wheel YAMAHA YZF-R6 2003 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2003, Model line: YZF-R6, Model: YAMAHA YZF-R6 2003Pages: 130, PDF Size: 5.81 MB
Page 3 of 130
EAU04980
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM
Page 49 of 130
PRE-OPERATION CHECKS
4-2
4
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-23, 6-34
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-34
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-32–6-34
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-24–6-27
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-35–6-36
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-35
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-36
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-29
Air intake ductCheck that the screen is not clogged.
Clean if necessary.6-22 ITEM CHECKS PAGE
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM
Page 57 of 130
6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings and panels ..... 6-5
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-19
Air intake duct .................................................... 6-22
Adjusting the engine idling speed ...................... 6-23
Adjusting the throttle cable free play .................. 6-23
Adjusting the valve clearance ............................ 6-24
Tires ................................................................... 6-24
Cast wheels ....................................................... 6-27
Adjusting the clutch lever free play .................... 6-27
Adjusting the brake pedal position ..................... 6-29
Adjusting the rear brake light switch .................. 6-29
Checking the front and rear brake pads ............. 6-30
Checking the brake fluid level ............................ 6-31
Changing the brake fluid .................................... 6-32
Drive chain slack ................................................ 6-32
Lubricating the drive chain ................................. 6-33
Checking and lubricating the cables .................. 6-34Checking and lubricating the throttle grip and
cable ............................................................... 6-34
Checking and lubricating the brake and
clutch levers .................................................... 6-35
Checking and lubricating the brake and
shift pedals ...................................................... 6-35
Checking and lubricating the sidestand ............ 6-36
Checking the front fork ...................................... 6-37
Checking the steering ....................................... 6-37
Checking the wheel bearings ............................ 6-38
Battery ............................................................... 6-38
Replacing the fuses .......................................... 6-40
Replacing a headlight bulb ................................ 6-41
Replacing an auxiliary light bulb ....................... 6-43
Tail/brake light ................................................... 6-44
Replacing a turn signal light bulb ...................... 6-44
Replacing the license plate light bulb ................ 6-45
Supporting the motorcycle ................................ 6-45
Front wheel ....................................................... 6-46
Rear wheel ........................................................ 6-49
Troubleshooting ................................................. 6-51
Troubleshooting charts ...................................... 6-52
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM
Page 59 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4*Air filter elementClean.√√
Replace.√√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
9*WheelsCheck runout and for damage.√√√√
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM
Page 60 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 800 km and after washing
the motorcycle or riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
21*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter cartridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5SLE0.book Page 3 Wednesday, September 11, 2002 11:46 AM
Page 83 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
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)
U5SLE0.book Page 26 Wednesday, September 11, 2002 11:46 AM
Page 84 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
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
Page 89 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU00744
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:@ When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it. @2. Shift the transmission into the neu-
tral position.3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain
slack as shown.
4. If the drive chain slack is incorrect,
adjust it as follows.
a. Drive chain slackDrive chain slack:
35–45 mm
U5SLE0.book Page 32 Wednesday, September 11, 2002 11:46 AM
Page 90 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU03608
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction
b, and then
push the rear wheel forward.
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:@ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. @1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:@ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. @2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
Tightening torque:
Axle nut:
110 Nm (11.0 m·kgf)
U5SLE0.book Page 33 Wednesday, September 11, 2002 11:46 AM
Page 94 of 130
PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
U5SLE0.book Page 37 Wednesday, September 11, 2002 11:46 AM