warning YAMAHA YZF-R6 2004 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
CAUTION:
ECA10301
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10310


Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
EAU17211
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310


Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on soft
ground, otherwise the vehiclemay overturn.
CAUTION:
ECA10380
Never park in an area where there
are fire hazards such as grass orother flammable materials.
5SLE1.book Page 4 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17490
Owner’s tool kit The owner’s tool kit is located inside the
storage compartment under the pas-
senger seat. (See page 3-17.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
5SLE1.book Page 1 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
613. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately 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 theoil level is sufficient.CAUTION:
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
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.
EAU20111
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:

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


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove the
coolant reservoir cover by remov-
ing the bolts, remove the reservoir
cap, and then add coolant to the
maximum level mark.
1. Maximum level mark
2. Minimum level mark
1. Coolant reservoir cover
2. Bolt
5SLE1.book Page 12 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
CAUTION:
ECA10470


If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
4. Install the reservoir cap, and then
install the coolant reservoir cover
by installing the bolts.NOTE:

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page6-43 for further instructions.
EAU20342
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.2. Remove panel A and cowling A.
(See page 6-6.)
3. Place a container under the engine
to collect the used coolant.
4. Loosen the clamp screw, and then
disconnect the air intake duct.
5. Remove the radiator cap.
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
1. Clamp screw
2. Air intake duct
5SLE1.book Page 13 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EAU21161
Checking the air filter element The air filter element should be
checked at the intervals specified in the
periodic maintenance and lubrication
chart. Check the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the rider seat. (See page
3-17.)
2. Remove the fuel tank bolts and
slightly lift the fuel tank.
3. Disconnect the fuel tank breather
hose and fuel tank overflow hose
from the fuel tank.
NOTE:Before disconnecting the fuel tank
breather hose and fuel tank overflow
hose, mark them to ensure that they willbe reinstalled in their correct positions.
4. Tilt the front of the fuel tank back to
position the tank away from the air
filter case, and then support the
tank as shown.
WARNING
EWA10410


Make sure that the fuel tank is
well supported.


Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, whichcould cause fuel leakage.
5. Remove the air filter case cover by
removing the screws.
6. Pull the air filter element out.
1. Bolt
1. Fuel tank breather hose
2. Fuel tank overflow hose
1. Screw
2. Air filter case cover
5SLE1.book Page 16 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6 7. Check the condition of the air filter
element and replace it if it is dam-
aged or excessively dusty.
8. Insert the element into the air filter
case.
CAUTION:
ECA10480


Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
9. Install the air filter case cover by in-
stalling the screws.10. Connect the fuel tank breather
hose and fuel tank overflow hose
to the fuel tank.
11. Place the fuel tank in the original
position, and then install the bolts.
WARNING
EWA11360


Before placing the fuel tank in
the original position, make sure
that the fuel hoses are not dam-
aged. If any fuel hose is dam-
aged, do not start the engine but
have a Yamaha dealer replace
the hose, otherwise fuel may
leak.


Make sure that the fuel hoses
are properly connected and
routed, and not pinched.


Be sure to place the fuel tank
breather hose and the fuel tank
overflow hose in the original po-sition.
12. Install the rider seat.
1. Air filter element
1. Fuel tank breather hose
2. Fuel tank overflow hose
1. Fuel tank breather hose
2. Fuel tank overflow hose
5SLE1.book Page 17 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU21380
Adjusting the throttle cable
free play The throttle cable free play should mea-
sure 6.0–8.0 mm (0.24–0.31 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21400
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU21771
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10500


The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
1. Throttle cable free play
5SLE1.book Page 19 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
WARNING
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.


NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


Check the tire condition and airpressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
90–193 kg (198–425 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Maximum load*:
193 kg (425 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
5SLE1.book Page 20 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
WARNING
EWA10470


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.


The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-edge and experience.
Tire informationThis motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING
EWA10480


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.


Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.


Use only the tire valves and
valve cores listed below to
avoid tire deflation during ahigh-speed ride.
WARNING
EWA10600
This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.

Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.


Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Front tire:
Size:
120/60 ZR17M/C (55W)
Manufacturer/model:
MICHELIN/Pilot SPORT N
DUNLOP/D208F J
Rear tire:
Size:
180/55 ZR17M/C (73W)
Manufacturer/model:
MICHELIN/Pilot SPORT B
DUNLOP/D208 AJ
FRONT and REAR:
Tire air valve:
TR412
Va l ve c o r e :
#9000A (original)
5SLE1.book Page 21 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
NOTE:If the specified clutch lever free play
cannot be obtained as describedabove, proceed as follows.
1. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
2. Remove cowling A. (See page
6-6.)
3. Loosen the locknut at the crank-
case.
4. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
ver free play, turn the adjusting nut
in direction (b).5. Tighten the locknut.
6. Install the cowling.
EAU22251
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 11.0 mm
(0.43 in) below the bottom of the foot-
rest bracket as shown. Periodically
check the brake pedal position and, if
necessary, have a Yamaha dealer ad-
just it.
WARNING
EWA10690
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
1. Locknut
2. Clutch lever free play adjusting nut
(crankcase)
1. Distance between brake pedal and footrest
bracket
5SLE1.book Page 23 Friday, August 1, 2003 4:09 PM