Yamaha Thundercat YZF600R Owner`s manual

OWNER’S MANUAL
YZF600RR
YZF600RRC
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2002.04-1.2×1 CR
(E)
LIT-11626-16-10
5AH-28199-16
EAU03438
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EAU00002
INTRODUCTION
Congratulations on your purchase of the Yamaha YZF600R/YZF600RC. This model
is the result of Yamaha’s vast experience in the production of fine sporting, touring,
and pacesetting racing machines. It represents the high degree of craftsmanship
and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met
these standards without reducing the performance or economy of operation of the
motorcycle. To maintain these high standards, it is important that you and your
Yamaha dealer pay close attention to the recommended maintenance schedules and
operating instructions contained within this manual.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
WARNING
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.
@
@
EAU00003
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IMPORTANT MANUAL INFORMATION
EW000000
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING
TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
@
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IMPORTANT MANUAL INFORMATION
AFFIX DEALER
LABEL HERE
EAU04247
YZF600RR/YZF600RRC
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
1st edition, March 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-10
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TABLE OF CONTENTS
EAU00009
1 SAFETY INFORMATION
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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SAFETY INFORMATION
Safe riding .......................................................................................... 1-1
Protective apparel .............................................................................. 1-3
Modifications ...................................................................................... 1-3
Loading and accessories ................................................................... 1-3
Gasoline and exhaust gas.................................................................. 1-5
Location of important labels .............................................................. 1-7
1
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SAFETY INFORMATION
EAU00014
1-
1
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE
DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE
OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who
did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
1-1
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SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many accidents have been caused by error of the motorcycle operator. A typical error made by the
operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean
angle for the speed).
a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.
6. The posture of the operator and passenger is important for proper control.
a. The operator should keep both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with
both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or other drugs.
8. This motorcycle is designed for on-road use only. It is not suitable for off-road use.
1-2
1
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SAFETY INFORMATION
Protective apparel
1
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels
and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and can
cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. A passenger should also observe the above precautions.
Modifications
Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,
may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may
also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the
weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme
caution when adding cargo or accessories to your motorcycle. Use extra care when riding a
motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading
cargo or adding accessories to your motorcycle:
1-3
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SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum
load limit of YZF600R 182 kg (401 lb) / YZF600RC 180 kg (397 lb). When loading within this weight
limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make
sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such items as sleeping bags, duffel bags, or tents, can create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories that may be available, you must personally be responsible
for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when
selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting
accessories.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground
clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.
1-4
1
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SAFETY INFORMATION
1
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross
winds. These accessories may also cause instability when passing or being passed by large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore,
such accessories are not recommended.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the
main switch. When parking the motorcycle, note the following:
1-5
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SAFETY INFORMATION
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash
the affected area with soap and water and change your clothes.
1-6
1
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SAFETY INFORMATION
EAU02977
Location of important labels
Please read the following important labels carefully before operating this motorcycle.
1
1-7
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SAFETY INFORMATION
1
5
CAUTION
Cleaning with alkaline or
acid cleaner, gasoline or
solvent will damage
windshield.
Use neutral detergent.
1
5JW-2835Y-00
2
6
3
7
4
1-8
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DESCRIPTION
Left view ............................................................................................. 2-1
Right view........................................................................................... 2-2
Controls and instruments ................................................................... 2-3
2
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DESCRIPTION
EAU00026
2-
Left view
2
1. Air intake duct
2. Fuel tank
3. Shock absorber assembly spring preload adjusting ring
4. Shock absorber assembly rebound damping force adjusting knob
5. Shock absorber assembly compression damping force adjusting screw
6. Storage compartment
7. Helmet holder
8. Grab bar
9. Shift pedal
10. Radiator
2-1
(page 6-21)
(page 3-7)
(page 3-14)
(page 3-14)
(page 3-15)
(page 3-11)
(page 3-10)
(page 3-6)
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DESCRIPTION
Right view
2
11. Luggage strap holders
12. Rear brake fluid level check window
13. Coolant reservoir
14. Front fork spring preload adjusting bolt
15. Front fork rebound damping force adjusting screw
16. Radiator cap
17. Front fork compression damping force adjusting screw
18. Engine oil level check window
19. Brake pedal
20. Engine oil filler cap
(page 3-17)
(page 6-30)
(page 6-17)
(page 3-12)
(page 3-12)
(page 6-18)
(page 3-13)
(page 6-13)
(page 3-7)
(page 6-13)
2-2
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DESCRIPTION
Controls and instruments
2
1. Clutch lever
2. Left handlebar switches
3. Starter (choke) lever
4. Speedometer unit
5. Tachometer
6. Coolant temperature gauge
7. Right handlebar switches
8. Brake lever
9. Throttle grip
10. Main switch/steering lock
(page 3-6)
(page 3-5)
(page 3-9)
(page 3-3)
(page 3-3)
(page 3-4)
(page 3-5)
(page 3-6)
(page 6-22)
(page 3-1)
2-3
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INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .....................................3-1
Indicator and warning lights ................................3-2
Speedometer unit ................................................3-3
Tachometer ..........................................................3-3
Self-diagnosis device ...........................................3-3
Coolant temperature gauge .................................3-4
Handlebar switches .............................................3-5
Clutch lever ..........................................................3-6
Shift pedal ............................................................3-6
Brake lever ...........................................................3-6
Brake pedal ..........................................................3-7
Fuel tank cap .......................................................3-7
Fuel ..................................................................... 3-8
Starter (choke) lever ............................................ 3-9
Seat ..................................................................... 3-9
Helmet holder .................................................... 3-10
Storage compartment ....................................... 3-11
Adjusting the front fork ...................................... 3-11
Adjusting the shock absorber assembly ............ 3-13
Matching the front and rear suspension
settings ............................................................ 3-16
Luggage strap holders ...................................... 3-17
Sidestand .......................................................... 3-17
Ignition circuit cut-off system ............................. 3-18
3
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INSTRUMENT AND CONTROL FUNCTIONS
EAU00027
3-
3
EAU00029
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00032
ON
All electrical systems are supplied with
power, and the headlight, meter lighting, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.
EAU00040
LOCK
The steering is locked, and all electrical
systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
3-1
1. Push.
2. Turn.
EW000016
WARNING
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motorcycle is stopped before turning the
key to “OFF” or “LOCK”.
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INSTRUMENT AND CONTROL FUNCTIONS
1.
2.
3.
4.
5.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on while
pushing the start switch, have a
Yamaha dealer check the electrical circuit.
Neutral indicator light “ ”
Oil level warning light “
”
Fuel level warning light “ ”
Turn signal indicator light “
”
High beam indicator light “
”
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on, have a
Yamaha dealer check the electrical circuit.
NOTE:
This model is equipped with a self-diagnosis device for the fuel level warning light circuit. (See page 3-3 for an
explanation of the self-diagnosis
device.)
@
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 malfunction.
@
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 following procedure.
@
@
EAU00057
EAU03509
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
3.1 L (0.7 Imp gal, 0.8 US gal). When
this occurs, refuel as soon as possible.
The electrical circuit of the warning light
can be checked according to the following procedure.
3-2
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.
