE:

Make sure that the slot in the brake
caliper bracket is fit over the retain-
er on the swingarm.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-25.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
1. Locknut
2. Drive chain slack adjusting bolt
3. Wheel axle
4. Brake caliper bracket
5. Brake caliper
1. Retainer
2. Slot
U4S8E1E0.book Page 40 Monday, July 2, 2007 10:33 AM

INDEX
AABS ...................................................... 3-15
ABS warning light (for ABS models) ....... 3-7
Air filter element, replacing ................... 6-16
Anti-theft alarm (optional) ..................... 3-12
Auxiliary light bulb, replacing ................ 6-37BBattery .................................................. 6-31
Brake and clutch levers, checking and
lubricating ........................................... 6-28
Brake and shift pedals, checking and
lubricating ........................................... 6-27
Brake fluid, changing ............................ 6-24
Brake fluid level, checking .................... 6-23
Brake lever ........................................... 3-15
Brake pedal .......................................... 3-15CCables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converters .............................. 3-18
Centerstand and sidestand, checking
and lubricating .................................... 6-29
Clutch lever........................................... 3-14
Clutch lever free play, adjusting ........... 6-22
Coolant ................................................. 6-12
Coolant temperature warning light.......... 3-4DDimmer switch ...................................... 3-13
Drive chain, cleaning and lubricating .... 6-26
Drive chain slack .................................. 6-25EEngine break-in ...................................... 5-3
Engine idling speed .............................. 6-17
Engine oil and oil filter cartridge ........... 6-10Engine stop switch ................................ 3-13
Engine trouble warning light .................... 3-7
FFront and rear brake pads, checking .... 6-23
Front fork, checking...............................6-29
Fuel ....................................................... 3-17
Fuel consumption, tips for reducing ........ 5-3
Fuel tank breather hose ........................ 3-18
Fuel tank cap......................................... 3-16
Fuses, replacing .................................... 6-32HHandlebar switches ............................... 3-13
Hazard switch........................................ 3-14
Headlight bulb, replacing....................... 6-34
Helmet holder ........................................ 3-19
High beam indicator light......................... 3-4
Horn switch ........................................... 3-13IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-22
Immobilizer system .................................3-1
Immobilizer system indicator light ........... 3-7
Indicator and warning lights .................... 3-4KKey identification number ........................ 9-1LLicense plate light bulb, replacing ......... 6-36MMain switch/steering lock ........................ 3-2
Matte color, caution .................................7-1
Model label .............................................. 9-2
Multi-function meter unit .......................... 3-8NNeutral indicator light .............................. 3-4
OOil level warning light .............................. 3-4PPanels, removing and installing .............. 6-7
Parking.................................................... 5-4
Part locations .......................................... 2-1
Pass switch ........................................... 3-13
Periodic maintenance and lubrication
chart...................................................... 6-2
Pre-operation check list .......................... 4-2RRear brake light switch ......................... 6-22SSafety information ................................... 1-1
Seat ...................................................... 3-18
Shifting .................................................... 5-2
Shift pedal ............................................. 3-14
Shock absorber assembly, adjusting .... 3-20
Sidestand .............................................. 3-21
Spark plugs, checking............................. 6-9
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ........................................... 3-13
Steering, checking ................................ 6-30
Storage ................................................... 7-3
Storage compartment ........................... 3-19
Swingarm pivots, lubricating ................. 6-29TTail/brake light bulb, replacing .............. 6-35
Throttle cable free play, checking ......... 6-18
Throttle grip and cable, checking and
lubricating ........................................... 6-27
Tires ...................................................... 6-19
Tool kit .................................................... 6-1
U4S8E1E0.book Page 1 Monday, July 2, 2007 10:33 AM