check engine light YAMAHA YZF-R6 2002 Owners Manual

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU04222
Oil level/coolant temperature warn-
ing light “”
This warning light has the following
three functions.

When the engine oil level is low,
the warning light comes on and
symbol “” flashes. If this oc-
curs, stop the engine immediately
and add engine oil to the specified
level.


When the coolant temperature is
too high, the warning light comes
on and symbol “” flashes. 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 6-45 for further instruc-
tions.)


When the engine oil level is low
and the coolant temperature is too
high, the warning light flashes and
symbols “” and “” come on.
To check that the warning light is work-
ing properly:


Put the transmission in neutral or
apply the clutch lever.


Turn the engine stop switch to
“” and the key to “ON”.


The warning light will come on,
and symbols “” and “” will
appear in the display.
If the warning light does not come on,
have a Yamaha dealer inspect the
electrical circuit.
EC000118
CAUTION:_

Do not operate the motorcycle
until you know that the engine
oil level is sufficient.


Do not operate the engine if it is
overheated.
_NOTE:_ Even if the oil is filled to the specified
level, the warning light may flicker
when riding on a slope or during sud-
den acceleration or deceleration, but
this is normal. _
1. Oil level symbol “”
2. Oil level/coolant temperature
warning light “”
3. Coolant temperature symbol “”U5MTE1.book Page 3 Monday, August 6, 2001 6:10 PM

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.
@
EAU01382*
Starting a cold 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 3-25.


Never ride with the sidestand
down.
@1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA00005
CAUTION:@ The oil level/coolant temperature
warning light and fuel level warning
light should come on for a few sec-
onds, then go off. If a warning light
does not go off, see page 3-4 for the
corresponding warning 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
circuit. @3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-13 for starter (choke)
operation.)
4. Start the engine by pushing the
start switch.
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU00424
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Thoroughly warm up the engine.


Turn the starter (choke) off as
soon as possible.


Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU01128
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU03749*
0–1,000 km
Avoid prolonged operation above
5,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
6,000 r/min.
EC000052*
CAUTION:_ After 1,000 km of operation, the en-
gine oil must be changed and the oil
filter cartridge replaced. _1,600 km and beyond
The vehicle can now be operated nor-
mally.
EC000053
CAUTION:_

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.
_
U5MTE1.book Page 4 Monday, August 6, 2001 6:10 PM

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
6-8
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
6-9
6Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:
@
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
ECA00021
CAUTION:@ Do not use any tools to remove or
install the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in. @
EAU04224
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _
a. Spark plug gapSpark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
U5MTE1.book Page 9 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 7. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.9. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00105
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_10. 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. _11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowlings.
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)Left side
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.5 L
With oil filter cartridge
replacement:
2.7 L
Total amount (dry engine):
3.5 L
U5MTE1.book Page 12 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU04227
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.
_
2. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum 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, open the reservoir
cap, and then add coolant to the
maximum level mark.
1. Maximum level mark
2. Minimum level markLeft side
1. Bolt (× 2)
Coolant reservoir capacity:
0.44 LLeft side
U5MTE1.book Page 13 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
617. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap.
18. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
19. Install the panel and the cowlings.
EAU04256*
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 3-13 for rider seat removal
and installation procedures.)
2. Remove the fuel tank bolts and
slightly lift the fuel tank.3. Turn the fuel cock lever to “OFF”,
and then disconnect the hoses
and the fuel sender coupler.
NOTE:_ Before removing the hoses, mark them
to ensure that they will be reinstalled in
their correct positions. _
1. Bolt (× 2)
1. Fuel cock
2. Hose (× 2)
3. Fuel sender coupler
U5MTE1.book Page 17 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU03730
Tail/brake light This motorcycle is equipped with an
LED type of tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it
counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
CAUTION:@ Do not overtighten the screw, other-
wise the lens may break. @
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
1. Screw
U5MTE1.book Page 39 Monday, August 6, 2001 6:10 PM