3
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INSTRUMENT AND CONTROL FUNCTIONS
EAU00105
Self-diagnosis device
This model is equipped with a self-diagnosis device for the following electrical circuits:
● throttle position sensor
● fuel level warning light
If any of those circuits are defective,
the tachometer will repeatedly display
the following error code:
3
1. Odometer
2. Tripmeter reset knob
3. Tripmeter
1. Tachometer
2. Tachometer red zone
CB-11E
EAU00101
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 enable you to plan future fuel stops.
Tachometer
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
EC000003
CAUTION:
Do not operate the engine in the tachometer red zone.
Red zone: 13,200 r/min and above
0 r/min for
3 seconds
Circuit-specific
number of r/min
for 2.5 seconds
(See the table
below.)
Current
engine
speed for
3 seconds
Use the table below to identify the
faulty electrical circuit.
@
@
3-3
CB-12E
Specific r/min
Faulty electrical circuit
3,000 r/min
Throttle position sensor
8,000 r/min
Fuel level warning light
U5AH16.book Page 4 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
If the tachometer displays such an error code, note the circuit-specific number of r/min, and then have a Yamaha
dealer check the motorcycle.
EC000004
CAUTION:
When the tachometer displays an
error code, the motorcycle should
be checked as soon as possible in
order to avoid engine damage.
@
3
1. Coolant temperature gauge
2. Coolant temperature gauge red zone
@
EAU01652
Coolant temperature gauge
With the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. The
coolant temperature varies with changes in the weather and engine load. If
the needle reaches or enters the red
zone, stop the motorcycle and let the
engine cool. (See page 6-47 for further
instructions.)
EC000002
CAUTION:
Do not operate the engine if it is
overheated.
@
@
3-4
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INSTRUMENT AND CONTROL FUNCTIONS
EAU03889
Turn signal switch “
/
”
To signal a right-hand turn, push this
switch to “
”. To signal a left-hand
turn, push this switch to “
”. When
released, the switch returns to the center position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
3
1. Dimmer switch “
/
2. Turn signal switch “
3. Horn switch “
”
”
/
1. Engine stop switch “
2. Start switch “
”
”
/
”
EAU00129
EAU00118
Handlebar switches
Horn switch “
”
Press this switch to sound the horn.
EAU03888
Dimmer switch “
/
”
Set this switch to “
” for the high
beam and to “
” for the low beam.
EAU03890
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is
stuck.
EAU00143
Start switch “ ”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
@
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3-5
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INSTRUMENT AND CONTROL FUNCTIONS
3
1. Clutch lever
1. Shift pedal
EAU00152
EAU00157
Clutch lever
Shift pedal
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition
circuit cut-off system. (See page 3-18
for an explanation of the ignition circuit
cut-off system.)
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 6-speed constant-mesh transmission equipped on
this motorcycle.
3-6
1.
2.
3.
a.
Arrow mark
Brake lever position adjusting dial
Brake lever
Distance between brake lever and handlebar
grip
EAU00161
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
The brake lever is equipped with a position adjusting dial. To adjust the distance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure that
the appropriate setting on the adjusting
dial is aligned with the arrow mark on
the brake lever.
U5AH16.book Page 7 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
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 unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
@
3
1. Brake pedal
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.
@
1. Fuel tank cap lock cover
2. Unlock.
EWA00025
EAU02935
Fuel tank cap
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
@
@
To open the fuel tank cap
Open the fuel tank cap lock cover, insert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position with the key inserted in the
lock.
3-7
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INSTRUMENT AND CONTROL FUNCTIONS
EAU00185
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
@
@
EAU04265
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total amount:
19.0 L (4.2 Imp gal, 5.0 US gal)
Reserve amount:
3.1 L (0.7 Imp gal, 0.8 US gal)
1. Fuel tank filler tube
2. Fuel level
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, otherwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot
engine.
ECA00104
CAUTION:
Use only unleaded gasoline. The
use of leaded gasoline will cause severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust system.
_
_
3-8
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or 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.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
3
U5AH16.book Page 9 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
ECA00038
CAUTION:
Do not use the starter (choke) for
more than 3 minutes as the exhaust
pipe may discolor from excessive
heat. In addition, extended use of
the starter (choke) will cause afterburning. If this occurs, turn off the
starter (choke).
@
3
1. Starter (choke) lever “
”
@
1. Unlock.
EAU02973
Starter (choke) lever “
EAU04158
”
Seat
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).
Move the lever in direction b to turn off
the starter (choke).
To remove the seat
1. Insert the key into the helmet holder lock, and then turn it as shown.
2. Pull the seat off.
3-9
U5AH16.book Page 10 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Seat holder
2. Projection (× 2)
To install the seat
1. Insert the projections on the front
of the seat into the seat holder as
shown.
2. Push the rear of the seat down to
lock it in place.
3. Remove the key.
NOTE:
Make sure that the seat is properly secured before riding.
1. Helmet holder
2. Unlock.
EAU00261
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, turn the key
to the original position, and then remove it.
EW000030
_
_
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
@
@
3-10
U5AH16.book Page 11 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
When storing the owner’s manual or
other documents in the storage compartment, be sure to wrap them in a
plastic bag so that they will not get wet.
When washing the motorcycle, be
careful not to let any water enter the
storage compartment.
EAU01862
Adjusting the front fork
This front fork is equipped with spring
preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting
screws.
EW000035
3
WARNING
Always adjust both fork legs equally, otherwise poor handling and loss
of stability may result.
@
1. Storage compartment
EAU04101
Storage compartment
The storage compartment is located
under the seat. (See page 3-9 for seat
removal and installation procedures.)
@
EWA00005
_
WARNING
Do not exceed the load limit of
3 kg (7 lb) for the storage compartment.
● Do not exceed the maximum
load of YZF600R 182 kg (401 lb)
/ YZF600RC 180 kg (397 lb) for
the vehicle.
●
_
3-11
U5AH16.book Page 12 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Spring preload adjusting bolt
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in direction a. To decrease the spring preload
and
thereby
soften
the
suspension, turn the adjusting bolt on
each fork leg in direction b.
1. Current setting
2. Front fork cap bolt
1. Rebound damping force adjusting screw
CI-10E
Setting
Minimum (soft)
8
Standard
5
Maximum (hard)
1
NOTE:
Align the appropriate groove on the adjusting mechanism with the top of the
front fork cap bolt.
Rebound damping force
To increase the rebound damping
force and thereby harden the rebound
damping, turn the adjusting screw on
each fork leg in direction a. To decrease the rebound damping force and
thereby soften the rebound damping,
turn the adjusting screw on each fork
leg in direction b.
CI-02E
@
Minimum (soft)
10 clicks in direction b*
Standard
7 clicks in direction b*
Maximum (hard)
1 click in direction b*
* With the adjusting screw fully turned in direction a
@
3-12
U5AH16.book Page 13 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
EC000015
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
@
@
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above specifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
@
3
1. Compression damping force adjusting screw
Compression damping force
To increase the compression damping
force and thereby harden the compression damping, turn the adjusting screw
on each fork leg in direction a. To decrease the compression damping force
and thereby soften the compression
damping, turn the adjusting screw on
each fork leg in direction b.
@
CI-02E
Minimum (soft)
10 clicks in direction b*
Standard
7 clicks in direction b*
Maximum (hard)
1 click in direction b*
* With the adjusting screw fully turned in direction a
3-13
EAU03643
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjusting ring, a rebound damping force adjusting knob and a compression
damping force adjusting screw.
ECA00071
CAUTION:
Never attempt to turn the spring preload and rebound damping force adjusting mechanisms beyond the
maximum or minimum settings.
