brake YAMAHA YZF600 2002 Owner's Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: YZF600, Model: YAMAHA YZF600 2002Pages: 114, PDF Size: 4.94 MB
Page 89 of 114
PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
EAU03582
Front wheel To remove the front wheel
EW000122
WARNING
_
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Disconnect the speedometer ca-
ble from the front wheel.2. Remove the front fender by re-
moving the bolts.
3. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
4. Lift the front wheel off the ground
according to the procedure on
page 6-39.
5. Remove the brake hose holders
on each side by removing the
bolts.6. Remove the brake calipers on
each side by removing the bolts.
7. Pull the wheel axle out, remove
the speedometer gear unit, and
then remove the wheel.
ECA00046
CAUTION:_ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. _
1. Speedometer cable
2. Bolt (× 2)
3. Front fender
4. Bolt (× 2)
5. Brake caliper
6. Brake hose holderLeft side
1. Front fender
2. Bolt (× 2)
3 Front wheel axle pinch bolt
4. Wheel axle
5. Bolt (× 2)
6. Brake caliper
7. Brake hose holderRight side
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Page 90 of 114
PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
EAU04196
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:_ Make sure that the slot in the speedom-
eter gear unit fits over the retainer on
the fork leg. _3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.5. Install the brake calipers by install-
ing the bolts.
NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _6. Tighten the wheel axle, then the
front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
7. Install the brake hose holders by
installing the bolts.
8. Connect the speedometer cable.
9. Install the front fender by installing
the bolts.
10. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU04197
Rear wheel To remove the rear wheel
EW000122
WARNING
_
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no danger
of it falling over.
_
1. Speedometer gear unit
2. Slot
3. Speedometer gear unit retainer
Tightening torques:
Wheel axle:
65 Nm (6.5 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
1. Axle nut
2. Left wheel axle guide
3. Locknut
4. Drive chain slack adjusting nut
5. Wheel axle
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Page 91 of 114
PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6 1. Loosen the wheel axle nut, the
brake torque rod nut at the brake
caliper bracket, and the brake cal-
iper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-39.3. Remove the axle nut and the left
wheel axle guide, and then re-
move the brake caliper by remov-
ing the bolts.
4. Disconnect the brake torque rod
from the brake caliper bracket by
removing the cotter pin, the nut,
and the bolt.
5. Loosen the locknut and the drive
chain slack adjusting nut on both
sides of the swingarm.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the wheel. _
7. Pull the wheel axle out along with
the right wheel axle guide, remove
the brake caliper bracket, and then
remove the wheel.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
1. Cotter pin
2. Nut
3. Bolt
4. Brake torque rod
1. Bolt (× 2)
2. Right wheel axle guide
1. Brake caliper bracket
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Page 92 of 114
PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
6
EAU04283
To install the rear wheel
1. Install the wheel, right wheel axle
guide, and caliper bracket by in-
serting the wheel axle from the
right-hand side.
2. Install the drive chain onto the rear
sprocket, and then install the left
wheel axle guide and the axle nut.
3. Install the brake caliper by install-
ing the bolts, and then connect the
brake torque rod to the brake cali-
per bracket by installing the bolt
and nut.NOTE:_ Make sure that there is enough space
between the brake pads before installing
the brake caliper onto the brake disc. _
4. Adjust the drive chain slack. (See
page 6-29 for drive chain slack ad-
justment procedures.)
5. Lower the rear wheel so that it is
on the ground.
6. Tighten the axle nut, the brake cal-
iper bolts and the brake torque rod
nut to the specified torques.
7. Install a new cotter pin into the
brake torque rod bolt.
EWA00051
WARNING
_ Always use a new cotter pin for the
brake torque rod bolt. _
EAU03087
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
Tightening torques:
Axle nut:
117 Nm (11.7 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
Brake torque rod nut:
30 Nm (3.0 m·kgf)
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Page 97 of 114
MOTORCYCLE CARE AND STORAGE
7-2
7
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switch-
es and lights), breather hoses
and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
_After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:_ Salt sprayed on roads in the winter may
remain well into spring. _1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:_ Do not use warm water since it in-
creases the corrosive action of the
salt. _2. Apply a corrosion protection spray
on all metal, including chrome-
and nickel-plated, surfaces to pre-
vent corrosion.
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Page 98 of 114
MOTORCYCLE CARE AND STORAGE
7-3
7After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
_
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
Before operating the motor-
cycle test its braking perfor-
mance and cornering behavior.
