maintenance YAMAHA YZF600 2002 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU04281*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove the fuel tank bolts.
3. Lift the fuel tank to position it away
from the air filter case. (Do not dis-
connect the fuel hoses!)
EW000071
WARNING
_

Make sure that the fuel tank is
well supported.


Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
_4. Remove the air filter case cover by
removing the screws.5. Pull the air filter element out.
6. Clean the air filter element with
solvent, and then squeeze the re-
maining solvent out.
1. Fuel tank bolt (× 2)
1. Air filter case cover
2. Screw (× 8)
1. Air filter element
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 7. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
NOTE:_ The air filter element should be wet but
not dripping. _8. Insert the air filter element into the
air filter case.
EC000082*
CAUTION:_

Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
_9. Install the air filter case cover by
installing the screws.
10. Place the fuel tank in the original
position, and then install the bolts.
EW000072
WARNING
_

Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.


Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
_11. Install the seat.
EAU00626
Checking the air vent hose Periodically check the air vent hose for
dust or water that may be deposited in
the hose. If dust or water is found, re-
move the air vent hose, thoroughly
clean it, and then install it.
EC000093
CAUTION:_ Do not operate the motorcycle with
the air vent hose removed. _
Recommended oil:
Engine oil
1. Air vent hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU01335
Air intake duct Check that the screen of the intake
duct is not blocked. Clean the screen if
necessary.
EAU00630
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000095
CAUTION:_ The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. _
EAU00632
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–5,000 r/min.NOTE:_ The engine is warm when it quickly re-
sponds to the throttle. _
1. Air intake ductU4TVE6.book Page 19 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.
NOTE:_ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. _
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–7 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle stop screw
Engine idling speed:
1,200–1,300 r/min
a. Throttle cable free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00658
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
_

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
_
CE-01E
CE-07EEWA00012
WARNING
_ 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.
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg225 kPa
(2.25 kgf/cm
2,
2.25 bar)250 kPa
(2.50 kgf/cm
2,
2.50 bar)
90 kg–maximum250 kPa
(2.50 kgf/cm
2,
2.50 bar)290 kPa
(2.90 kgf/cm
2,
2.90 bar)
High-speed riding250 kPa
(2.50 kgf/cm
2,
2.50 bar)290 kPa
(2.90 kgf/cm
2,
2.90 bar)
Maximum load*180 kg (except for A, CH, S)
178 kg (for A, CH, S)
* Total weight of rider, passenger, cargo and
accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6


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 air
pressure 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 side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.CE-08ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
EW000079
WARNING
_

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility 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.
_
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
_

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 a
high-speed ride.
_
CE-10E
CE-14E
1. Tire air valve
2. Tire valve core
3. Tire valve cap with seal
FRONT
Manufacturer Size Model
Dunlop
120/60 ZR17 (55W)
D204F
120/60 ZR17 M/C (55W)
Metzeler
120/60 ZR17 (55W)
MEZ1 FRONT
120/60 ZR17 M/C (55W)
Bridgestone
120/60 ZR17 (55W)
BT57F
120/60 ZR17 M/C (55W)
Michelin
120/60 ZR17 (55W)
MACADAM 90X
120/60 ZR17 M/C (55W)
REAR
Manufacturer Size Model
Dunlop
160/60 ZR17 (69W)
D204
160/60 ZR17 M/C (69W)
Metzeler
160/60 ZR17 (69W)
MEZ1
160/60 ZR17 M/C (69W)
Bridgestone
160/60 ZR17 (69W)
BT57
160/60 ZR17 M/C (69W)
Michelin
160/60 ZR17 (69W)
MACADAM 90X
160/60 ZR17 M/C (69W)FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU00684
WARNING
_ This motorcycle is fitted with su-
per-high-speed tires. Note the fol-
lowing points in order to make the
most efficient 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
“broken in”. Therefore, it is ad-
visable before doing any
high-speed riding to ride con-
servatively for approximately
100 km after installing a new
tire.


The tires must be warmed up
before a high-speed run.


Always adjust the tire air pres-
sure according to the operating
conditions.
_
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU00692
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.
NOTE:_ If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism. _
EAU00712
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 42 mm below
the top of the footrest as shown. Peri-
odically check the brake pedal position
and, if necessary, have a Yamaha
dealer adjust it.
1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
a. Distance between brake pedal and footrest
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EW000109
WARNING
_ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b. 1. Rear brake light switch
2. Rear brake light switch adjusting nut
U4TVE6.book Page 26 Saturday, August 4, 2001 12:14 PM