@
@
U5AH16.book Page 14 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
NOTE:
Although the total number of clicks of
the rebound damping force adjusting
mechanism may not exactly match the
above specifications due to small differences in production, the actual number of clicks always represents the
entire adjusting range. To obtain a precise adjustment, it would be advisable
to check the number of clicks of the rebound damping force adjusting mechanism and to modify the specifications
as necessary.
@
1. Spring preload adjusting ring
2. Position indicator
1. Rebound damping force adjusting knob
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction a. To decrease the spring preload and thereby
soften the suspension, turn the adjusting ring in direction b.
CI-10E
Rebound damping force
To increase the rebound damping
force and thereby harden the rebound
damping, turn the adjusting knob in direction a. To decrease the rebound
damping force and thereby soften the
rebound damping, turn the adjusting
knob in direction b.
CI-03E
Minimum (soft)
Setting
Minimum (soft)
25 clicks in direction b*
1
Standard
10 clicks in direction b*
Maximum (hard)
3 clicks in direction b*
Standard
3
Maximum (hard)
7
* With the adjusting knob fully turned in direction a
3-14
@
3
U5AH16.book Page 15 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00315
WARNING
This shock absorber contains highly pressurized nitrogen gas. For
proper handling, read and understand the following information before handling the shock absorber.
The manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
● Always have a Yamaha dealer
service the shock absorber.
@
3
1. Compression damping force adjusting screw
2. Position indicator
Compression damping force
To harden the compression damping,
decrease the setting by turning the adjusting screw. To soften the compression damping, increase the setting by
turning the adjusting screw. Make sure
that the position indicator is aligned
with the appropriate setting.
CI-10E
Setting
Minimum (soft)
6
Standard
4
Maximum (hard)
1
@
3-15
U5AH16.book Page 16 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU01580
Matching the front and rear suspension settings
Use this table as a guide to match the suspension and damping adjustments of the front fork and shock absorber assembly
according to various load conditions.
CI-05E
Load condition
Front fork adjustment
Shock absorber assembly adjustment
Spring preload
Compression
damping force
Rebound
damping force
Spring preload
Compression
damping force
Rebound
damping force
Rider only
1–8
1–10
1–10
1–5
1–6
3–25
With passenger
1–8
1–10
1–10
3–7
1–4
3–10
3
EC000015
CAUTION:
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
@
@
3-16
U5AH16.book Page 17 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
Left
EAU00330
Right
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
@
3
1. Luggage strap holder (× 4)
EAU04276
Luggage strap holders
There are four luggage strap holders,
two of which can be turned out for easier access.
@
EW000044
WARNING
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), otherwise the sidestand could contact
the ground and distract the operator, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the sidestand before starting off. Therefore,
check this system regularly as described below and have a Yamaha
dealer repair it if it does not function
properly.
@
@
3-17
U5AH16.book Page 18 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU03720
Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
● It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
3
EW000045
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
_
_
3-18
U5AH16.book Page 19 Wednesday, May 8, 2002 9:16 AM
INSTRUMENT AND CONTROL FUNCTIONS
CD-01E
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
3
YES
NOTE:
This check is most reliable if performed with
a warmed-up engine.
”.
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES
The system is OK. The motorcycle can be ridden.
3-19
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
PRE-OPERATION CHECKS
Pre-operation check list ..................................................................... 4-1
4
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
PRE-OPERATION CHECKS
EAU01114
4-
The 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 inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
3-8
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
6-13
Coolant
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
6-16–6-17
Front brake
•
•
•
•
•
Check 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.
6-29–6-30
Rear brake
•
•
•
•
•
Check 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.
6-27–6-30
Clutch
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
4
6-27
4-1
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
PRE-OPERATION CHECKS
ITEM
CHECKS
PAGE
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
6–22, 6-33
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
6-33
Drive chain
•
•
•
•
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
6-31
Wheels and tires
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-33
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-34
Sidestand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
6-34
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, lights, signals
and switches
• Check operation.
• Correct if necessary.
—
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
3-17
Air intake duct
• Check that the screen is not clogged.
• Clean if necessary.
6-21
4-2
6-23–6-26
4
U5AH16.book Page 3 Wednesday, May 8, 2002 9:16 AM
PRE-OPERATION CHECKS
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
@
@
EWA00033
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
@
@
4
4-3
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
Starting and warming up a cold engine ............................................. 5-1
Starting a warm engine ..................................................................... 5-3
Shifting .............................................................................................. 5-3
Engine break-in ................................................................................. 5-5
Parking .............................................................................................. 5-6
5
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU00372
5-
@
5
EAU00373
EAU00376
WARNING
● Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly
understand.
● Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
● Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
CAUTION:
● Make sure not to store personal
items near the air cleaner intake, otherwise air intake will be
blocked and performance will
suffer.
● Make sure not to put anything
near the battery and its terminals, otherwise electrical failure
and acid corrosion may result.
_
EAU01164*
Starting and warming up a
cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
● The transmission is in the neutral
position.
● The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
_
@
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-19.
● Never ride with the sidestand
down.
●
@
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
@
5-1
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
EC000035
not go off after starting with sufficient engine oil, have a
Yamaha dealer check the electrical circuit.
● If the fuel level warning light remains 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 after starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
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 preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
@
CAUTION:
If the fuel level warning light comes
on, check the fuel level, and, if necessary, refuel as soon as possible.
@
@
2. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
@
EC000038
@
@
3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-9 for starter (choke) operation.)
4. Start the engine by pushing the
start switch.
@
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
released.
● If the oil level warning light flickers or remains on after starting,
immediately stop the engine,
and then check the engine oil
level and the vehicle for oil leakage. If necessary, add engine
oil, and then check the warning
light again. If the warning light
does not come on when pushing the start switch, or if it does
5-2
@
5. After starting the engine, move the
starter (choke) lever back halfway.
ECA00055
CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
@
@
5
U5AH16.book Page 3 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
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. To avoid the possibility of excessive exhaust emissions,
never leave the starter (choke) on longer than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Temperatures above 10 °C (50 °F) require about
7 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) require about 35 seconds with the starter
(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
@
5
EAU01258
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
1. Shift pedal
N. Neutral position
EAU00423
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the
illustration.
@
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@
@
5-3
U5AH16.book Page 4 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
EC000048
@
@
CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU02988
EAU00427
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.
4. At the recommended shift points
shown in the table on page 5-5,
close the throttle, and at the same
time, quickly pull the clutch lever
in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral
position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
25 km/h (15.5 mi/h). If the engine
is about to stall or runs very roughly, pull the clutch lever in and use
the brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.
NOTE:
Always shift gears at the recommended shift points.
@
@
5-4
5
U5AH16.book Page 5 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU01128
EAU02989
Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
CF-05E
1st
2nd
3rd
4th
5th
5
→
→
→
→
→
2nd
3rd
4th
5th
6th
Acceleration
shift point
km/h (mi/h)
Deceleration
shift point
km/h (mi/h)
16 (10)
24 (15)
32 (20)
40 (25)
48 (30)
–
25 (15.5)
25 (15.5)
25 (15.5)
25 (15.5)
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 (1,000 mi).
For this reason, you should read the
following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km (1,000 mi). The various parts
in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
5-5
EAU03749*
0–1,000 km (0–600 mi)
Avoid prolonged operation
6,500 r/min.
above
1,000–1,600 km (600–1,000 mi)
Avoid prolonged operation above
8,000 r/min.
