YAMAHA YZF600 2000 Repair Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
68. Apply a light coat of engine oil to
the O-ring of the new oil filter.
NOTE:@ Make sure the O-ring is seated proper-
ly. @9. Install the oil filter and tighten it to
the specified torque with an oil fil-
ter wrench.NOTE:When installing the oil filter, tighten it to
the proper torque by using a torque
wrench.
10. Fill the engine with sufficient oil to
reach the specified level. Install
the oil filler cap and tighten it.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@
11. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.NOTE:@ After the engine is started, the oil level
indicator light should go off if the oil is at
the specified level. @
EC000067
CAUTION:@ If the indicator light flickers or re-
mains on, immediately stop the en-
gine and consult with a Yamaha
dealer. @12. Install the cowling stay and cowl-
ing.
1. O-ring
Tightening torque:
Oil filter:
17 Nm (1.7 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
3.5 L
Periodic oil change:
2.6 L
With oil filter replacement:
2.9 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU03024
Cooling system1. Remove the seat. (See page 3-14
for seat removal and installation
procedures.)
2. Check the coolant level in the res-
ervoir tank when the engine is cold
as the coolant level will vary with
engine temperature. The coolant
level should be between the maxi-
mum and minimum marks.
3. If the level is low, add coolant or
distilled water to raise it to the
specified level.
4. Install the seat.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @NOTE:@ l
If water is added, have a Yamaha
dealer check the antifreeze con-
tent of the coolant as soon as pos-
sible.
l
The radiator fan operation is com-
pletely automatic. It is switched on
or off according to the coolant tem-
perature in the radiator.
@5. If your motorcycle overheats, see
page 6-41 for details.
1. Maximum level mark
2. Minimum level mark
Coolant reservoir capacity:
0.55 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU03025
Changing the coolant1. Put the motorcycle on a level place.
2. Remove the seat. (See page 3-14
for removal and installation proce-
dures.)
3. Remove cowling C. (See page 6-7
for removal and installation proce-
dures.)
4. Remove the bolts and the coolant
reservoir.
5. Drain the coolant from the coolant
reservoir.
6. Remove cowlings A and B. (See
page 6-5 for removal and installa-
tion procedures.)7. Remove the fuel tank bolts, then
lift the fuel tank upward. (Do not
remove the fuel hoses.)
EW000071
WARNING
@ l
Support the fuel tank carefully
during this procedure.
l
Do not tilt the fuel tank too
much or pull it too hard because
the fuel hose connections may
become loose causing fuel
leakage.
@
8. Remove the right air intake duct by
loosening and removing the screw
clamps.
1. Bolt (´ 2)
2. Coolant reservoir
1. Bolt (´ 2)
1. Screw clamp (´ 2)
2. Right air intake duct
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 9. Remove the radiator cap.
EW000067
WARNING
@ Do not remove the radiator cap
when the engine is hot. @10. Place a container under the en-
gine.
11. Remove the water pump drain bolt
and drain the coolant.
12. Remove the cylinder drain bolts
and drain the coolant.13. Install the water pump drain bolt
and cylinder drain bolts and tight-
en to the specified torque.
14. Pour the recommended coolant
into the radiator until it is full.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @15. Install the radiator cap.
16. Run the engine several minutes to
recheck the coolant level in the ra-
diator. If it is low, fill with more
coolant until it reaches the top of
the radiator.
17. Check for coolant leakage.
1. Radiator cap
1. Water pump drain bolt
2. Cylinder drain bolt (´ 2)
Tightening torque:
Drain bolt:
10 Nm (1.0 m·kg)
Recommended anti-freeze:
High quality ethylene glycol anti-
freeze containing corrosion inhib-
itors for aluminum engines.
Antifreeze and water mix ratio:
1:1
Total amount:
1.95 L
Coolant reservoir capacity:
0.55 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
NOTE:@ If you find any leaks, ask a Yamaha
dealer to inspect. @18. Install the right air intake duct, then
install and tighten the screw
clamps.
19. Install the fuel tank and fuel tank
bolts.
20. Install the coolant reservoir and
bolts.
21. Fill the coolant reservoir with the
recommended coolant to the
specified level.
22. Install cowlings A and B.
23. Install cowling C.
24. Install the seat.
EAU01475
Air filterThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat.
2. Remove the bolts holding the fuel
tank.
