air condition YAMAHA YZF-R6 2002 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: YZF-R6, Model: YAMAHA YZF-R6 2002Pages: 116, PDF Size: 5.24 MB
Page 42 of 116
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
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-11–3-12
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-9–6-10
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-13–6-14
Front brake•Check 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.6-27–6-29
Rear brake•Check 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.6-26–6-29
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.6-25
Throttle grip•Make sure that operation is smooth.
•Check free play.
•If necessary, have Yamaha dealer make adjustment or lubricate.6-21
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM
Page 43 of 116
PRE-OPERATION CHECKS
4-2
4
Control cables•Make sure that operation is smooth.
•Lubricate if necessary.6-31
Drive chain•Check chain slack.
•Adjust if necessary.
•Check chain condition.
•Lubricate if necessary.6-29–6-31
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-21–6-24
Brake and shift pedals•Make sure that operation is smooth.
•Lubricate pedal pivoting points if necessary.6-32
Brake and clutch levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.6-32
Sidestand•Make sure that operation is smooth.
•Lubricate pivot if necessary.6-33
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.—
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-23
Air intake duct•Check that the screen is not clogged.
•Clean if necessary.6-19 ITEM CHECKS PAGE
U5MTE1.book Page 2 Monday, August 6, 2001 6:10 PM
Page 52 of 116
6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication 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 main-
tenance and lubrication chart should be
simply considered as a general guide
under normal riding conditions. Howev-
er, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TION, AND INDIVIDUAL USE, THE
MAINTENANCE INTERVALS MAY
NEED TO BE SHORTENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01296
CAUTION:@ Do not test this motorcycle on a dy-
namometer stand for an extended
period of time, otherwise heat-in-
duced discoloration of the fiber-con-
structed muffler may occur. @
EAU04223
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment under the
passenger seat. (See page 3-14 for
passenger seat removal and installa-
tion procedures.)
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.1. Owner’s tool kit
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM
Page 54 of 116
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
Page 59 of 116
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
Page 69 of 116
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 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.5. Remove the air filter case cover by
removing the screws.6. Pull the air filter element out.
7. Check the condition of the air filter
element and replace it if it is dam-
aged or excessively dusty.
1. Screw (× 6)
2. Air filter case cover
1. Air filter element
U5MTE1.book Page 18 Monday, August 6, 2001 6:10 PM
Page 73 of 116
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
CE-01E
CE-07EEWA00012
WARNING
@ 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 air
pressure before each ride.
@
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg250 kPa
2.50 kgf/cm
2
2.50 bar250 kPa
2.50 kgf/cm
2
2.50 bar
90 kg–maximum250 kPa
2.50 kgf/cm
2
2.50 bar290 kPa
2.90 kgf/cm
2
2.90 bar
High-speed riding250 kPa
2.50 kgf/cm
2
2.50 bar250 kPa
2.50 kgf/cm
2
2.50 bar
Maximum load* 189 kg
* Total weight of rider, passenger, cargo and
accessories
U5MTE1.book Page 22 Monday, August 6, 2001 6:10 PM
Page 75 of 116
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
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 a
high-speed ride.
@CE-10E
CE-14EEAU00684
WARNING
@ 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
“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
after installing a new tire.
The tires must be warmed up
before a high-speed run.
Always adjust the tire air pres-
sure according to the operating
conditions.
@
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
FRONT
Manufacturer Size Model
Michelin
120/60 ZR17 (55W)
Pilot SPORT B
120/60 ZR17 M/C (55W)
Dunlop
120/60 ZR17 (55W)
D207FJ
120/60 ZR17 M/C (55W)
REAR
Manufacturer Size Model
Michelin
180/55 ZR17 (73W)
Pilot SPORT B
180/55 ZR17 M/C (73W)
Dunlop
180/55 ZR17 (73W)
D207N
180/55 ZR17 M/C (73W)FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
U5MTE1.book Page 24 Monday, August 6, 2001 6:10 PM
Page 82 of 116
PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:@ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. @1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:@ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. @2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:@ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. @
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
Recommended lubricant:
Engine oil
U5MTE1.book Page 31 Monday, August 6, 2001 6:10 PM
Page 84 of 116
PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU03165
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
@ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. @
EAU03166
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5MTE1.book Page 33 Monday, August 6, 2001 6:10 PM