brake YAMAHA YZF-R6 2000 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU01356
Clutch lever free play
adjustmentThe clutch lever free play should be ad-
justed to 10 ~ 15 mm.
1. Turn the adjusting bolt at the
clutch lever in direction
a to in-
crease free play or in direction
b
to decrease free play. If the speci-
fied free play cannot be obtained,
proceed with the following steps.
2. Turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the cable.3. Remove cowling A. (See page 6-6
for removal and installation proce-
dures.)
4. Loosen the locknut at the crank-
case side.
5. Turn the adjusting nut at the
crankcase in direction
a to in-
crease free play or in direction
b
to decrease free play. Then tight-
en the locknut.
6. Install the cowling.
EAU00713
Brake light switch adjustmentThe rear brake light switch is activated
by the brake pedal and is properly ad-
justed when the brake light comes on
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
a to
make the brake light come on earlier.
Turn the adjusting nut in direction
b to
make the brake light come on later.
1. Adjusting bolt
2. Free play
1. Locknut
2. Adjusting nut
1. Brake light switch
2. Adjusting nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU00721
Checking the front and rear
brake pads
EAU00725
Front brake
A wear indicator groove is provided on
each brake pad. This indicator allows
checking of brake pad wear without
disassembling the brake. Inspect the
groove. If the groove has almost disap-
peared, ask a Yamaha dealer to re-
place the pads.
EAU01641
Rear brake
A wear indicator groove is provided on
each brake pad. This indicator allows
checking of brake pad wear without
disassembling the brake. Remove the
rear caliper bolt and tilt the caliper for-
ward. Inspect the groove. If the groove has
almost disappeared, ask a Yamaha
dealer to replace the pads. Install the
caliper and caliper bolt, then tighten the
bolt to the specified torque.
1. Wear indicator groove
1. Caliper bolt
1. Wear indicator grooveTightening torque:
Caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU00731
Inspecting the brake fluid
levelInsufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake fluid
is above the minimum level and replen-
ish when necessary.
Observe these precautions:l
When checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.
l
Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
Have a Yamaha dealer check the
cause if the brake fluid level goes
down.
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid: DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU00742
Brake fluid replacementThe brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:l
oil seals (every two years)
l
brake hoses (every four years)
EAU00744
Drive chain slack checkNOTE:@ Spin the wheel several times and find
the tightest position of the chain. Check
and/or adjust the chain slack while it’s
in this tightest position. @To check the chain slack the motor-
cycle must be held straight up with both
wheels on the ground and without rider.
Check the slack at the position shown
in the illustration. Normal slack is ap-
proximately 40 ~ 50 mm. If the slack
exceeds 50 mm, adjust.a. Chain slack
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU02962
Cable inspection and
lubrication
EW000112
WARNING
@ Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions. @Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it.
EAU00773
Throttle cable and grip
lubricationThe throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
EAU01290*
Brake pedal lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oilRecommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
WARNING
@ If the sidestand does not move
smoothly, consult a Yamaha dealer. @
EAU00791
Rear suspension lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium soap base grease
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU02939
Front fork inspectionVisual check
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @Check for scratches or damage on the
inner tube and excessive oil leakage
from the front fork.
Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:@ If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer. @
EAU00794
Steering inspectionPeriodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EC000104
CAUTION:@ To prevent damage to the following:l
Headlight bulb
Avoid touching the glass part of
the bulb. Keep it free from oil;
otherwise, the transparency of
the glass, life of the bulb, and il-
luminous flux will be adversely
affected. If oil gets on the bulb,
thoroughly clean it with a cloth
moistened with alcohol or lac-
quer thinner.
l
Headlight lens
• Do not affix any type of tinted
film or stickers to the head-
light lens.
• Do not use headlight bulbs of
wattage higher than speci-
fied.
@5. Install the bulb holder cover and
reconnect the headlight connec-
tor.
If the headlight beam adjustment is
necessary, ask a Yamaha dealer to
make that adjustment.
EAU01823
Tail/brake light bulb
replacement1. Remove the passenger seat. (See
page 3-15 for seat removal and in-
stallation procedures.)
2. To remove the socket, turn it coun-
terclockwise.
3. To remove the defective bulb, turn
it counterclockwise.
4. Push a new bulb into the socket
and turn it clockwise.
5. Install the socket and turn it clock-
wise.
6. Install the passenger seat.
EAU01095
Turn signal light bulb
replacement1. Remove the screw and the lens.
2. Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
3. Install a new bulb by pushing it in-
ward and turning it clockwise.
4. Install the lens and tighten the
screw.
1. Bulb socket
1. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6 3. Elevate the front wheel.
4. Remove the brake hose holders
and calipers.
NOTE:@ Do not depress the brake lever when
the calipers are off the discs as the
brake pads will be forced shut. @5. Pull out the wheel axle and re-
move the wheel by pulling it back-
wards.
EAU01638
Front wheel installation1. Lift up the wheel between the front
fork legs.
2. Install the wheel axle and let the
motorcycle down.
3. Push down hard on the handle-
bars several times to check for
proper fork operation.
4. Install the calipers, caliper bolts
and brake hose holders. Make
sure there is enough gap between
the brake pads before installing
the calipers onto the brake discs.
5. Tighten the wheel axle, pinch bolt
and caliper bolts to the specified
torques.
1. Brake hose holder bolt
2. Caliper bolt (´ 2)
Tightening torque:
Wheel axle:
72 Nm (7.2 m·kg)
Pinch bolt:
20 Nm (2.0 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU01247
Rear wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@1. Loosen the axle nut and caliper
bolts.
2. Elevate the rear wheel.3. Remove the axle nut, caliper bolts
and caliper.
4. Loosen the locknuts on each side
of the swingarm.
5. Turn the chain adjusting bolts fully
inward.
6. Push the wheel forward and re-
move the drive chain.
7. Pull out the wheel axle and re-
move the wheel assembly by pull-
ing backwards.
NOTE:@ l
Do not depress the brake pedal
when the caliper is off the disc as
the brake pads will be forced shut.
l
You do not have to disassemble
the chain in order to remove or in-
stall the rear wheel.
@
1. Axle nut
2. Adjusting bolt
3. Locknut
1. Caliper bolt (´ 2)
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