fuel cap YAMAHA YZF600 2002 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: YZF600, Model: YAMAHA YZF600 2002Pages: 114, PDF Size: 4.94 MB
Page 15 of 114
3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................ 3-2
Speedometer unit ................................................ 3-3
Tachometer .......................................................... 3-4
Self-diagnosis device ........................................... 3-4
Coolant temperature gauge ................................. 3-5
Anti-theft alarm (optional) .................................... 3-5
Handlebar switches ............................................. 3-5
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-7
Brake lever ........................................................... 3-7
Brake pedal .......................................................... 3-8
Fuel tank cap ....................................................... 3-8Fuel ..................................................................... 3-9
Fuel tank breather hose (for Germany only) ..... 3-10
Starter (choke) lever .......................................... 3-11
Seat ................................................................... 3-11
Helmet holder .................................................... 3-12
Storage compartment ....................................... 3-12
Adjusting the front fork ...................................... 3-13
Adjusting the shock absorber assembly ............ 3-15
Matching the front and rear suspension
settings ............................................................ 3-17
Luggage strap holders ...................................... 3-18
Sidestand .......................................................... 3-18
Ignition circuit cut-off system ............................. 3-19
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM
Page 23 of 114
INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
EAU00162
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU02935
Fuel tank cap To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock. 2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
NOTE:_ The fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked. _
EWA00025
WARNING
_ Make sure that the fuel tank cap is
properly closed before riding. _
1. Brake pedal
1. Fuel tank cap lock cover
2. Unlock.
U4TVE6.book Page 8 Saturday, August 4, 2001 12:14 PM
Page 24 of 114
INSTRUMENT AND CONTROL FUNCTIONS
3-9
3
EAU03753
Fuel Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
WARNING
_
Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot
engine.
_
EAU00186
CAUTION:_
Immediately wipe off spilled fuel
with a clean, dry, soft cloth,
since fuel may deteriorate paint-
ed surfaces or plastic parts.
For Germany only: Whenever
replacement is necessary, use a
fuel tank cap of the same spe-
cial design as the original.
_
EAU04255ECA00104
CAUTION:_ Use only unleaded gasoline. The
use of leaded gasoline will cause se-
vere damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem. _Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
1. Fuel tank filler tube
2. Fuel level
Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
Total amount:
19 L
Reserve amount:
3.1 L
U4TVE6.book Page 9 Saturday, August 4, 2001 12:14 PM
Page 63 of 114
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _NOTE:_
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
If the engine overheats, see
page 6-45 for further instructions.
_
EAU04280
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove cowling D. (See page 6-7
for cowling removal and installa-
tion procedures.)
4. Remove the coolant reservoir by
removing the bolts.
5. Drain the coolant from the coolant
reservoir.
6. Remove cowlings A and C. (See
page 6-5 for cowling removal and
installation procedures.)7. Remove the fuel tank bolts, and
then lift the fuel tank. (Do not re-
move 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.
_
1. Bolt (× 2)
2. Coolant reservoir
1. Fuel tank bolt (× 2)
U4TVE6.book Page 14 Saturday, August 4, 2001 12:14 PM
Page 65 of 114
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 15. Install the coolant reservoir by in-
stalling the bolts.
16. Pour the specified amount of rec-
ommended coolant into the radia-
tor and reservoir.
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. _17. Install the radiator cap and the
coolant reservoir cap, start the en-
gine, let it idle for several minutes,
and then turn it off.
18. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap.
19. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
21. Install the right air intake duct, and
then tighten the clamp screws.22. Place the fuel tank in the original
position, and then install the bolts.
23. Install the cowlings.
24. Install the seat. Tightening torques:
Water pump drain bolt:
10 Nm (1.0 m·kgf)
Cylinder drain bolt:
7.0 Nm (0.7 m·kgf)
Antifreeze/water mixture ratio:
1:1
Recommended anti-freeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
1.95 L
Coolant reservoir capacity:
0.55 L
U4TVE6.book Page 16 Saturday, August 4, 2001 12:14 PM
Page 99 of 114
MOTORCYCLE CARE AND STORAGE
7-4
7
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:_
Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
_
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” posi-
tion: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.a. 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 then place the
spark plugs on the cylinder head
so that the electrodes are ground-
ed. (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, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM
Page 103 of 114
SPECIFICATIONS
8-2
8
Cooling system capacity
(total amount)
1.95 L
Air filterWet element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 19 L
Reserve amount 3.1 L
Carburetor
Manufacturer KEIHIN
Model × quantity CVKD36 × 4
Spark plug
Manufacturer/model NGK / CR9E or
DENSO / U27ESR-N
Gap 0.7–0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.708
Secondary reduction system Chain drive
Secondary reduction ratio 3.133
Number of drive chain
sprocket teeth (front/rear) 15/47
Transmission type Constant-mesh 6-speed
Operation Left footGear ratio
1st 2.846
2nd 1.947
3rd 1.545
4th 1.333
5th 1.190
6th 1.074
Chassis
Frame type Diamond
Caster angle 25°
Trail 97 mm
Tires
Front
Type Tubeless tire
Size 120/60 ZR17 (55W)
120/60 ZR17 M/C (55W)
Manufacturer/model Bridgestone / BT57F
Dunlop / D204F
Metzeler / MEZ1 FRONT
Michelin / MACADAM 90X
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM
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
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM
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
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM