maintenance YAMAHA YZF-R6 2003 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-46
6 To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU04956
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle bolt, the wheel
axle pinch bolts, and then the
brake caliper bolts.2. Lift the front wheel off the ground
according to the procedure on
page 6-45.
3. Remove the brake hose holder on
each side by removing the bolt.
4. Remove the brake caliper on each
side by removing the bolts.1. Front wheel axle pinch bolt (× 4)
1. Brake hose holder
2. Brake caliper
3. Axle bolt
4. Bolt (× 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-47
65. Remove the axle bolt, pull the
wheel axle out, and then remove
the wheel.
ECA00046
CAUTION:_ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. _
EAU05021
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts, and then tightening
them to the specified torque.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _5. Install the brake hose holders by
installing the bolts.
6. Secure the wheel axle by installing
the axle bolt, and then tightening
the wheel axle to the specified
torque.
NOTE:_ While tightening the wheel axle, hold
the axle bolt to keep it from turning. _
1. Wheel axle
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf)
Tightening torque:
Wheel axle:
91 Nm (9.1 m·kgf)
E_5sl_Periodic.fm Page 47 Thursday, October 17, 2002 1:13 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-48
6 7. Tighten wheel axle pinch bolt B,
and then tighten pinch bolt A to the
specified torque.
8. Retighten pinch bolt B to the spec-
ified torque.
9. Tap the outer side of the left fork
leg with a rubber mallet to align it
with the end of the wheel axle.10. Tighten wheel axle pinch bolt D,
and then tighten pinch bolt C to the
specified torque.
11. Retighten pinch bolt D to the spec-
ified torque.
12. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
1. Front wheel axle pinch bolt A
2. Front wheel axle pinch bolt B
3. Front wheel axle pinch bolt C
4. Front wheel axle pinch bolt D
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf)
E_5sl_Periodic.fm Page 48 Thursday, October 17, 2002 1:13 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-49
6
EAU04947
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut.2. Lift the rear wheel off the ground
according to the procedure on
page 6-46.
3. Remove the axle nut.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction
a.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
5. Brake caliper bracketU5SLE0.book Page 49 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-50
6 7. While supporting the brake caliper
bracket, pull the wheel axle out,
and then remove the wheel.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
EAU04948
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.NOTE:_

Be sure to insert the retainer on
the brake caliper bracket into the
slot in the swingarm.


Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
_
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-33 for
drive chain slack adjustment pro-
cedures.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
1. Wheel axle
1. Retainer
2. Slot
Tightening torque:
Axle nut:
110 Nm (11.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-51
6
EAU03087
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. U5SLE0.book Page 51 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-52
6
EAU02990
Troubleshooting charts Starting problems or poor engine performance
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-53
6Engine overheating
EW000070
WARNING
@

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.


After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
@aNOTE:@ If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible. @
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
U5SLE0.book Page 53 Wednesday, September 11, 2002 11:46 AM

10-INDEXAAir filter element, checking ..................... 6-19
Air intake duct ........................................ 6-22
Anti-theft alarm ...................................... 3-13
Auxiliary light bulb, replacing .................. 6-43BBattery ................................................... 6-38
Brake and clutch levers, checking and
lubricating ............................................ 6-35
Brake and shift pedals, checking and
lubricating ............................................ 6-35
Brake fluid, changing ............................. 6-32
Brake fluid level, checking...................... 6-31
Brake lever............................................. 3-16
Brake light switch (rear), adjusting ......... 6-29
Brake pads, checking............................. 6-30
Brake pedal............................................ 3-16
Brake pedal position, adjusting .............. 6-29CCables, checking and lubricating............ 6-34
Care.........................................................7-1
Catalytic converter ................................. 3-19
Clutch lever ............................................ 3-15
Clutch lever free play, adjusting ............. 6-27
Conversion table ......................................8-5
Coolant .................................................. 6-13
Changing .......................................... 6-15
Checking .......................................... 6-13
Coolant temperature warning light............3-6
Cowlings and panels, removing and
installing ................................................6-5
DDimmer switch ....................................... 3-13
Drive chain, lubricating .......................... 6-33
Drive chain slack ................................... 6-32
Adjusting .......................................... 6-33
Checking .......................................... 6-32EEngine break-in ....................................... 5-3
Engine idling speed ............................... 6-23
Engine oil and oil filter cartridge ............... 6-9
Engine stop switch................................. 3-14
Engine trouble warning light .................... 3-5FFront fork, adjusting ............................... 3-23
Front fork, checking ............................... 6-37
Fuel ....................................................... 3-17
Fuel consumption, tips for reducing ......... 5-3
Fuel level warning light ............................ 3-4
Fuel tank breather hose ......................... 3-18
Fuel tank cap ......................................... 3-17
Fuses, replacing .................................... 6-40HHandlebar switches ............................... 3-13
Hazard switch ........................................ 3-14
Headlight bulb, replacing ....................... 6-41
Helmet holders ...................................... 3-21
High beam indicator light ......................... 3-5
Horn switch ........................................... 3-14
IIdentification numbers ..............................9-1
Ignition circuit cut-off system ..................3-28
Immobilizer system..................................3-1
Immobilizer system indicator light.............3-6
Indicator and warning lights......................3-4KKey identification number .........................9-1LLicense plate light bulb, replacing...........6-45
Luggage strap holders ...........................3-27MMain switch/steering lock .........................3-2
Model label ..............................................9-2
Multi-function display................................3-8NNeutral indicator light ...............................3-5OOil level warning light ...............................3-5PParking.....................................................5-4
Part locations ...........................................2-1
Pass switch ............................................3-13
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1
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