EC000052*
CAUTION:
After 1,000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge replaced.
_
_
U5AH16.book Page 6 Wednesday, May 8, 2002 9:16 AM
OPERATION AND IMPORTANT RIDING POINTS
1,600 km (1,000 mi) and beyond
The vehicle can now be operated normally.
EC000053
_
CAUTION:
● Keep the engine speed out of
the tachometer red zone.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
EAU00460
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
@
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
●
_
@
5-6
5
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance ..........................................6-1
Owner’s tool kit ....................................................6-1
Periodic maintenance chart for the emission
control system ...................................................6-3
General maintenance and lubrication chart .........6-4
Removing and installing cowlings ........................6-7
Checking the spark plugs ..................................6-10
Canister (for California only) ..............................6-12
Engine oil and oil filter cartridge ........................6-13
Coolant ..............................................................6-16
Cleaning the air filter element ............................6-19
Checking the air vent hose ................................6-21
Air intake duct ....................................................6-21
Adjusting the carburetors ...................................6-22
Adjusting the throttle cable free play ..................6-22
Adjusting the valve clearance ............................6-22
Tires ...................................................................6-23
Cast wheels .......................................................6-26
Accessories and replacement parts ..................6-26
Adjusting the clutch lever free play ....................6-27
Adjusting the brake pedal position .....................6-27
Adjusting the rear brake light switch ..................6-28
Checking the front and rear brake pads .............6-29
Checking the brake fluid level ............................6-29
Changing the brake fluid ................................... 6-30
Drive chain slack ............................................... 6-31
Lubricating the drive chain ................................ 6-32
Checking and lubricating the cables ................. 6-33
Checking and lubricating the throttle grip and
cable ............................................................... 6-33
Checking and lubricating the brake and
shift pedals ...................................................... 6-33
Checking and lubricating the brake and clutch
levers ............................................................... 6-34
Checking and lubricating the sidestand ............ 6-34
Lubricating the rear suspension ........................ 6-34
Checking the front fork ...................................... 6-35
Checking the steering ....................................... 6-35
Checking the wheel bearings ............................ 6-36
Battery ............................................................... 6-37
Replacing the fuses .......................................... 6-38
Replacing the headlight bulb ............................. 6-39
Replacing the tail/brake light bulb ..................... 6-40
Replacing a turn signal light bulb ...................... 6-41
Supporting the motorcycle ................................ 6-41
Front wheel ....................................................... 6-42
Rear wheel ........................................................ 6-43
Troubleshooting ................................................. 6-45
Troubleshooting charts ...................................... 6-46
6
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00462
6-
EAU01790
Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
EW000060
6
WARNING
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
@
@
EAU00467
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE
MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.
THESE CONTROLS NOT ONLY
FUNCTION TO ENSURE CLEANER
AIR, BUT ARE ALSO VITAL TO
PROPER ENGINE OPERATION AND
MAXIMUM PERFORMANCE. IN THE
FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES
RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.
6-1
1. Owner’s tool kit
EAU04479
Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-9 for seat removal
and installation procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
_
_
EW000062
WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
_
_
6
6-2
U5AH16.book Page 3 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00471
Periodic maintenance chart for the emission control system
INITIAL
No.
6
ITEM
ROUTINE
600 mi
(1,000 km)
or
1 month
ODOMETER READINGS
4,000 mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
1 * Valve clearance
• Check and adjust valve clearance when
engine is cold.
2
• Check condition.
• Adjust gap and clean.
√
Replace.
√
Replace.
√
Crankcase ventilation
3 *
system
• Check ventilation hose for cracks or damage.
• Replace if necessary.
√
√
√
√
√
4 * Fuel line
• Check fuel hose for cracks or damage.
• Replace if necessary.
√
√
√
√
√
5 * Fuel filter
• Replace every 20,000 mi (31,000 km) or
30 months.
6 * Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
Carburetor
7 *
Synchronization
• Adjust synchronization of carburetors.
8 * Idle speed
• Check and adjust engine idle speed.
• Adjust throttle cable free play.
Evaporative emission
9 * control system
(For California only)
• Check control system for damage.
• Replace if necessary.
Spark plugs
Every 30,000 mi (42,000 km) or 42 months
Replace.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-3
√
U5AH16.book Page 4 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00472
General maintenance and lubrication chart
INITIAL
No.
ITEM
ROUTINE
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
√
√
√
√
√
1
Engine oil
• Replace (warm engine before draining).
(See NOTE on page 6-6.)
√
2 *
Engine oil filter
cartridge
• Replace at 600 mi (1,000 km) or 1 month,
and thereafter every 8,000 mi (13,000 km) or
12 months.
√
3 *
Air filter element/
surge tank
• Clean.
• Replace if necessary.
√
√
√
√
√
• Check hose for cracks or damage.
• Replace if necessary.
√
√
√
√
√
4 *
Cooling system
√
√
• Replace coolant every 24 months.
• Ethylene glycol anti-freeze coolant.
Replace.
5 *
Brake system
• Check operation, pad wear, and fluid
leakage. (See NOTE on page 6-6.)
• Replace pads if necessary.
√
√
√
√
√
√
6 *
Clutch
• Check operation.
• Correct if necessary.
√
√
√
√
√
√
7 *
Control and meter
cables
• Apply chain lube thoroughly.
• Yamaha Chain and Cable Lube or engine oil
SAE 10W-30 (API SE).
√
√
√
√
√
√
8 *
Swingarm pivot
bearing
• Check bearing assembly for looseness.
• Moderately repack every 16,000 mi
(25,000 km) or 24 months.
• Lithium-soap-based grease
√
Repack.
9 *
Rear suspension link
pivots
• Check operation.
• Apply grease lightly every 16,000 mi
(25,000 km) or 24 months.
• Lithium-soap-based grease
√
√
10 *
Shock absorber
assembly
• Check operation and for oil leakage.
• Replace if necessary.
√
6-4
√
√
√
√
6
U5AH16.book Page 5 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ROUTINE
ODOMETER READINGS
4,000 mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000 mi
(19,000 km)
or
18 months
16,000 mi
(25,000 km)
or
24 months
20,000 mi
(31,000 km)
or
30 months
Front fork
• Check operation and for oil leakage.
• Replace if necessary.
√
√
√
√
√
12 *
Steering bearings
• Check bearing assembly for looseness.
• Moderately repack every 16,000 mi
(25,000 km) or 24 months.
• Lithium-soap-based grease
√
√
√
Repack.
√
13
Brake and clutch
lever pivot shafts
• Apply chain lube lightly.
• Lithium-soap-based grease
(all-purpose grease)
√
√
√
√
√
14
Brake and shift pedal
pivot shafts
• Apply chain lube lightly.
• Lithium-soap-based grease
(all-purpose grease)
√
√
√
√
√
15 *
Drive chain
• Check chain slack/alignment condition.
• Adjust and lubricate chain thoroughly.
• Special O-ring chain lubricant.
16 *
Wheel bearings
• Check bearing for smooth rotation.
√
√
√
√
√
17 *
Sidestand pivot
• Check operation and lubricate.
• Apply chain lube lightly.
• Lithium-soap-based grease
(all-purpose grease)
√
√
√
√
√
18 *
Sidestand switch
• Check and clean or replace if necessary.
√
√
√
√
√
Chassis fasteners
• Check all chassis fittings and fasteners.
• Correct if necessary.
√
√
√
√
√
11 *
6
ITEM
600 mi
(1,000 km)
or
1 month
19 *
Every 600 mi (1,000 km) and after washing the motorcycle or riding in the rain.
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAU03907
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
_
_
6-5
U5AH16.book Page 6 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03234
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 cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
● Engine oil type
• Yamalube 4 (20W-40) or engine oil SAE 20W-40 (API SE) for temperatures of 5 °C (40 °F) or above.
• Yamalube 4 (10W-30) or engine oil SAE 10W-30 (API SE) for temperatures of 15 °C (60 °F) or below.
_
_
6
6-6
U5AH16.book Page 7 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Cowling A
2. Cowling B
EAU01065
Removing and installing
cowlings
6
1. Cowling C
2. Cowling D
1. Bolt (× 3 on each side)
Refer to this section each time a cowling needs to be removed and installed.
Cowlings A and C
To remove one of the cowlings
1. Remove the bolts.
EAU04277
The cowlings shown above need to be
removed to perform some of the maintenance jobs described in this chapter.
6-7
U5AH16.book Page 8 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Left side
Bolt (× 13)
Right side
Left side
1. Bolt (× 5 on each side)
Right side
1. Auxiliary light coupler
2. Turn signal connector (× 2)
2. Disconnect the turn signal connectors (and, for the left-side cowling,
also the auxiliary light coupler),
and then take the cowling off.
To install the cowling
1. Connect the turn signal connectors (and, for the left-side cowling,
also the auxiliary light coupler).
2. Place the cowling in the original
position, and then install the bolts.
6-8
6
U5AH16.book Page 9 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
To install the cowling
1. Place the cowling in the original
position, and then install the
screw.
2. Install the grab bar by installing the
bolts.
3. Install the cowling and the seat.
1. Screw (× 2)
EAU03595
6
Cowling B
To remove the cowling
1. Remove the seat. (See page 3-9
for seat removal and installation
procedures.)
2. Remove the screws, and then pull
the cowling off as shown.
NOTE:
Pull the cowling up, then back to remove it.
_
1. Bolt (× 2)
2. Screw
EAU04278*
Cowling D
To remove the cowling
1. Remove the seat and cowling B.
(See page 3-9 for seat removal
and installation procedures.)
2. Remove the grab bar by removing
the bolts.
3. Remove the screw, and then pull
the cowling off as shown.
_
To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Install the seat.
6-9
U5AH16.book Page 10 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Spark plug cap (× 2 on each side)
1. Spark plug wrench
EAU03329
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
2. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-tolight tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:
If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
@
To remove a spark plug
1. Remove the spark plug cap.
@
6-10
6
U5AH16.book Page 11 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
Specified spark plug:
CR9E (NGK) or
U27ESR-N (DENSO)
@
a. Spark plug gap
6
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
2. Clean the surface of the spark
plug gasket and its mating surface, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
6-11
@
4. Install the spark plug cap.
U5AH16.book Page 12 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01796
Canister (for California only)
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere.
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if
damaged.
● Make sure the vent hose is not
blocked. Clean it if necessary.
1.
2.
3.
4.
Fuel tank
Canister
Vent hose
Carburetor
6
6-12
U5AH16.book Page 13 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04627
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 cartridge replaced at the intervals specified 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.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2. Start the engine, warm it up for
several minutes, and then turn it off.
3. Wait a few minutes until the oil settles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
6
NOTE:
Make sure that the motorcycle is positioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.
_
_
NOTE:
The engine oil should be between the
minimum and maximum level marks.
_
_
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
6-13
1. Engine oil filler cap
To change the engine oil (with or
without oil filter cartridge replacement)
1. Remove cowling A. (See page 6-7
for cowling removal and installation 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.
U5AH16.book Page 14 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Left side
1. Engine oil drain bolt
4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:
Skip steps 5–7 if the oil filter cartridge is
not being replaced.
_
1. Oil filter cartridge
2. Oil filter wrench
1. O-ring
5. Remove the oil filter cartridge with
an oil filter wrench.
6. Apply a thin coat of engine oil to
the O-ring of the new oil filter cartridge.
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
NOTE:
Make sure that the O-ring is properly
seated.
_
_
_
_
_
7. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
6-14
6
U5AH16.book Page 15 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.6 L (2.3 Imp qt, 2.8 US qt)
With oil filter cartridge
replacement:
2.9 L (2.6 Imp qt, 3.1 US qt)
Total amount (dry engine):
3.5 L (3.1 Imp qt, 3.7 US qt)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
9. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
NOTE:
After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.
_
_
EC000067
CAUTION:
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealer check the vehicle.
_
ECA00133
6
_
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
● Make sure that no foreign material enters the crankcase.
_
6-15
_
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowling.
U5AH16.book Page 16 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03987
Coolant
Coolant reservoir capacity:
0.55 L (0.48 Imp qt, 0.58 US qt)
The coolant level should be checked
before each ride. In addition, the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
EC000080
_
1. Maximum level mark
2. Minimum level mark
2. Check the coolant level in the
coolant reservoir.
_
_
NOTE:
The coolant should be between the
minimum and maximum level marks.
_
_
3. If the coolant is at or below the
minimum level mark, remove the
seat (See page 3-9 for seat removal and installation procedures.), and then open the coolant
reservoir cap.
4. Add coolant or distilled water to
raise the coolant to the specified
level, close the coolant reservoir
cap, and then install the seat.
6-16
_
CAUTION:
● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
● If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling system will not be protected
against frost and corrosion.
● If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
6
U5AH16.book Page 17 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000067
WARNING
Never attempt to remove the radiator cap when the engine is hot.
_
_
NOTE:
● The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator.
● If the engine overheats, see page
6-47 for further instructions.
_
_
6
1. Bolt (× 2)
2. Coolant reservoir
1. Fuel tank bolt (× 2)
7. Remove the fuel tank bolts, and
then lift the fuel tank. (Do not remove the fuel hoses.)
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 3-9
for seat removal and installation
procedures.)
3. Remove cowling D. (See page 6-9
for cowling removal and installation 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 6-7 for cowling removal and
installation procedures.)
6-17
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.
U5AH16.book Page 18 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Clamp screw (× 2)
2. Right air intake duct
8. Remove the right air intake duct by
loosening the clamp screws.
1. Radiator cap
1. Water pump drain bolt
2. Cylinder drain bolt (× 2)
9. Remove the radiator cap.
EW000067
WARNING
Never attempt to remove the radiator cap when the engine is hot.
_
_
10. Place a container under the engine to collect the used coolant.
11. Remove the water pump drain bolt
to drain the cooling system.
12. Remove the cylinder drain bolts to
drain the cooling system.
13. After the coolant is completely
drained, thoroughly flush the cooling system with clean tap water.
14. Install the water pump drain bolt
and cylinder drain bolts, and then
tighten them to the specified
torques.
Tightening torques:
Water pump drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder drain bolt:
7.0 Nm (0.7 m·kgf, 5.1 ft·lbf)
15. Install the coolant reservoir by installing the bolts.
6-18
6
U5AH16.book Page 19 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
16. Pour the specified amount of recommended coolant into the radiator and reservoir.
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 (1.72 Imp, 2.06 US qt)
Coolant reservoir capacity:
0.55 L (0.48 Imp, 0.58 US qt)
6
ECA00041
CAUTION:
Hard water or salt water is harmful
to the engine. You may use soft water if you can’t get distilled water.
