YAMAHA YZF-R6 2004 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6 Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU18711
Removing and installing
cowlings and panels The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAU19010
Cowlings A and B
To remove one of the cowlingsRemove the bolts, slide the cowling for-
ward (for A) or backward (for B), and
then pull it off as shown.
1. Cowling A
2. Panel A
1. Cowling B
2. Panel B
1. Bolt
1. Bolt
2. Cowling A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
To install the cowling
1. Fit the slots and projections at the
rear bottom of each cowling to-
gether, and then slide the cowling
into place.2. Place the cowling in the original
position, and then install the bolts.
NOTE:Make sure that the tabs at the front of
each cowling fit side by side as shown
and that all slots and projections fit to-gether.
EAU19460
Panels A and B
To remove one of the panels
Remove the bolts, slide the panel for-
ward, and then take it off.
1. Bolt
2. Cowling B
1. Cowling A
2. Cowling B
1. Slot
2. Projection
1. Tab
1. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6To install the panel
1. Fit the tabs on the panel into the
slots and slide it backward.
2. Install the bolts.
EAU19651
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be defective. Do
not attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
1. Tab
2. Slot
Specified spark plug:
NGK/CR9EK,CR10EK
1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.CAUTION:
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twistit back and forth while pushing it in.
EAU19930
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles.4. Remove the engine oil dipstick and
wipe it clean, insert it back into the
hole (without screwing it in), and
then remove it again to check the
oil level.
1. Dipstick
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
NOTE:The engine oil should be between theminimum and maximum level marks.
5. If the engine oil is at or below the
minimum level mark, remove the
oil filler cap, and then add sufficient
oil of the recommended type to
raise it to the correct level.
6. Insert and tighten the engine oil
dipstick, and then install and tight-
en the oil filler cap.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:Skip steps 4–10 if the oil filter cartridgeis not being replaced.
4. Remove the coolant reservoir cov-
er by removing the bolts.5. Remove cowling B. (See page
6-6.)
6. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:An oil filter wrench is available at aYamaha dealer.
7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
1. Engine oil drain bolt
1. Coolant reservoir cover
2. Bolt
1. Oil filter wrench
2. Engine oil filter cartridge
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
NOTE:
Make sure that the O-ring is properlyseated.
8. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.9. Install the cowling.
10. Install the coolant reservoir cover
by installing the bolts.
11. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.12. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
ECA11620


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 high-
er 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.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.40 L (2.54 US qt) (2.11 Imp.qt)
With oil filter cartridge replacement:
2.60 L (2.75 US qt) (2.29 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
613. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately 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 theoil level is sufficient.CAUTION:
ECA10400
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealercheck the vehicle.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
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.
EAU20111
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.3. If the coolant is at or below the
minimum level mark, remove the
coolant reservoir cover by remov-
ing the bolts, remove the reservoir
cap, and then add coolant to the
maximum level mark.
1. Maximum level mark
2. Minimum level mark
1. Coolant reservoir cover
2. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
CAUTION:
ECA10470


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 ofthe coolant will be reduced.WARNING
EWA10380
Never attempt to remove the radiatorcap 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 page6-43 for further instructions.
EAU20342
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.2. Remove panel A and cowling A.
(See page 6-6.)
3. Place a container under the engine
to collect the used coolant.
4. Loosen the clamp screw, and then
disconnect the air intake duct.
5. Remove the radiator cap.
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
1. Clamp screw
2. Air intake duct
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
66. 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.8. Remove the coolant reservoir cov-
er by removing the bolts.
9. Remove cowling B. (See page
6-6.)
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.
16. Install the coolant drain bolt, and
then tighten it to the specified
torque.
1. Radiator cap
1. Coolant drain bolt
2. Clamp screw
1. Coolant reservoir cover
2. Bolt
1. Fuel tank breather hose
2. Fuel tank overflow hose
1. Coolant reservoir cap
2. Coolant reservoir
3. Bolt
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