_
ECA00013
CAUTION:_
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
_
NOTE:_ Consult a Yamaha dealer for advice on
what products to use. _
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Page 104 of 114
SPECIFICATIONS
8-3
8
Rear
Type Tubeless tire
Size 160/60 ZR17 (69W)
160/60 ZR17 M/C (69W)
Manufacturer/model Bridgestone / BT57
Dunlop / D204
Metzeler / MEZ1
Michelin / MACADAM 90X
Maximum load* 180 kg (except for A, CH, S)
178 kg (for A, CH, S)
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 225 kPa (2.25 kgf/cm
2, 2.25 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 290 kPa (2.90 kgf/cm2, 2.90 bar)
High-speed riding
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 290 kPa (2.90 kgf/cm2, 2.90 bar)
* Total weight of rider, passenger, cargo and accessoriesWheels
Fr o n t
Type Cast wheel
Size 17 × MT 3.50
17 M/C × MT 3.50
Rear
Type Cast wheel
Size 17 × MT 5.00
17 M/C × MT 5.00
Brakes
Fr o n t
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (link suspention)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
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Page 105 of 114
SPECIFICATIONS
8-4
8
Wheel travel
Front 130 mm
Rear 120 mm
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 18.5 A @ 5,000 r/min
Battery
Model YTX12-BS
Voltage, capacity 12 V, 10 Ah
Headlight typeQuar tz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
Auxiliary light 12 V, 4 W × 1
Meter lighting 12 V, 1.7 W × 4
Neutral indicator light 12 V, 3.4 W × 1
High beam indicator light 12 V, 3.4 W × 1
Oil level warning light 12 V, 3.4 W × 1
Turn signal indicator light 12 V, 3.4 W × 1
Fuel level warning light 12 V, 3.4 W × 1Fuses
Main fuse 30 A
Headlight fuse 20 A
Signaling system fuse 15 A
Radiator fan fuse 7.5 A
Ignition fuse 7.5 A
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Page 110 of 114
INDEXAAir filter element, cleaning ...................... 6-17
Air intake duct ........................................ 6-19
Air vent hose, checking .......................... 6-18
Anti-theft alarm ........................................3-5BBattery ................................................... 6-35
Brake and clutch levers, checking and
lubricating ............................................ 6-32
Brake and shift pedals, checking and
lubricating ............................................ 6-31
Brake fluid, changing ............................. 6-28
Brake fluid level, checking...................... 6-27
Brake lever...............................................3-7
Brake light switch (rear), adjusting ......... 6-26
Brake pads, checking............................. 6-27
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-25CCables, checking and lubricating............ 6-31
Carburetors, adjusting............................ 6-19
Care.........................................................7-1
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-25
Conversion table ......................................8-5
Coolant .................................................. 6-13
Changing .......................................... 6-14
Checking .......................................... 6-13
Coolant temperature gauge .....................3-5
Cowlings, removing and installing ............6-5
DDimmer switch ......................................... 3-5
Drive chain, lubricating .......................... 6-30
Drive chain slack ................................... 6-29
Adjusting .......................................... 6-29
Checking .......................................... 6-29EEngine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............. 6-10
Engine stop switch................................... 3-6FFront and rear suspension settings ........ 3-17
Front fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-33
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel level warning light ............................ 3-3
Fuel tank breather hose
(Germany only) ................................... 3-10
Fuel tank cap ........................................... 3-8
Fuses, replacing .................................... 6-36HHandlebar switches ................................. 3-5
Headlight bulb, replacing ....................... 6-37
Helmet holder ........................................ 3-12
High beam indicator light ......................... 3-3
Horn switch ............................................. 3-6
IIdentification numbers ..............................9-1
Idling speed, adjusting ...........................6-19
Ignition circuit cut-off system ..................3-19
Indicator and warning lights......................3-2KKey identification number .........................9-1LLight switch ..............................................3-6
Luggage strap holders ...........................3-18MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level warning light ...............................3-2PParking.....................................................5-6
Part locations ...........................................2-1
Pass switch ..............................................3-5
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seat .......................................................3-11
Self-diagnosis device ...............................3-4
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INDEX
Shifting .................................................... 5-3
Shift pedal ............................................... 3-7
Shift points (for Switzerland only)............. 5-4
Shock absorber assembly, adjusting ..... 3-15
Sidestand .............................................. 3-18
Sidestand, checking and lubricating....... 6-32
Spark plugs, checking ............................. 6-8
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever .............................. 3-11
Starting a warm engine ............................ 5-3
Starting the engine .................................. 5-1
Start switch .............................................. 3-6
Steering, checking ................................. 6-33
Storage.................................................... 7-4
Storage compartment ............................ 3-12
Supporting the motorcycle ..................... 6-39
Suspension (rear), lubricating ................ 6-32TTachometer ............................................. 3-4
Tail/brake light bulb, replacing ............... 6-38
Throttle cable free play, adjusting .......... 6-20
Throttle grip and cable, checking and
lubricating............................................ 6-31
Tires ...................................................... 6-21
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-43
Troubleshooting charts .......................... 6-44
Turn signal indicator light ......................... 3-3
Turn signal light bulb, replacing ............. 6-39
Turn signal switch .................................... 3-6
VValve clearance, adjusting .................... 6-20
Vehicle identification number................... 9-1WWheel bearings, checking ..................... 6-34
Wheel (front) ......................................... 6-40
Installing ............................................. 6-41
Removing ........................................ 6-40
Wheel (rear) .......................................... 6-41
Installing .......................................... 6-43
Removing ........................................ 6-41
Wheels .................................................. 6-24
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