3. Lift the fuel tank upward and posi-
tion it away from the air filter case.
(Do not remove the fuel hoses.)
EW000071
WA R N I N G
@ l
Support the fuel tank carefully
during this procedure.
l
Do not tilt the fuel tank too
much or pull it too hard because
the fuel hose connections may
become loose causing fuel
leakage.
@4. Remove the screws holding the air
filter case cover.
1. Bolt (´ 2)
1. Air filter case cover
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 5. Pull out the air filter.
6. Remove the air filter from its guide
and clean it with solvent. After
cleaning, squeeze the air filter to
remove the remaining solvent.7. Apply recommended oil to the en-
tire surface of the filter and
squeeze out the excess oil. The air
filter should be wet but not drip-
ping.
EC000082
CAUTION:@ l
Make sure the air filter is prop-
erly seated in the air filter case.
l
The engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@8. Reverse the removal procedures
for installation.
EW000131
WA R N I N G
@ Make sure that the fuel hoses and
vacuum hose are properly connect-
ed, in place and not pinched. If a
hose is damaged, be sure to replace
it. @
1. Air filter element
2. Air filter guide
Recommended oil:
SAE 10W30 type SE motor oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00626
Air vent hoseIf dust or water collects in this hose, re-
move the hose and clean it.
EC000093
CAUTION:@ Do not operate the motorcycle with
the air vent hose removed. @
EAU01335
Air intake ductCheck that the screen of the intake
duct is not blocked. Clean the screen if
necessary.
EAU00630
Carburetor adjustmentThe carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
as part of routine maintenance.
EC000095
CAUTION:@ The carburetors were set at the
Yamaha factory after many tests. If
they are changed, poor engine per-
formance and damage may result. @
1. Hose
1. Air intake duct
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU00632
Idle speed adjustment1. Start the engine and warm it up for
a few minutes at approximately
1,000 to 2,000 r/min. Occasionally
rev the engine to 4,000 to
5,000 r/min. The engine is warm
when it quickly responds to the
throttle.
2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rection a
to increase engine
speed and in direction b
to de-
crease engine speed.
NOTE:@ If the specified idle speed cannot be
obtained by performing the above ad-
justment, consult a Yamaha dealer. @
EAU00635
Throttle cable free play
inspectionThere should be a free play of 3 ~
7 mm at the throttle grip. If the free play
is incorrect, ask a Yamaha dealer to
make this adjustment.
1. Throttle stop screw
Standard idle speed:
1,200 ~ 1,300 r/min
a. Free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician.
EAU00658
TiresTo ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
WARNING
@ Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed. @
CE-33EMaximum load*180 kg (except for A, CH, S)
178 kg (for A, CH, S)
Cold tire pressure Front Rear
Up to 90 kg load*225 kPa
(2.25 kg/cm
2,
2.25 bar)250 kPa
(2.50 kg/cm
2,
2.50 bar)
90 kg Maximum load*250 kPa
(2.50 kg/cm
2,
2.50 bar)290 kPa
(2.90 kg/cm
2,
2.90 bar)
High speed riding250 kPa
(2.50 kg/cm
2,
2.50 bar)290 kPa
(2.90 kg/cm
2,
2.90 bar)
* Load is the total weight of cargo, rider, passenger
and accessories.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EW000083
WARNING
@ Proper loading of your motorcycle
is important for several characteris-
tics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and dis-
tribute the weight evenly from side
to side. Properly adjust the suspen-
sion for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTOR-
CYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury. @
Tire inspection
Always check the tires before operating
the motorcycle. If center tread depth
reaches the limit as shown, if the tire
has a nail or glass fragments in it, or if
the side wall is cracked, contact a
Yamaha dealer immediately and have
the tire replaced.
EW000095
WA R N I N G
@ Operating the motorcycle with ex-
cessively worn tires decrease riding
stability and can lead to loss of con-
trol. Have excessively worn tires re-
placed by a Yamaha dealer
immediately. Brakes, tires, and relat-
ed wheel parts replacement should
be left to a Yamaha Service Techni-
cian. @CE-26ENOTE:@ These limits may be different by regula-
tion from country to country. If so, con-
form to the limits specified by the
regulations of your own country. @
1. Side wall
a. Tread depth
Minimum tire tread depth
(front and rear)1.6 mm
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