User manual YAMAHA FAZER FZ6-SS

OWNER'S MANUAL FZ6-SS(C) LIT-11626-17-50 5VX-28199-10 EAU10041 INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZ6-S(C). This model is the result of Yamaha's vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer. The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual. IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE: NOTE: G This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. G Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. EWA10010 WARNING PLEASE READ THIS MANUAL AND THE "YOU AND YOUR MOTORCYCLE: RIDING TIPS" BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZ6-SS(C) OWNER'S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, September 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-17-50 TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ............3-2 LCD tachometer .............................3-3 Multi-function display ......................3-3 Handlebar switches ........................3-6 Clutch lever ....................................3-7 Shift pedal ......................................3-7 Brake lever .....................................3-7 Brake pedal ....................................3-8 Fuel tank cap ..................................3-8 Fuel ................................................3-9 Catalytic converter ........................3-10 Seat ..............................................3-10 Storage compartment ...................3-11 Adjusting the shock absorber assembly ...................................3-11 Sidestand .....................................3-12 Ignition circuit cut-off system ........3-13 PRE-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 Engine break-in .............................. 5-3 Parking ........................................... 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR................................. 6-1 PERIODIC MAINTENANCE .......... 6-1 Owner's tool kit .............................. 6-1 Periodic maintenance chart for the emission control system ............. 6-3 General maintenance and lubrication chart .......................... 6-4 Removing and installing panels ..... 6-8 Checking the spark plugs .............. 6-9 Canister (for California only) ........ 6-10 Engine oil and oil filter cartridge ... 6-10 Coolant ........................................ 6-13 Replacing the air filter element .... 6-15 Adjusting the throttle cable free play .................................... 6-16 Adjusting the valve clearance ...... 6-16 Tires ............................................. 6-17 Cast wheels ................................. 6-19 Accessories and replacement parts ......................................... 6-20 Adjusting the clutch lever free play ........................................... 6-20 Adjusting the brake pedal position ..................................... 6-21 Adjusting the rear brake light switch ........................................ 6-22 Checking the front and rear brake pads .......................................... 6-22 Checking the brake fluid level ...... 6-23 Changing the brake fluid .............. 6-24 Drive chain slack .......................... 6-24 Lubricating the drive chain ........... 6-25 Checking and lubricating the cables ....................................... 6-26 Checking and lubricating the throttle grip and cable ............... 6-26 Checking and lubricating the brake and shift pedals ............... 6-27 Checking and lubricating the brake and clutch levers ............. 6-27 Checking and lubricating the centerstand and sidestand ........ 6-28 Checking the front fork ................. 6-28 Checking the steering .................. 6-29 Checking the wheel bearings ....... 6-30 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 ........................................... 6-34 TABLE OF CONTENTS Replacing the license plate light bulb ...........................................6-34 Front wheel ...................................6-35 Rear wheel ...................................6-36 Troubleshooting ............................6-38 Troubleshooting charts .................6-39 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............................8-1 CONSUMER INFORMATION.............9-1 Identification numbers ....................9-1 Reporting safety defects .................9-3 Motorcycle noise regulation ............9-4 Maintenance record ........................9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ................................9-7 YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................9-9 SAFETY INFORMATION EAU10280 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: G OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. G OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL. G OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. G OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. Safe riding G Always make pre-operation checks. Careful checks may help prevent an accident. G This motorcycle is designed to carry the operator and a passenger. G The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: · Wear a brightly colored jacket. · Use extra caution when you are approaching and passing through intersections, since in- G G tersections are the most likely places for motorcycle accidents to occur. · Ride where other motorists can see you. Avoid riding in another motorist's blind spot. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. · Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. · Know your skills and limits. Staying within your limits may help you to avoid an accident. · We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls. Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a 1 1-1 SAFETY INFORMATION turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). · Always obey the speed limit and never travel faster than warranted by road and traffic conditions. · Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. · The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle. · The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. · Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. Never ride under the influence of alcohol or other drugs. G This motorcycle is designed for onroad use only. It is not suitable for off-road use. G 1 G G Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. G Always wear an approved helmet. G Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard. G The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. G Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. G Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. A passenger should also observe the above precautions. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: 1-2 SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 189 kg (417 lb) (CAL) 190 kg (419 lb) (U49). When loading within this weight limit, keep the following in mind: G Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. G Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently. G Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under "Loading" when mounting accessories. G Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. · Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories 1-3 G are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. · Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. · Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle's electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power. 1 SAFETY INFORMATION Gasoline and exhaust gas G GASOLINE IS HIGHLY FLAMMABLE: · Always turn the engine off when refueling. · Take care not to spill any gasoline on the engine or exhaust system when refueling. · Never refuel while smoking or in the vicinity of an open flame. G Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. G Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: · The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. · Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. · Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes. 1 G G 1-4 SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. 1 1 2 3 4 5,6,7,8,9,10 1-5 SAFETY INFORMATION 1 1 CAUTION Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 5JW-00 4 2 5 WARNING Improper loading can cause loss of control. Read owner's manual for proper loading. 3JJ-28446-A1 3 6 1-6 SAFETY INFORMATION 7 California only 9 California only 1 8 California only 10 1-7 DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. Main fuse (page 6-31) Battery (page 6-30) Air filter element (page 6-15) Shock absorber assembly spring preload adjusting ring (page 3-11) Owner's tool kit (page 6-1) Shift pedal (page 3-7) Engine oil drain bolt (page 6-10) Engine oil filter cartridge (page 6-10) 2-1 DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. Fuse box (page 6-31) Rear brake fluid reservoir (page 6-23) Engine oil filler cap (page 6-10) Front brake fluid reservoir (page 6-23) Dipstick (page 6-10) Brake pedal (page 3-8) 2-2 DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. Clutch lever (page 3-7) Left handlebar switches (page 3-6) LCD tachometer (page 3-3) Multi-function display (page 3-3) Right handlebar switches (page 3-6) Brake lever (page 3-7) Throttle grip (page 6-16) Main switch/steering lock (page 3-1) 2-3 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10660 Main switch/steering lock OFF All electrical systems are off. The key can be removed. EAU10680 To unlock the steering LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU26900 3 1. Push. 2. Turn. Push the key in, and then turn it to "OFF" while still pushing it. EWA10060 WARNING ON All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed. NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to "OFF", even if the engine stalls. Never turn the key to "OFF" or "LOCK" while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to "OFF" or "LOCK". 1. Push. 2. Turn. 1. Turn the handlebars all the way to the left. 2. Push the key in from the "OFF" position, and then turn it to "LOCK" while still pushing it. 3. Remove the key. 3-1 INSTRUMENT AND CONTROL FUNCTIONS EAU11001 EAU11080 Indicator and warning lights High beam indicator light " " This indicator light comes on when the high beam of the headlight is switched on. EAU11250 oil level warning light will flash ten times, then go off for 2.5 seconds. If this occurs, have a Yamaha dealer check the vehicle. EAU11530 3 1. 2. 3. 4. 5. Oil level warning light " " Engine trouble warning light " " Neutral indicator light " " High beam indicator light " " Turn signal indicator lights " " and " " EAU11030 Oil level warning light " " This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to "ON". If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. NOTE: G Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. G This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The 3-2 Turn signal indicator lights " " and "" The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Engine trouble warning light " " This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. (See page 3-3 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to "ON". If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. Neutral indicator light " " This indicator light comes on when the transmission is in the neutral position.