_
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 radiator, and then install the radiator
cap.
19. Check the coolant level in the reservoir. 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.
_
17. Install the radiator cap and the
coolant reservoir cap, start the engine, let it idle for several minutes,
and then turn it off.
6-19
1. Fuel tank bolt (× 2)
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 frequently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-9
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 disconnect the fuel hoses!)
U5AH16.book Page 20 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Air filter case cover
2. Screw (× 8)
1. Air filter element
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.
●
7. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.
5. Pull the air filter element out.
6. Clean the air filter element with
solvent, and then squeeze the remaining solvent out.
6
NOTE:
The air filter element should be wet but
not dripping.
_
_
_
Recommended oil:
YAMAHA FOAM FILTER OIL or
engine oil
4. Remove the air filter case cover by
removing the screws.
8. Insert the air filter element into the
air filter case.
6-20
U5AH16.book Page 21 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000082*
_
CAUTION:
● Make sure that the air filter element is properly seated in the
air filter case.
● The engine should never be operated without the air filter element installed, otherwise the
pistons and/or cylinders may
become excessively worn.
1. Air vent hose
1. Air intake duct
EAU00626
_
6
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, otherwise fuel may leak.
● Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
●
Air intake duct
Periodically check the air vent hose for
dust or water that may be deposited in
the hose. If dust or water is found, remove the hose, thoroughly clean it, and
then install it.
Check that the screen of the intake
duct is not blocked. Clean the screen if
necessary.
EC000093
CAUTION:
Do not operate the motorcycle with
the air vent hose removed.
@
@
_
11. Install the seat.
EAU01335
Checking the air vent hose
6-21
U5AH16.book Page 22 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00628
EAU00637
Adjusting the carburetors
Adjusting the valve clearance
The carburetors are important parts of
the engine and emission control system, which require very sophisticated
adjustment. Therefore, all carburetor
adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience.
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.
a. Throttle cable free play
EAU00635
Adjusting the throttle cable
free play
The throttle cable free play should
measure 3–7 mm (0.12–0.28 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
6-22
6
U5AH16.book Page 23 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03581
CE-22E
Tires
To maximize the performance, durability, and safe operation of your motorcycle, 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
@
6
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, cargo, and accessories approved
for this model.
EW000083
Tire air pressure
(measured on cold tires)
WARNING
Proper loading of your motorcycle
is important for several characteristics 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 distribute the weight evenly from side
to side. Properly adjust the suspension for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTORCYCLE. Make sure that the total
weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this
model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle
could cause tire damage, an accident, or even injury.
@
Load*
Front
Rear
Up to 90 kg (198 lb)
225 kPa
250 kPa
(2.25 kgf/cm2, (2.50 kgf/cm2,
33 psi)
36 psi)
90 kg (198 lb)–
maximum
250 kPa
290 kPa
(2.50 kgf/cm2, (2.90 kgf/cm2,
36 psi)
42 psi)
High-speed riding
250 kPa
290 kPa
(2.50 kgf/cm2, (2.90 kgf/cm2,
36 psi)
42 psi)
CE-16E
Maximum load*
YZF600R: 182 kg (401 lb)
YZF600RC: 180 kg (397 lb)
* Total weight of rider, passenger, cargo and
accessories
@
@
6-23
U5AH16.book Page 24 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000094
@
1. Tire sidewall
2. Tire wear indicator
a. Tire tread depth
Tire inspection
Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise lines (minimum tread depth),
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.
WARNING
● It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.
● The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
@
CE-09E
Minimum tire tread depth
(front and rear)
1.0 mm (0.04 in)
6-24
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
6
U5AH16.book Page 25 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000080
@
●
●
●
6
●
WARNING
The front and rear tires should
be of the same make and design, otherwise the handling
characteristics of the motorcycle cannot be guaranteed.
After extensive tests, only the
tires listed below have been approved 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
FRONT
EAU00684
Manufacturer
Size
Model
WARNING
This motorcycle is fitted with superhigh-speed tires. Note the following
points in order to make the most efficient use of these tires.
● Use only the specified replacement tires. Other tires may run
the danger of bursting at super
high speeds.
● Brand-new tires can have a relatively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km
(60 mi) after installing a new
tire.
● The tires must be warmed up
before a high-speed run.
● Always adjust the tire air pressure according to the operating
conditions.
@
Dunlop
Metzeler
Bridgestone
Michelin
120/60 ZR17 (55W)
D204FG
120/60 ZR17 M/C (55W)
120/60 ZR17 (55W)
MEZ1
120/60 ZR17 M/C (55W)
120/60 ZR17 (55W)
BT57F
120/60 ZR17 M/C (55W)
120/60 ZR17 (55W)
MACADAM 90X
120/60 ZR17 M/C (55W)
REAR
Manufacturer
Dunlop
Metzeler
Bridgestone
Michelin
@
Size
Model
160/60 ZR17 (69W)
160/60 ZR17 M/C (69W)
160/60 ZR17 (69W)
160/60 ZR17 M/C (69W)
160/60 ZR17 (69W)
160/60 ZR17 M/C (69W)
160/60 ZR17 (69W)
160/60 ZR17 M/C (69W)
D204G
MEZ1
BT57R
MACADAM 90X
CE-14E
FRONT & REAR
Tire air valve
TR412
Valve core
#9000A (original)
@
6-25
U5AH16.book Page 26 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03773
Cast wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage before each ride. If any damage is
found, have a Yamaha dealer replace 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 handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
EAU00691
Accessories and replacement
parts
EW000098
WARNING
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories or replacement parts you choose for your
motorcycle should be designed specifically for this model, and they
must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts
and Accessories are designed and
tested to be compatible with your
motorcycle. Please consider Genuine Yamaha Parts and Accessories
before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held lia-
ble for any consequences caused
by the use of items which have not
been approved by Yamaha.
@
@
6-26
6
U5AH16.book Page 27 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Tighten the locknut.
NOTE:
If the specified free play cannot be obtained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.
@
@
1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
a. Distance between brake pedal and footrest
EAU00712
Adjusting the brake pedal
position
EAU00692
6
Adjusting the clutch lever free
play
The top of the brake pedal should be
positioned approximately 42 mm
(1.65 in) below the top of the footrest
as shown. Periodically check the brake
pedal position and, if necessary, have
a Yamaha dealer adjust it.
The clutch lever free play should measure 10–15 mm (0.4–0.6 in) as shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as
follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in direction a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction b.
6-27
U5AH16.book Page 28 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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 before operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.
@
@
1. Rear brake light switch
2. Rear brake light switch adjusting nut
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is activated 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.
6-28
6
U5AH16.book Page 29 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Front
Rear
1. Brake pad wear indicator (× 2)
1. Brake pad wear indicator (× 2)
EAU00715
Checking the front and rear
brake pads
6
Front
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake.
To check the brake pad wear, check
the position of the wear indicator while
applying the brake. If a brake pad has
worn to the point that the wear indicator
almost touches the brake disc, have a
Yamaha dealer replace the brake pads
as a set.
6-29
1. Minimum level mark
EAU03294
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake system for leakage.
U5AH16.book Page 30 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Rear
1. Minimum level mark
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
●
Be careful that water does not enter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
● As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid: DOT 4
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
6-30
EAU03976
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
● Oil seals: Replace every two
years.
