maintenance YAMAHA YZF600 2000 Service Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6 6. Pull out the wheel axle along with
the right wheel axle guide, remove
the caliper bracket, and then the
wheel assembly by pulling back-
wards.
NOTE:@ l
Do not depress the brake pedal
when the caliper is off the disc as
the brake pads will be forced shut.
l
You do not have to disassemble
the chain in order to remove or in-
stall the wheel.
@
EAU01246*
Rear wheel installation1. Install the wheel assembly, right
wheel axle guide, caliper bracket,
and then insert the wheel axle.
2. Install the caliper and caliper bolts.
Make sure there is enough gap
between the brake pads before in-
stalling the caliper onto the brake
disc.
3. Tighten the brake torque rod bolt
to the specified torque.
4. Install and adjust the drive chain.
(See page 6-27 for details about
adjusting the drive chain slack.)5. Install the left wheel axle guide
and wheel axle nut and let the
motorcycle down.
6. Tighten the wheel axle nut and
caliper bolts to the specified
torques.
1. Caliper bracket
Tightening torque:
Brake torque rod bolt:
30 Nm (3.0 m·kg)
Axle nut:
117 Nm (11.7 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU01008
TroubleshootingAlthough Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.E_4tv_Periodic.fm Page 39 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
EAU02990*
Troubleshooting chart
EW000125
WARNING
@ Never check the fuel system while smoking or in the vicinity of an open flame. @
Check if there is fuel
in the fuel tank.1. Fuel
Enough fuel.
No fuel.
Go to compression check.
Supply fuel.
Engine doesn’t start, go to compression check.
Use the electric starter.2. Compression
There is compression.
No compression.
Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark plugs
and check electrodes.3. Ignition
Wet.
Dry.
Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, ask a Yamaha
dealer to inspect.Engine doesn’t start, go to battery
check.Open throttle half-way and start
the engine.
Use the electric starter.4. Battery
Engine turns over
quickly.
Engine turns over
slowly.
Battery good.Check connections or
recharge.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
Engine overheating
EW000070
WARNING
@ Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown
out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. @NOTE:@ If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible. @
Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.
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MOTORCYCLE CARE AND STORAGE
7-5
7a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs and place the spark
plugs on the cylinder head so that
the electrodes are grounded. (This
will limit sparking during the next
step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, install the spark
plugs and then the spark plug
caps.
EWA00003
WARNING
@ When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking. @
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, then raise 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.
8. Cover up the muffler outlet with a
plastic bag to prevent moisture
from entering.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
(less than 0 °C or more than
30 °C). For more information, see
“Battery storage” in the chapter
“PERIODIC MAINTENANCE AND
MINOR REPAIRS”.
NOTE:@ Make any necessary repairs before
storing the motorcycle. @
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INDEX
MMain switch/steering lock ......................... 3-1
Model label .............................................. 9-2NNeutral indicator light ............................... 3-2OOil level indicator circuit check ................. 3-4
Oil level indicator light .............................. 3-2PParking .................................................... 5-6
Pass switch ............................................. 3-8
Periodic maintenance and lubrication ...... 6-2
Pre-operation check list ........................... 4-1RRear brake pedal ................................... 3-10
Rear brake pedal height adjustment ...... 6-23
Rear shock absorber adjustment ........... 3-18
Rear suspension lubrication................... 6-30
Rear wheel installation........................... 6-38
Rear wheel removal............................... 6-37
Recommended combinations of the
front fork and the rear shock
absorber settings................................. 3-20
Recommended shift points
(for Switzerland only)............................. 5-5
Right view................................................ 2-2
SSeat ...................................................... 3-14
Shifting .................................................... 5-4
Shift pedal ............................................. 3-10
Sidestand .............................................. 3-21
Sidestand/clutch switch operation
check .................................................. 3-22
Sidestand lubrication ............................. 6-29
Spark plugs ............................................. 6-7
Specifications .......................................... 8-1
Speedometer .......................................... 3-6
Starter (choke) “ ” ............................. 3-13
Starting a warm engine ........................... 5-4
Starting the engine .................................. 5-1
Start switch ............................................. 3-9
Steering inspection................................ 6-31
Storage ................................................... 7-4
Storage compartment............................ 3-15TTachometer............................................. 3-6
Tail/brake light bulb replacement ........... 6-35
Throttle cable and grip lubrication.......... 6-28
Throttle cable free play inspection ......... 6-18
Tips for reducing fuel consumption .......... 5-5
Tires...................................................... 6-19
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-39
Troubleshooting chart ........................... 6-40
Turn indicator light................................... 3-3
Turn signal light bulb replacement ......... 6-35
Turn signal switch ................................... 3-8
VValve clearance adjustment ................... 6-19
Vehicle identification number ................... 9-1WWheel bearings...................................... 6-31
Wheels .................................................. 6-22
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