coolant YAMAHA YZF-R6 2002 Owners Manual

2-1
2
EAU00026
2-DESCRIPTION Left view1. Front fork compression damping force
adjusting screw (page 3-18)
2. Front fork rebound damping force
adjusting screw (page 3-18)
3. Front fork spring preload adjusting bolt (page 3-17)
4. Air filter element (page 6-17)
5. Shock absorber assembly compression
damping force adjusting screw (page 3-20)6. Shock absorber assembly spring preload
adjusting ring (page 3-19)
7. Shock absorber assembly rebound
damping force adjusting knob (page 3-20)
8. Shift pedal (page 3-9)
9. Coolant reservoir (page 6-13)
10. Engine oil filter cartridge (page 6-9)
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

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

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
CB-19E
Coolant
temperatureDisplay Conditions What to do0–40 °C Symbol and message
“LO” are displayed.OK. Go ahead with riding.
41–117 °C Symbol and temperature
are displayed.OK. Go ahead with riding.
118–140 °C Symbol and temperature
flash.
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 6-45 for further instructions.)
Above 140 °CSymbol and message
“HI” flash.
Warning light comes on.Stop the engine and allow it to cool.
(See the “Engine overheating” sec-
tion on page 6-45 for further in-
structions.)
˚C˚C˚C˚C
U5MTE1.book Page 4 Monday, August 6, 2001 6:10 PM

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

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

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
6-5
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
•Replace the brake hoses every four years and if cracked or damaged.
_25
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change. Every 3 years
26*Front and rear brake
switches•Check operation.√√√√√ √
27 Moving parts and cables•Lubricate.√√√√ √
28*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5MTE1.book Page 5 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
6-14
6
EC000080
CAUTION:_

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 of
the coolant will be reduced.
_
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _4. Close 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 page
6-45 for further instructions.
_
EAU01612
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove panel A, and cowlings A
and B. (See pages 6-6–6-8 for
panel and cowling removal and in-
stallation procedures.)
3. Place a container under the en-
gine to collect the used coolant.
4. Remove the radiator cap.
EW000067
WARNING
@ Never attempt to remove the radia-
tor cap when the engine is hot. @1. Radiator capRight side
U5MTE1.book Page 14 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
65. Remove the water pump drain bolt
to drain the water pump housing.
6. Loosen the clamp screw, and then
disconnect the radiator hose to
drain the radiator.
7. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
8. Connect the radiator hose, and
then tighten the clamp screw.
9. Install the coolant drain bolt, and
then tighten it to the specified
torque.
NOTE:@ Check the washer for damage and re-
place it if necessary. @
10. Remove the coolant reservoir cov-
er by removing the bolts.
1. Water pump drain bolt
2. Clamp screwRight side
Tightening torque:
Coolant drain bolt:
12 Nm (1.2 m·kgf)
1. Bolt (× 2)Left side
U5MTE1.book Page 15 Monday, August 6, 2001 6:10 PM