ECU YAMAHA YZF-R6 2004 Owners Manual

SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
193 kg (425 lb). When loading within
this weight limit, keep the following in
mind:

Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessoriesare added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
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INSTRUMENT AND CONTROL FUNCTIONS
3-1
3
EAU10971
Immobilizer system This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing.

a code re-registering key (with a
red bow)


two standard keys (with a black
bow) that can be re-registered with
new codes


a transponder (which is installed in
the code re-registering key)


an immobilizer unit


the ECU


an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-reg-
istered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
CAUTION:
ECA11820


DO NOT LOSE THE CODE RE-
REGISTERING KEY! CONTACT
YOUR DEALER IMMEDIATELY
IF IT IS LOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard
keys can still be used to start
the vehicle, however if code re-
registering is required (i.e., if a
new standard key is made or all
keys are lost) the entire immobi-
lizer system must be replaced.
Therefore, it is highly recom-mended to use either standard
key and keep the code re-regis-
tering key in a safe place.


Do not submerse any key in wa-
ter.


Do not expose any key to exces-
sively high temperatures.


Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).


Do not place heavy items on any
key.


Do not grind any key or alter its
shape.


Do not disassemble the plastic
part of any key.


Do not put two keys of any im-
mobilizer system on the same
key ring.


Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle’s code re-registering key.


Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-ference.
1. Code re-registering key (red bow)
2. Standard keys (black bow)
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INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
Passenger seat
To remove the passenger seat
1. Insert the key into the seat lock,
and then turn it counterclockwise.2. While holding the key in that posi-
tion, lift the front of the passenger
seat and pull it forward.
To install the passenger seat
1. Insert the projection on the rear of
the passenger seat into the seat
holder as shown, and then push
the front of the seat down to lock it
in place.
2. Remove the key.NOTE:Make sure that the seats are properlysecured before riding.
EAU14380
Helmet holders The helmet holders are located on the
bottom of the passenger seat.
To secure a helmet to a helmet hold-
er
1. Remove the passenger seat. (See
page 3-17.)
2. Attach the helmet to a helmet hold-
er, and then securely install the
passenger seat.
WARNING
EWA11040
Never ride with a helmet attached to
a helmet holder, since the helmet
may hit objects, causing loss of con-trol and possibly an accident.
1. Projection
2. Seat holder
1. Passenger seat lock
2. Unlock.
1. Projection
2. Seat holder
1. Helmet holder
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INSTRUMENT AND CONTROL FUNCTIONS
3-19
3
CAUTION:
ECA11600
Some helmets may contact the muf-
fler when secured to the right side
helmet holder because of their size
or shape. Be sure that your helmet
does not contact the muffler when itis secured to the helmet holder.
To release a helmet from a helmet
holder
Remove the passenger seat, remove
the helmet from the helmet holder, and
then install the seat.
EAU14431
Storage compartment The storage compartment is located
under the passenger seat. (See page
3-17.)
This storage compartment is designed
to hold a genuine Yamaha U-LOCK.
(Other locks may not fit.)
WARNING
EWA10961


Do not exceed the load limit of 3
kg (7 lb) for the storage com-
partment.


Do not exceed the maximum
load of 193 kg (425 lb) for the ve-hicle.
To place a U-LOCK in the storage
compartment
1. Remove the rubber cap from the
hole at the bottom of the storage
compartment, and then store it in a
safe place to prevent losing the
cap.
2. Insert the ends of the U-LOCK bar
into the holes at the bottom of the
storage compartment as shown.
3. Place the lock of the U-LOCK in
the location shown.
4. Securely fasten the U-LOCK bar
and lock with the strap as shown.
NOTE:

When the U-LOCK is not in the
storage compartment, be sure to
cover the hole at the bottom of the
storage compartment with the rub-
ber cap.
1. U-LOCK bar (optional)
2. Lock of U-LOCK (optional)
3. Strap
4. Rubber cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
WARNING
EWA11020
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 airpressure 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 sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
90–193 kg (198–425 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Maximum load*:
193 kg (425 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
WARNING
EWA10470


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability 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 informationThis motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING
EWA10480


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 ahigh-speed ride.
WARNING
EWA10600
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
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Front tire:
Size:
120/60 ZR17M/C (55W)
Manufacturer/model:
MICHELIN/Pilot SPORT N
DUNLOP/D208F J
Rear tire:
Size:
180/55 ZR17M/C (73W)
Manufacturer/model:
MICHELIN/Pilot SPORT B
DUNLOP/D208 AJ
FRONT and REAR:
Tire air valve:
TR412
Va l ve c o r e :
#9000A (original)
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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
6-35
6
EAU23940
Replacing a headlight bulb This model is equipped with quartz bulb
headlights. If a headlight bulb burns
out, replace it as follows.
1. Remove panel B (if replacing the
left headlight bulb) or panel A (if re-
placing the right headlight bulb).
(See page 6-6.)
2. Remove the headlight bulb cover
by turning it counterclockwise.
3. Disconnect the headlight coupler.4. Unhook the headlight bulb holder,
and then remove the defective
bulb.
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
5. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.CAUTION:
ECA10650
Take care not to damage the follow-
ing parts:

Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.
1. Headlight bulb cover
1. Headlight coupler
1. Headlight bulb holder
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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
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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