Yamaha · Modern chain-drive motorcycle (2000-)

FZ 6 (600 cc)

Library entry covers 2004

33 factory 29 guideline

Published source

Yamaha FZ6 / FZ6-S 2006 Owner's Manual 5VX-28199-12 (US, English), periodic maintenance charts pp.6-3 to 6-6

Factory owner's handbook. Covers FZ6 / FZ6-S (FZS6); catalog row is 2004, this is the 2006 US owner's manual 5VX-28199-12, English. Chart columns: initial 600 mi (1000 km) or 1 month, then 4000/8000/12000/16000/20000 mi (7000/13000/19000/25000/31000 km) or 6/12/18/24/30 months, whichever comes first. Chain drive. Page 6-7 (likely TIPs: repeat rule, brake fluid) was not among the provided pages; no brake fluid change row appears on pp.6-3 to 6-6.

Open the source

62 items for a 2004 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2004 Yamaha FZ 6 (600 cc)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 500 mi

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain (check chain slack, alignment and condition; adjust and lubricate with special O-ring chain lubricant thoroughly). Factory: Every 500 mi (800 km) and after washing the motorcycle or riding in the rain, printed as text; not a dealer item

Every 3,000 mi or 12 months

3 items

Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 4,000 mi or 6 months

22 items

Change engine oil

Engine

Factory

Manual: Engine oil (change, warm engine before draining). Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months
Chassis fasteners (check all chassis fittings and fasteners, correct if necessary)

Engine

Factory

Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Check engine breather and oil return

Engine

Factory

Manual: Crankcase breather system (check breather hose for cracks or damage, replace if necessary). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Exhaust system (check for leakage, tighten if necessary, replace gasket(s) if necessary)

Engine

Factory

Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Inspect coolant hoses and clamps

Engine

Factory

Manual: Cooling system (check hoses for cracks or damage, replace if necessary). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Control cables (apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly). Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line (check fuel hoses for cracks or damage, replace if necessary). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Synchronize throttle bodies

Fuel and air

Factory

Manual: Fuel injection (check and adjust engine idle speed and synchronization). Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check operation, adjust or replace cable). Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; cable clutch; dealer item
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check bearing assemblies for looseness). Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Front fork (check operation and for oil leakage, replace if necessary)

Front end

Factory

Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; no fork oil change interval printed; dealer item
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Centerstand and sidestand pivots (check operation, apply lithium-soap-based grease (all-purpose grease) lightly). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assembly (check operation and for oil leakage, replace if necessary). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Sidestand switch (check operation, replace if necessary)

Rear suspension and frame

Factory

Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Brake and clutch lever pivot shafts (apply lithium-soap-based grease (all-purpose grease) lightly)

Brakes

Factory

Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial
Brake and shift pedal pivot shafts (apply lithium-soap-based grease (all-purpose grease) lightly)

Brakes

Factory

Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial
Check brake pads and discs

Brakes

Factory

Manual: Front brake (check operation, fluid level and fluid leakage; replace brake pads if necessary). Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Rear brake (check operation, fluid level and fluid leakage; replace brake pads if necessary)

Brakes

Factory

Factory: Every column incl. 600 mi (1000 km) / 1 month initial, then every 4000 mi (7000 km) or 6 months; dealer item
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check for smooth operation, replace if necessary). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth and for damage, replace if necessary, check and correct air pressure). Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Wheels (check runout and for damage, replace if necessary)

Wheels and tires

Factory

Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item
Throttle grip housing and cable (check operation and free play, adjust throttle cable free play if necessary, lubricate throttle grip housing and cable)

Controls and cables

Factory

Factory: Marked at 4000, 8000, 12000, 16000, 20000 mi (7000-31000 km) or 6-30 months; not at 600 mi initial; dealer item

Every 6,000 mi or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 8,000 mi or 12 months

4 items

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (check condition, adjust gap and clean). Factory: Check marked at 4000, 12000, 20000 mi (7000/19000/31000 km; 6/18/30 months); not at initial; dealer item
Replace oil filter

Engine

Factory

Manual: Engine oil filter cartridge (replace). Factory: Marked at 600 mi (1000 km) / 1 month initial, 8000 mi (13000 km) / 12 months and 16000 mi (25000 km) / 24 months; dealer item
Replace spark plugs

Engine

Factory

Manual: Spark plugs (replace). Factory: 'Replace.' printed at 8000 and 16000 mi (13000/25000 km; 12/24 months); routine text says replace every 8000 mi (13000 km) or 12 months; dealer item
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter element (check condition and damage; replace if necessary). Factory: Chart has two sub-rows: 'Check condition and damage' marked at 4000 and 20000 mi (7000/31000 km; 6/30 months); 'Replace if necessary' marked at 12000 mi (19000 km) / 18 months only. Combined the filter is attended at 4000, 12000, 20000 mi, i.e. every 8000 mi; no fixed replacement interval printed (the chart pages provided, pp.6-3 to 6-6, print no repeat rule after 20000 mi; p.6-7 was not provided); dealer item

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline

Every 12,000 mi

1 item

Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (moderately repack with lithium-soap-based grease). Factory: Every 12000 mi (19000 km), printed as text; no time interval; dealer item

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 16,000 mi or 2 years

3 items

Replace coolant

Engine

Factory

Manual: Cooling system (change with ethylene glycol anti-freeze coolant every 24 months). Factory: 'Change.' printed in the 16000 mi (25000 km) / 24 month column only; routine text says every 24 months; dealer item
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm pivot bearings (moderately repack with lithium-soap-based grease). Factory: 'Repack.' printed at 16000 mi (25000 km) / 24 months only (the chart pages provided, pp.6-3 to 6-6, print no repeat rule after 20000 mi; p.6-7 was not provided); dealer item
Swingarm pivot bearings (check bearing assemblies for looseness)

Rear suspension and frame

Factory

Factory: Check marked at 8000 mi (13000 km) / 12 months only (the chart pages provided, pp.6-3 to 6-6, print no repeat rule after 20000 mi; p.6-7 was not provided); dealer item

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 26,600 mi

1 item

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance (check and adjust when engine is cold). Factory: Every 26600 mi (42000 km), printed as text; no time interval; dealer item

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses (replace). Factory: Every 4 years; check for cracks or damage at 4000-20000 mi (7000-31000 km) or 6-30 months, not at initial; dealer item
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.