● Brake hoses: Replace every four
years.
6
U5AH16.book Page 31 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00744
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
@
6
@
a. Drive chain slack
2. Shift the transmission into the neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tightest portion of the drive chain, and
then measure the drive chain
slack as shown.
Drive chain slack:
20–30 mm (0.8–1.2 in)
4. If the drive chain slack is incorrect,
adjust it as follows.
6-31
1.
2.
3.
4.
Axle nut
Alignment marks
Drive chain slack adjusting nut
Locknut
EAU03752
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction a. To loosen the drive chain, turn the adjusting nut at each end of the
swingarm in direction b, and then
push the rear wheel forward.
U5AH16.book Page 32 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same position for proper wheel alignment.
_
_
EC000096
CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
_
EAU03006
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
@
CAUTION:
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
@
@
1. Clean the drive chain with kerosene and a small soft brush.
ECA00053
CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam
cleaners,
high-pressure
washers or inappropriate solvents.
@
Tightening torque:
Axle nut:
117 Nm (11.7 m·kgf, 85 ft·lbf)
@
EC000097
_
3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
ECA00052
CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
@
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
6-32
6
U5AH16.book Page 33 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03297
EAU04034
EAU03370
Checking and lubricating the
cables
Checking and lubricating the
throttle grip and cable
Checking and lubricating the
brake and shift pedals
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Yamaha Chain and Cable Lube
or engine oil SAE 10W-30
(API SE)
6
EW000111
WARNING
Damage to the outer housing of cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables as soon as possible to prevent
unsafe conditions.
@
@
6-33
U5AH16.book Page 34 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03164
EAU03165
EAU04282
Checking and lubricating the
brake and clutch levers
Checking and lubricating the
sidestand
Lubricating the rear
suspension
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EW000113
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
@
Recommended lubricant:
Lithium-soap-based grease
@
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-34
6
U5AH16.book Page 35 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
EAU00794
Checking the front fork
Checking the steering
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
To check the condition
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
@
6
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
@
@
6-35
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
@
U5AH16.book Page 36 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01144
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.
6
6-36
U5AH16.book Page 37 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
● Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
EAU00800
Battery
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:
Never attempt to remove the battery
cell seals, as this would permanently damage the battery.
@
@
EW000116
6
@
●
WARNING
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
@
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with optional electrical accessories.
6-37
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals.
U5AH16.book Page 38 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000102
@
@
CAUTION:
keep the battery
● Always
charged. Storing a discharged
battery can cause permanent
battery damage.
● To charge a sealed-type (MF)
battery, a special (constantvoltage) battery charger is required. Using a conventional
battery charger will damage the
battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha
dealer charge your battery.
1.
2.
3.
4.
5.
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Spare fuse (× 2)
1. Main fuse
Specified fuses:
Main fuse:
Headlight fuse:
Signaling system fuse:
Radiator fan fuse:
Ignition fuse:
EAU04538*
Replacing the fuses
The main fuse and the fuse box, which
contains the fuses for the individual circuits, are located under the seat. (See
page 3-9 for seat removal and installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
6-38
30 A
20 A
15 A
7.5 A
7.5 A
EC000103
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
_
_
6
U5AH16.book Page 39 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Headlight coupler
2. Headlight bulb cover
1. Headlight bulb holder
EAU04160
Replacing the headlight bulb
6
This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight coupler,
and then remove the bulb cover.
6-39
2. Unhook the headlight bulb holder,
and then remove the defective
bulb.
U5AH16.book Page 40 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000104
CAUTION:
Take care not to damage the following parts:
● Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life
will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb
using a cloth moistened with alcohol or thinner.
● Headlight lens
• Do not affix any type of tinted
film or stickers to the headlight lens.
• Do not use a headlight bulb of
a wattage higher than specified.
_
1. Do not touch the glass part of the bulb.
EW000119
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_
_
3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1. Screw (× 2)
EAU01623
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screws.
_
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EC000108
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
@
@
6-40
6
U5AH16.book Page 41 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01579
Supporting the motorcycle
1. Screw
EAU03497
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screw.
6
ECA00065
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance requiring the motorcycle to
stand upright. Check that the motorcycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
CAUTION:
Do not overtighten the screw, otherwise the lens may break.
@
@
6-41
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
U5AH16.book Page 42 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Left side
7. Pull the wheel axle out, remove
the speedometer gear unit, and
then remove the wheel.
Right side
ECA00046
CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
@
1.
2.
3.
4.
5.
6.
Speedometer cable
Bolt (× 2)
Front fender
Bolt(× 2)
Brake caliper
Brake hose holder
EAU03582
Front wheel
To remove the front wheel
EW000122
@
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle
so that there is no danger of it
falling over.
@
1. Disconnect the speedometer cable from the front wheel.
2. Remove the front fender by removing the bolts.
1.
2.
3.
4.
5.
6.
7.
Front fender
Bolt (× 2)
Front wheel axle pinch bolt
Wheel axle
Bolt (× 2)
Brake caliper
Brake hose holder
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 6-41.
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.
6-42
@
6
U5AH16.book Page 43 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
5. Install the brake calipers by installing the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing
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.
1. Speedometer gear unit
2. Slot
3. Speedometer gear unit retainer
EAU04196
6
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the projections mesh with the slots.
2. Lift the wheel up between the fork
legs.
Tightening torques:
Wheel axle:
65 Nm (6.5 m·kgf, 47 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
1.
2.
3.
4.
5.
EAU04197
Rear wheel
To remove the rear wheel
EW000122
_
NOTE:
Make sure that the slot in the speedometer 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.
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.
6-43
Axle nut
Left wheel axle guide
Locknut
Drive chain slack adjusting nut
Wheel axle
_
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
U5AH16.book Page 44 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1.
2.
3.
4.
Cotter pin
Nut
Bolt
Brake torque rod
1. Loosen the wheel axle nut, the
brake torque rod nut at the brake
caliper bracket, and the brake caliper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-41.
3. Remove the axle nut and the left
wheel axle guide, and then remove the brake caliper by removing the bolts.
4. Disconnect the brake torque rod
from the brake caliper bracket by
removing the cotter pin, the nut,
and the bolt.
1. Bolt (× 2)
2. Right wheel axle guide
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.
_
_
6-44
1. Brake caliper bracket
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.
_
_
6
U5AH16.book Page 45 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
4. Adjust the drive chain slack. (See
page 6-31 for drive chain slack adjustment procedures.)
5. Lower the rear wheel so that it is
on the ground.
6. Tighten the axle nut, the brake caliper bolts and the brake torque rod
nut to the specified torques.
Tightening torques:
Axle nut:
117 Nm (11.7 m·kgf, 85 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
Brake torque rod nut:
30 Nm (3.0 m·kgf, 21 ft·lbf)
EAU04283
6
To install the rear wheel
1. Install the wheel, right wheel axle
guide, and caliper bracket by inserting 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 installing
the bolts, and then connect the
brake torque rod to the brake caliper
bracket by installing the bolt and nut.
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.
_
_
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake caliper onto the brake disc.
_
_
6-45
EAU03087
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during 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 yourself. 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 replacement 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.
U5AH16.book Page 46 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02990
Troubleshooting charts
Starting problems or poor engine performance
EW000125
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
@
@
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
6
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-46
The engine does not start.
Have a Yamaha dealer
check the vehicle.
