warning YAMAHA YZF-R6 2003 Owner's Manual

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. @
EAU04223
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment under the
passenger seat. (See page 3-20 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.
NOTE:_ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. _
EW000063
WARNING
_ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. _
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
ECA00133
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-
rial enters the crankcase.
_13. 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. _14. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU04945
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.
_
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
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. Install 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
6-53 for further instructions.
_
EAU04970
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove panel A and cowling A.
(See pages 6-5–6-8 for panel and
cowling removal and installation
procedures.)
3. Place a container under the en-
gine to collect the used coolant.
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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
6-20
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
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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
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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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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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6
EW000079
WARNING
@

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
@
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
@

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.


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-14E
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
FRONT
Manufacturer Size Model
Michelin
120/60 ZR17 M/C (55W)
Pilot SPORT N
Dunlop
120/60 ZR17 M/C (55W)
D208F L
REAR
Manufacturer Size Model
Michelin
180/55 ZR17 M/C (73W)
Pilot SPORT B
Dunlop
180/55 ZR17 M/C (73W)
D208 L
FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
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6
EAU00684
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.
EAU01356
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
To increase the clutch lever free play,
turn the adjusting bolt at the clutch le-
ver in direction
a. To decrease the
clutch lever free play, turn the adjusting
bolt in direction
b.1. Clutch lever free play adjusting bolt
c. Clutch lever free play
U5SLE0.book Page 27 Wednesday, September 11, 2002 11:46 AM