wheel YAMAHA YZF-R6 2004 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6 4. If the drive chain slack is incorrect,
adjust it as follows.
EAU22940
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.CAUTION:
ECA10570
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 thespecified limits.3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
1. Drive chain slack
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
Tightening torque:
Axle nut:
110 Nm (11.0 m·kgf, 80 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU23271
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
WARNING
EWA10750
Securely support the vehicle so thatthere 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 vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
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.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
5SLE1.book Page 31 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU23290
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU23440
Battery This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
WARNING
EWA10760


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
5SLE1.book Page 32 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
63. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by pushing it in.
6. Install the auxiliary light bulb cover
by installing the quick fastener.
NOTE:To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the auxiliary light bulb cover,
and then push the protruding pin in untilit is flush with the fastener head.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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
1. Auxiliary light bulb
2. Auxiliary light bulb socket
1. Quick fastener
2. Pin
12
5SLE1.book Page 38 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6 a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU24510
To remove the front wheel
WARNING
EWA10820


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


Securely support the motor-
cycle so that there is no dangerof 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 6-38.3. Remove the brake hose holder on
each side by removing the bolt.
4. Remove the brake caliper on each
side by removing the bolts.
5. Remove the axle bolt, pull the
wheel axle out, and then remove
the wheel.
1. Front wheel axle pinch bolt
1. Brake hose holder
2. Brake caliper
3. Axle bolt
4. Bolt
5SLE1.book Page 39 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
EAU25031
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 brakediscs.
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, holdthe axle bolt to keep it from turning.
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.
1. Wheel axle
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
Tightening torque:
Wheel axle:
91 Nm (9.1 m·kgf, 66 ft·lbf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
5SLE1.book Page 40 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6 12. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU25310
To remove the rear wheel
WARNING
EWA10820


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


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.2. Lift the rear wheel off the ground
according to the procedure on
page 6-38.
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 andinstall the rear wheel.
7. While supporting the brake caliper
bracket, pull the wheel axle out,
and then remove the wheel.
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
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
5. Brake caliper bracket
5SLE1.book Page 41 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU25660
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 6-26.)
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.
EAU25870
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 inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Wheel axle
1. Retainer
2. SlotTightening torque:
Axle nut:
110 Nm (11.0 m·kgf, 80 ft·lbf)
5SLE1.book Page 42 Friday, August 1, 2003 4:09 PM

MOTORCYCLE CARE AND STORAGE
7-1
7
EAU26030
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10770


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound afterwashing.
5SLE1.book Page 1 Friday, August 1, 2003 4:09 PM

MOTORCYCLE CARE AND STORAGE
7-4
74. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place
[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more in-
formation on storing the battery,
see page 6-32.
NOTE:Make any necessary repairs beforestoring the motorcycle.5SLE1.book Page 4 Friday, August 1, 2003 4:09 PM