engine coolant YAMAHA YZF-R6 2003 Owners Manual

2-1
2
EAU00026
2-DESCRIPTION Left view1. Front fork rebound damping force
adjusting screw (page 3-24)
2. Front fork spring preload adjusting bolt (page 3-23)
3. Fuse box 2 (page 6-40)
4. Coolant reservoir (page 6-14)
5. Shock absorber assembly spring
preload adjusting ring (page 3-25)
6. Shock absorber assembly compression
damping force adjusting screw (page 3-26)7. Owner’s tool kit (page 6-1)
8. Shock absorber assembly rebound
damping force adjusting screw (page 3-26)
9. Shift pedal (page 3-15)
10. Engine oil drain bolt (page 6-11)
11. Engine oil filter cartridge (page 6-11)
12. Front fork compression damping force
adjusting screw (page 3-24)
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM

DESCRIPTION
2-2
2
Right view13. Luggage strap holder (page 3-27)
14. Helmet holder (page 3-21)
15. Fuse box 1 (page 6-40)
16. Main fuse (page 6-40)
17. Battery (page 6-38)
18. Throttle stop screw (page 6-23)
19. Air filter element (page 6-19)20. Front brake fluid reservoir (page 6-31)
21. Radiator cap (page 6-16)
22. Coolant drain bolt (page 6-16)
23. Engine oil filler cap (page 6-10)
24. Brake pedal (page 3-16)
25. Engine oil dipstick (page 6-10)
26. Rear brake fluid reservoir (page 6-31)
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU04972*
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and
30 seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After
24 hours have passed, the indicator
light will stop flashing, however the im-
mobilizer system is still enabled.NOTE:_ This model is also equipped with a self-
diagnosis device for the immobilizer
system. If the immobilizer system is de-
fective, the indicator will start flashing
and the multi-function meter will display
an error code. (See “Self-diagnosis de-
vice” on page 3-9 for details.) _
EAU04975
Shift timing indicator light
This indicator light can be set to come
on and go off at the desired engine
speeds and is used to inform the rider
when it is time to shift to the next higher
gear.
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit. (See pages 3-10–3-12 for a de-
tailed explanation of the function of this
indicator light and on how to set it.)
EAU04923
Coolant temperature warning light
“”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
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 cir-
cuit.
EC000002
CAUTION:_ Do not operate the engine if it is
overheated. _
1. Shift timing indicator light
2. Coolant temperature warning light “”
3. Coolant temperature display
U5SLE0.book Page 6 Wednesday, September 11, 2002 11:46 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-7
3
CB-25E
Coolant
temperatureDisplay Conditions What to do0–39 °CMessage “LO” is
displayed.OK. Go ahead with riding.
40–116 °CTemperature is
displayed.OK. Go ahead with riding.
117–139 °CTemperature flashes.
Warning light comes on.Stop the motorcycle and allow it to
idle until the coolant temperature
goes down.
If the temperature does not go
down, stop the engine. (See the
“Engine overheating” section on
page 6-53 for further instructions.)
Above 140 °CMessage “HI” flashes.
Warning light comes on.Stop the engine and allow it to cool.
(See the “Engine overheating” sec-
tion on page 6-53 for further in-
structions.)
U5SLE0.book Page 7 Wednesday, September 11, 2002 11:46 AM

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-17–3-18
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9–6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13–6-15
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-30–6-32
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-29–6-32
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-27–6-28
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5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate
ventilation.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU04953
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
_

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-29.


Never ride with the sidestand
down.
_1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA00147
CAUTION:_ The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light


Fuel level warning light


Coolant temperature warning
light


Shift timing indicator light


Engine trouble warning light


Immobilizer system indicator
light
If a warning or indicator light does
not go off, see pages 3-4–3-7 for the
corresponding warning and indica-
tor light circuit check.
_2. Shift the transmission into the neu-
tral position.NOTE:_ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit. _
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings and panels ..... 6-5
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-19
Air intake duct .................................................... 6-22
Adjusting the engine idling speed ...................... 6-23
Adjusting the throttle cable free play .................. 6-23
Adjusting the valve clearance ............................ 6-24
Tires ................................................................... 6-24
Cast wheels ....................................................... 6-27
Adjusting the clutch lever free play .................... 6-27
Adjusting the brake pedal position ..................... 6-29
Adjusting the rear brake light switch .................. 6-29
Checking the front and rear brake pads ............. 6-30
Checking the brake fluid level ............................ 6-31
Changing the brake fluid .................................... 6-32
Drive chain slack ................................................ 6-32
Lubricating the drive chain ................................. 6-33
Checking and lubricating the cables .................. 6-34Checking and lubricating the throttle grip and
cable ............................................................... 6-34
Checking and lubricating the brake and
clutch levers .................................................... 6-35
Checking and lubricating the brake and
shift pedals ...................................................... 6-35
Checking and lubricating the sidestand ............ 6-36
Checking the front fork ...................................... 6-37
Checking the steering ....................................... 6-37
Checking the wheel bearings ............................ 6-38
Battery ............................................................... 6-38
Replacing the fuses .......................................... 6-40
Replacing a headlight bulb ................................ 6-41
Replacing an auxiliary light bulb ....................... 6-43
Tail/brake light ................................................... 6-44
Replacing a turn signal light bulb ...................... 6-44
Replacing the license plate light bulb ................ 6-45
Supporting the motorcycle ................................ 6-45
Front wheel ....................................................... 6-46
Rear wheel ........................................................ 6-49
Troubleshooting ................................................. 6-51
Troubleshooting charts ...................................... 6-52
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
63. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 4–10 if the oil filter cartridge
is not being replaced. _
4. Remove the coolant reservoir cov-
er by removing the bolts.
5. Remove cowling B. (See page 6-5
for cowling removal and installa-
tion procedures.)6. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
1. Engine oil drain boltLeft side
1. Coolant reservoir cover
2. Bolt (× 2)
1. Oil filter wrench
2. Oil filter cartridge
U5SLE0.book Page 11 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
NOTE:_ Make sure that the O-ring is properly
seated. _
8. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
9. Install the cowling.
10. Install the coolant reservoir cover
by installing the bolts.
11. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:_ Check the washer for damage and re-
place it if necessary. _12. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
1. O-ring
1. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.4 L
With oil filter cartridge
replacement:
2.6 L
Total amount (dry engine):
3.4 L
U5SLE0.book Page 12 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
ECA00133
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
_13. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _14. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU04945
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
U5SLE0.book Page 13 Wednesday, September 11, 2002 11:46 AM