check oil YAMAHA YZF600 2002 Owners Manual

DESCRIPTION
2-2
2
Right view11. Luggage strap holders (page 3-18)
12. Rear brake fluid level check window (page 6-28)
13. Coolant reservoir (page 6-13)
14. Front fork spring preload adjusting bolt (page 3-13)
15. Front fork rebound damping force adjusting screw (page 3-14)
16. Radiator cap (page 6-15)
17. Front fork compression damping force adjusting screw (page 3-14)
18. Engine oil level check window (page 6-10)
19. Brake pedal (page 3-8)
20. Engine oil filler cap (page 6-10)
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU01590
(Parking)
The steering is locked, and the taillight
and auxiliary light are on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “”.
ECA00043
CAUTION:_ Do not use the parking position for
an extended length of time, other-
wise the battery may discharge. _
EAU03034
Indicator and warning lights
EAU00061
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU03201
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked according to the fol-
lowing procedure.1. Set the engine stop switch to “”
and turn the key to “ON”.
2. Shift the transmission into the neu-
tral position or pull the clutch lever.
3. Push the start switch. If the warn-
ing light does not come on while
pushing the start switch, have a
Yamaha dealer check the electri-
cal circuit.
NOTE:_ Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function. _
1. Neutral indicator light “”
2. Oil level warning light “”
3. Fuel level warning light “”
4. Turn signal indicator light “”
5. High beam indicator light “”
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU03509
Fuel level warning light “”
This warning light comes on when the
fuel level drops below approximately
3.1 L . When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light
can be checked according to the fol-
lowing procedure.
1. Set the engine stop switch to “”
and turn the key to “ON”.
2. Shift the transmission into the neu-
tral position or pull the clutch lever. 3. Push the start switch. If the warn-
ing light does not come on, have a
Yamaha dealer check the electri-
cal circuit.
NOTE:_ This model is equipped with a self-di-
agnosis device for the fuel level warn-
ing light circuit. (See page 3-4 for an
explanation of the self-diagnosis de-
vice.) _
EAU00057
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00063
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU00095
Speedometer unit The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops.
1. Neutral indicator light “”
2. Oil level warning light “”
3. Fuel level warning light “”
4. Turn signal indicator light “”
5. High beam indicator light “”
1. Odometer
2. Tripmeter reset knob
3. Tripmeter
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4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13–6-14
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-27–6-28
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-25–6-28
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-25
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
NOTE:_ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. _
EC000038
CAUTION:_

The oil level warning light and
fuel level warning light should
come on when the start switch
is pushed, and they should go
off when the start switch is re-
leased.


If the oil level warning light flick-
ers or remains on after starting,
immediately stop the engine,
and then check the engine oil
level and the vehicle for oil leak-
age. If necessary, add engine
oil, and then check the warning
light again. If the warning light
does not come on when push-
ing the start switch, or if it doesnot go off after starting with suf-
ficient engine oil, have a
Yamaha dealer check the elec-
trical circuit.


If the fuel level warning light re-
mains on after starting, stop the
engine, and then check the fuel
level. If necessary, refuel as
soon as possible, and then
check the warning light again. If
the warning light does not come
on when pushing the start
switch, or if it does not go off af-
ter starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
_5. After starting the engine, move the
starter (choke) lever back halfway.
ECA00045
CAUTION:_ For maximum engine life, never ac-
celerate hard when the engine is
cold! _
6. When the engine is warm, turn the
starter (choke) off.NOTE:_ The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. _
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM

OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU01128
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU03749*
0–1,000 km
Avoid prolonged operation above
6,500 r/min.
1,000–1,600 km
Avoid prolonged operation above
8,000 r/min.
EC000052*
CAUTION:_ After 1,000 km of operation, the en-
gine oil must be changed and the oil
filter cartridge replaced. _1,600 km and beyond
The vehicle can now be operated nor-
mally.
EC000053
CAUTION:_

Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
_
U4TVE6.book Page 5 Saturday, August 4, 2001 12:14 PM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings ........................ 6-5
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge ........................ 6-10
Coolant .............................................................. 6-13
Cleaning the air filter element ............................ 6-17
Checking the air vent hose ................................ 6-18
Air intake duct .................................................... 6-19
Adjusting the carburetors ................................... 6-19
Adjusting the engine idling speed ...................... 6-19
Adjusting the throttle cable free play .................. 6-20
Adjusting the valve clearance ............................ 6-20
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-25
Adjusting the brake pedal position ..................... 6-25
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-27
Checking the brake fluid level ............................ 6-27
Changing the brake fluid .................................... 6-28
Drive chain slack ................................................ 6-29
Lubricating the drive chain ................................. 6-30Checking and lubricating the cables ................. 6-31
Checking and lubricating the throttle grip and
cable ............................................................... 6-31
Checking and lubricating the brake and shift
pedals ............................................................. 6-31
Checking and lubricating the brake and clutch
levers ............................................................... 6-32
Checking and lubricating the sidestand ............ 6-32
Lubricating the rear suspension ........................ 6-32
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-33
Checking the wheel bearings ............................ 6-34
Battery ............................................................... 6-35
Replacing the fuses .......................................... 6-36
Replacing the headlight bulb ............................. 6-37
Replacing the tail/brake light bulb ..................... 6-38
Replacing a turn signal light bulb ...................... 6-39
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-40
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-43
Troubleshooting charts ...................................... 6-44
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
10*WheelsCheck runout and for damage.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
15*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 SidestandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
22*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_23 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridgeReplace.√√√
25
*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
26*Front and rear brake
switchesCheck operation.√√√√√ √
27 Moving parts and cablesLubricate.√√√√ √
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EAU04279
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _
2. Start the engine, warm it up for sev-
eral minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion procedures.)
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
U4TVE6.book Page 10 Saturday, August 4, 2001 12:14 PM