fork YAMAHA YZF-R6 2007 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Multi-function meter unit .................3-7
Anti-theft alarm (optional) .............3-13
Handlebar switches ......................3-13
Clutch lever ...................................3-15
Shift pedal .....................................3-15
Brake lever ...................................3-15
Brake pedal ..................................3-16
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather/overflow
hose ..........................................3-18
Catalytic converter ........................3-18
Seats ............................................3-19
Helmet holding cable ....................3-20
Adjusting the front fork ..................3-21
Adjusting the shock absorber
assembly ...................................3-23
Luggage strap holders ..................3-25
EXUP system ...............................3-26Sidestand ..................................... 3-26
Ignition circuit cut-off system ........ 3-27
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing cowlings
and panels .................................. 6-6
Checking the spark plugs ............. 6-10
Engine oil and oil filter cartridge ... 6-11
Coolant ......................................... 6-14
Air filter element ........................... 6-17
Checking the throttle cable free
play ........................................... 6-18
Valve clearance ............................ 6-18
Tires ............................................. 6-18
Cast wheels .................................. 6-21Adjusting the clutch lever free
play ........................................... 6-21
Adjusting the rear brake light
switch ....................................... 6-22
Checking the front and rear brake
pads .......................................... 6-22
Checking the brake fluid level ...... 6-23
Changing the brake fluid .............. 6-24
Drive chain slack .......................... 6-24
Cleaning and lubricating the
drive chain ................................ 6-26
Checking and lubricating the
cables ....................................... 6-26
Checking and lubricating the
throttle grip and cable ............... 6-27
Checking and lubricating the
brake and shift pedals .............. 6-27
Checking and lubricating the
brake and clutch levers ............ 6-28
Checking and lubricating the
sidestand .................................. 6-28
Lubricating the swingarm
pivots ........................................ 6-29
Checking the front fork ................. 6-29
Checking the steering .................. 6-30
Checking the wheel bearings ....... 6-30
Battery ......................................... 6-31
Replacing the fuses ..................... 6-32
Replacing a headlight bulb .......... 6-33
Tail/brake light ............................. 6-35U2C0E1E0.book Page 1 Friday, July 7, 2006 11:14 AM

SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
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 sleepingbags, 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 accessories
are 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-
Maximum load:
193 kg (425 lb)
U2C0E1E0.book Page 3 Friday, July 7, 2006 11:14 AM

DESCRIPTION
2-1
2
EAU10410
Left view1. Fuse box 2 (page 6-32)
2. Front fork spring preload adjusting bolt (page 3-21)
3. Front fork rebound damping force adjusting screw (page 3-21)
4. Shock absorber assembly spring preload adjusting ring (page 3-23)
5. Shock absorber assembly compression damping force adjusting screw
(for fast compression damping) (page 3-23)
6. Shock absorber assembly compression damping force adjusting screw
(for slow compression damping) (page 3-23)
7. Owner’s tool kit (page 6-1)8. Shock absorber assembly rebound damping force adjusting screw
(page 3-23)
9. Shift pedal (page 3-15)
10.Engine oil drain bolt (page 6-11)
11.Engine oil filter cartridge (page 6-11)
12.Front fork compression damping force adjusting bolt (for fast compres-
sion damping) (page 3-21)
13.Front fork compression damping force adjusting bolt (for slow com-
pression damping) (page 3-21)U2C0E1E0.book Page 1 Friday, July 7, 2006 11:14 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-21
3
EAU38941
Adjusting the front fork This front fork is equipped with spring
preload adjusting bolts, rebound damp-
ing force adjusting screws and com-
pression damping force adjusting bolts.
WARNING
EWA10180
Always adjust both fork legs equal-
ly, otherwise poor handling and lossof stability may result.
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in di-
rection (a). To decrease the spring pre-load and thereby soften the
suspension, turn the adjusting bolt on
each fork leg in direction (b).
NOTE:Align the appropriate groove on the ad-
justing mechanism with the top of thefront fork collar.Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damp-
ing, turn the adjusting screw on each
fork leg in direction (a). To decrease the
rebound damping force and thereby
soften the rebound damping, turn the
adjusting screw on each fork leg in di-
rection (b).
1. Spring preload adjusting bolt
1. Current setting
2. Front fork collar
Spring preload setting:
Minimum (soft):
0
Standard:
1
Maximum (hard):
5
1. Rebound damping force adjusting screw
Rebound damping setting:
Minimum (soft):
17 click(s) in direction (b)*
Standard:
15 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
U2C0E1E0.book Page 21 Friday, July 7, 2006 11:14 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-22
3Compression damping force
To adjust the compression damping
force (for fast compression damping)To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting bolt on
each fork leg in direction (a). To de-
crease the compression damping force
and thereby soften the compression
damping, turn the adjusting bolt on
each fork leg in direction (b).
NOTE:The compression damping force set-
ting is determined by measuring dis-
tance A, shown in the illustration. The
longer distance A is, the higher the
compression damping force; the short-
er distance A is, the lower the compres-sion damping force.To adjust the compression damping
force (for slow compression damping)To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting bolt on
each fork leg in direction (a). To de-
crease the compression damping force
and thereby soften the compression
damping, turn the adjusting bolt on
each fork leg in direction (b).CAUTION:
ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum orminimum settings.
1. Compression damping force adjusting bolt
(for fast compression damping)
2. Compression damping force adjusting bolt
(for slow compression damping)
1. Distance ACompression damping setting (for
fast compression damping):
Minimum (soft):
Distance A = 8 mm (0.31 in)
Standard:
Distance A = 10 mm (0.39 in)
Maximum (hard):
Distance A = 12 mm (0.47 in)
Compression damping setting (for
slow compression damping):
Minimum (soft):
16 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting bolt fully turned in
direction (a)
U2C0E1E0.book Page 22 Friday, July 7, 2006 11:14 AM

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 50000 km
13 Drive chainCheck chain slack, alignment and condition.
Adjust and lubricate chain with a special O-ring chain lu-
bricant thoroughly. 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 20000 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 assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
21*Fuel injection systemAdjust synchronization.√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040U2C0E1E0.book Page 3 Friday, July 7, 2006 11:14 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAUM1650
Lubricating the swingarm piv-
ots The swingarm pivots must be lubricat-
ed at the intervals specified in the peri-
odic maintenance and lubrication chart.
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.
Recommended lubricant:
Lithium-soap-based grease
U2C0E1E0.book Page 29 Friday, July 7, 2006 11:14 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
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.
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.
U2C0E1E0.book Page 30 Friday, July 7, 2006 11:14 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
EAU33932
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 and nuts.
6. Secure the wheel axle by installing
the axle bolt, and then tightening
the axle bolt to the specified
torque.NOTE:While tightening the axle bolt, hold the
wheel axle with a 19-mm hexagonwrench 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 right 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:
35 Nm (3.5 m·kgf, 25 ft·lbf)
Tightening torque:
Axle bolt:
91 Nm (9.1 m·kgf, 66 ft·lbf)
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:
21 Nm (2.1 m·kgf, 15 ft·lbf)
U2C0E1E0.book Page 38 Friday, July 7, 2006 11:14 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
612. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU25311
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 6-36.
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) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
NOTE:

If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
Tightening torque:
Wheel axle pinch bolt:
21 Nm (2.1 m·kgf, 15 ft·lbf)
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
5. Brake caliper bracket
U2C0E1E0.book Page 39 Friday, July 7, 2006 11:14 AM