maintenance YAMAHA YZF-R6 2003 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 4. Loosen the clamp screw, and then
disconnect the air intake duct.5. Remove the radiator cap.
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
6. Remove the coolant drain bolt to
drain the cooling system.
7. Loosen the clamp screw, and then
disconnect the radiator hose to
drain the radiator.
1. Clamp screw
2. Air intake duct
1. Radiator cap
1. Coolant drain bolt
2. Clamp screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
68. Remove the coolant reservoir cov-
er by removing the bolts.
9. Remove cowling B. (See page 6-5
for cowling removal and installa-
tion procedures.)10. Pull the fuel hoses upward to re-
move them from the guide.
11. Remove the coolant reservoir by
removing the bolts.
12. Remove the coolant reservoir cap,
and then turn the coolant reservoir
upside down to empty it.
13. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
14. Install the coolant reservoir by in-
stalling the bolts.
15. Connect the radiator hose, and
then tighten the clamp screw.
1. Coolant reservoir cover
2. Bolt (× 2)
1. Fuel hose (× 2)
1. Coolant reservoir cap
2. Coolant reservoir
3. Bolt (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 16. 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. _17. Pour the recommended coolant
into the reservoir to the maximum
level mark, and then install the
coolant reservoir cap.
18. Install the coolant reservoir cover
by installing the bolts.
19. Insert the fuel hoses into the guide
and place them in their original po-
sition.20. Install cowling B.
21. Pour the recommended coolant
into the radiator until it is full.
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.
_
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
2.15 L
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
622. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
23. 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.
24. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
25. Connect the air intake duct, and
then tighten the clamp screw.
26. Install the panel and the cowling.
EAU04946*
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
3-19 for rider seat removal and in-
stallation procedures.)
2. Remove the fuel tank bolts and
slightly lift the fuel tank.
1. Bolt (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 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
will be reinstalled in their correct posi-
tions. _
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.
EW000071
WARNING
_

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, which
could cause fuel leakage.
_
5. Remove the air filter case cover by
removing the screws.
1. Fuel tank breather hose
2. Fuel tank overflow hose
1. Screw (× 6)
2. Air filter case cover
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
66. 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.
8. Insert the element into the air filter
case.
EC000082*
CAUTION:_

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
pistons and/or cylinders may
become excessively worn.
_9. Install the air filter case cover by
installing 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.
1. Air filter element
1. Fuel tank breather hose
2. Fuel tank overflow hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EWA00071
WARNING
_

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 re-
place 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.
EAU01335
Air intake duct Check that the screen of the intake
duct is not blocked. Clean the screen if
necessary.1. Air intake duct
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU04578
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before
making this adjustment.NOTE:_ The engine is warm when it quickly re-
sponds to the throttle. _
Check the engine idling speed and, if
necessary, adjust it to specification by
turning the throttle stop screw. To in-
crease the engine idling speed, turn the
screw in direction
a. To decrease the
engine idling speed, turn the screw in
direction
b.NOTE:_ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. _
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 6–8 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
1. Throttle stop screw
Engine idling speed:
1,250–1,350 r/min
a. Throttle cable free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU00637
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.
EAU00658
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.
EW000082
WARNING
@

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
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
@
CE-01E
CE-07E
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg250 kPa
(2.50 kgf/cm
2,
2.50 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
90 kg–maximum250 kPa
(2.50 kgf/cm
2,
2.50 bar)290 kPa
(2.90 kgf/cm
2,
2.90 bar)
High-speed riding250 kPa
(2.50 kgf/cm
2,
2.50 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
Maximum load* 193 kg
* Total weight of rider, passenger, cargo and
accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EWA00012
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 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 side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.CE-08ENOTE:@ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. @1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
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