spark plugs YAMAHA YZF-R6 2002 Owners Manual

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-3
Removing and installing the cowlings and
panel .................................................................. 6-6
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-17
Air intake duct .................................................... 6-19
Adjusting the carburetors ................................... 6-20
Adjusting the engine idling speed ...................... 6-20
Adjusting the throttle cable free play .................. 6-21
Adjusting the valve clearance ............................ 6-21
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-25
Adjusting the brake pedal position ..................... 6-26
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-27
Checking the brake fluid level ............................ 6-28
Changing the brake fluid .................................... 6-29
Drive chain slack ................................................ 6-29Lubricating the drive chain ................................ 6-31
Checking and lubricating the cables ................. 6-31
Checking and lubricating the throttle grip and
cable ............................................................... 6-32
Checking and lubricating the brake and
clutch levers .................................................... 6-32
Lubricating the brake pedal ............................... 6-32
Checking and lubricating the sidestand ............ 6-33
Lubricating the rear suspension ........................ 6-33
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-34
Checking the wheel bearings ............................ 6-35
Battery ............................................................... 6-35
Replacing the fuses .......................................... 6-37
Replacing a headlight bulb ................................ 6-38
Tail/brake light ................................................... 6-39
Replacing a turn signal light bulb ...................... 6-39
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-40
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-43
Troubleshooting charts ...................................... 6-44
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
2*Fuel filter•Check condition.√√
3 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
4*Valves•Check valve clearance.
•Adjust.Every 40,000 km
5*Air filter element•Clean.√√
•Replace.√√
6Clutch•Check operation.
•Adjust.√√√√√
7*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√ √ √ √ √
•Replace brake pads. Whenever worn to the limit
8*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√ √ √ √ √
•Replace brake pads. Whenever worn to the limit
9*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.) Every 4 years
U5MTE1.book Page 3 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU01315
Panel A
To remove the panelRemove the screws, and then take the
panel off.To install the panel
Place the panel in the original position,
and then install the screws.
EAU01639
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw (× 2)
1. Projection
2. Slot
Specified spark plug:
CR10EK (NGK)
U5MTE1.book Page 8 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6
EAU02990
Troubleshooting charts Starting problems or poor engine performance
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.DryWet
The engine does not start.
Check the battery.Open the throttle halfway and operate
the electric starter.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
U5MTE1.book Page 44 Monday, August 6, 2001 6:10 PM

MOTORCYCLE CARE AND STORAGE
7-4
7
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:@

Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
@
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
WARNING
@ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. @
U5MTE1.book Page 4 Monday, August 6, 2001 6:10 PM

INDEX
Spark plugs, checking ............................. 6-8
Specifications .......................................... 8-1
Speedometer unit .................................... 3-5
Starter (choke) lever .............................. 3-13
Starting a cold engine .............................. 5-1
Starting a warm engine ............................ 5-2
Start switch .............................................. 3-9
Steering, checking ................................. 6-34
Storage.................................................... 7-4
Storage compartment ............................ 3-15
Supporting the motorcycle ..................... 6-39
Suspension (rear), lubricating ................ 6-33TTachometer ............................................. 3-6
Tail/brake light ....................................... 6-39
Throttle cable free play, adjusting .......... 6-21
Throttle grip and cable, checking and
lubricating............................................ 6-32
Tires ...................................................... 6-21
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-43
Troubleshooting charts .......................... 6-44
Turn signal indicator light ......................... 3-2
Turn signal light bulb, replacing ............. 6-39
Turn signal switch .................................... 3-8VValve clearance, adjusting ..................... 6-21
Vehicle identification number ................... 9-1
WWheel bearings, checking ..................... 6-35
Wheel (front) ......................................... 6-40
Installing .......................................... 6-41
Removing ........................................ 6-40
Wheel (rear) .......................................... 6-41
Installing .......................................... 6-43
Removing ........................................ 6-41
Wheels .................................................. 6-24
U5MTE1.book Page 2 Monday, August 6, 2001 6:10 PM