U5AH16.book Page 47 Wednesday, May 8, 2002 9:16 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EW000070
@
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
●
@
The coolant level is low.
Check the cooling system
for leakage.
Wait until the
engine has cooled.
6
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
@
@
6-47
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1
Storage .............................................................................................. 7-4
7
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
MOTORCYCLE CARE AND STORAGE
EAU03426
7-
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
7
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such products onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
7-1
Cleaning
ECA00010
@
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
MOTORCYCLE CARE AND STORAGE
●
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 removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switches 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 windshield. Test the product on a
small hidden part of the windshield to make sure that it does
not leave any marks. If the windshield is scratched, use a quality plastic polishing compound
after washing.
After riding in the rain, near the sea or
on salt-sprayed roads
Since 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
After normal use
Remove 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.
7-2
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
@
@
2. Apply a corrosion protection spray
on all metal, including chromeand nickel-plated, surfaces to prevent corrosion.
7
U5AH16.book Page 3 Wednesday, May 8, 2002 9:16 AM
MOTORCYCLE CARE AND STORAGE
7
After 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 stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner 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
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
@
@
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 acetone, and wash the tires with
warm water and a mild detergent.
● Before operating the motorcycle test its braking performance and cornering behavior.
@
ECA00013
@
CAUTION:
● Apply spray oil and wax sparingly 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.
@
7-3
@
U5AH16.book Page 4 Wednesday, May 8, 2002 9:16 AM
MOTORCYCLE CARE AND STORAGE
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 covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for
several 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” position: 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 protect 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
grounded. (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.
@
@
7-4
7
U5AH16.book Page 5 Wednesday, May 8, 2002 9:16 AM
MOTORCYCLE CARE AND STORAGE
7
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place [less
than 0 °C (30 °F) or more than
30 °C (90 °F)]. For more information on storing the battery, see
page 6-37.
NOTE:
Make any necessary repairs before
storing the motorcycle.
@
@
7-5
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
SPECIFICATIONS
Specifications .................................................................................... 8-1
8
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
SPECIFICATIONS
EAU01038
8-
Specifications
CS-01E
Model
YZF600R/YZF600RC
Engine oil
Type
Dimensions
Overall length
Overall width
Overall height
725 mm (28.5 in)
805 mm (31.7 in)
Wheelbase
1,415 mm (55.7 in)
Minimum turning radius
135 mm (5.3 in)
-20 -10
Recommended engine oil
classification
Basic weight (with oil and full
fuel tank)
YZF600R
212 kg (467 lb)
214 kg (472 lb)
Liquid-cooled 4-stroke, DOHC
Cylinder arrangement
Forward inclined parallel
4-cylinder
Displacement
599 cm3
Bore × stroke
62.0 × 49.6 mm (2.44 × 1.95 in)
Compression ratio
12:1
Starting system
Electric starter
Lubrication system
Wet sump
8
50
70
90
110 130 ˚F
0
10
20
30
40
50 ˚C
API Service SE, SF, SG or
higher
CAUTION:
In order to prevent clutch slippage (since the engine oil
also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of
“CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II”
or higher.
Engine
Engine type
30
YAMALUBE 4 (20W-40)
or SAE 20W-40
3,200 mm (126.0 in)
YZF600RC
10
YAMALUBE 4 (10W-30)
or SAE 10W-30
1,190 mm (46.9 in)
Seat height
Ground clearance
0
2,060 mm (81.1 in)
Quantity
8-1
Without oil filter cartridge
replacement
2.6 L (2.3 Imp qt, 2.8 US qt)
With oil filter cartridge
replacement
2.9 L (2.6 Imp qt, 3.1 US qt)
Total amount (dry engine)
3.5 L (3.1 Imp qt, 3.7 US qt)
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
SPECIFICATIONS
Cooling system capacity
(total amount)
1.95 L (1.72 lmp qt, 2.06 US qt)
Air filter
Wet element
Gear ratio
Fuel
Type
UNLEADED GASOLINE ONLY
Fuel tank capacity
19.0 L (4.2 Imp gal, 5.0 US gal)
Reserve amount
3.1 L (0.7 Imp gal, 0.8 US gal)
Carburetor
KEIHIN
Model × quantity
CVKD36 × 4
Frame type
Spark plug
Manufacturer/model
NGK / CR9E or
DENSO / U27ESR-N
Gap
0.7–0.8 mm (0.028–0.031 in)
1.947
3rd
1.545
4th
1.333
5th
1.190
6th
1.074
Caster angle
25°
Trail
97 mm (3.82 in)
Front
Wet, multiple-disc
Type
Tubeless tire
Size
120/60 ZR17 (55W)
120/60 ZR17 M/C (55W)
Spur gear
Primary reduction ratio
1.708
Secondary reduction system
Chain drive
Secondary reduction ratio
3.133
Diamond
Tires
Transmission
Primary reduction system
2.846
2nd
Chassis
Manufacturer
Clutch type
1st
Manufacturer/model
Bridgestone / BT57F
Dunlop / D204FG
Metzeler / MEZ1
Michelin / MACADAM 90X
Number of drive chain
sprocket teeth (front/rear)
15/47
Transmission type
Constant mesh 6-speed
Operation
Left foot
8-2
8
U5AH16.book Page 3 Wednesday, May 8, 2002 9:16 AM
SPECIFICATIONS
Rear
Wheels
Type
Tubeless tire
Size
160/60 ZR17 (69W)
Type
160/60 ZR17 M/C (69W)
Size
Manufacturer/model
Front
17 × MT 3.50
17 M/C × MT 3.50
Bridgestone / BT57R
Dunlop / D204G
Rear
Metzeler / MEZ1
Type
Michelin / MACADAM 90X
Size
Cast wheel
17 × MT 5.00
17 M/C × MT 5.00
Maximum load*
YZF600R
182 kg (401 lb)
YZF600RC
180 kg (397 lb)
Brakes
Front
Tire air pressure
(measured on cold tires)
Up to 90 kg (198 lb)*
Front
225 kPa (2.25 kgf/cm2, 33 psi)
Rear
250 kPa (2.50 kgf/cm2, 36 psi)
Front
250 kPa (2.50 kgf/cm2, 36 psi)
Rear
290 kPa (2.90 kgf/cm2, 42 psi)
250 kPa (2.50 kgf/cm2, 36 psi)
Rear
290 kPa (2.90 kgf/cm2, 42 psi)
Dual disc brake
Operation
Right hand
Fluid
DOT 4
Type
Single disc brake
Operation
Right foot
Fluid
DOT 4
Suspension
High-speed riding
Front
Type
Rear
90 kg (198 lb)–maximum*
8
Cast wheel
Front
Telescopic fork
Rear
Swingarm (link suspension)
Spring/shock absorber
* Total weight of rider, passenger, cargo and accessories.
8-3
Front
Coil spring / oil damper
Rear
Coil spring / gas-oil damper
U5AH16.book Page 4 Wednesday, May 8, 2002 9:16 AM
SPECIFICATIONS
Wheel travel
Fuses
Front
130 mm (5.1 in)
Main fuse
30 A
Rear
120 mm (4.7 in)
Headlight fuse
20 A
Signaling system fuse
15 A
Radiator fan fuse
7.5 A
Ignition fuse
7.5 A
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 type
Quartz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight
12 V, 60/55 W × 1
Tail/brake light
12 V, 8/27 W × 1
Front turn signal/position light
12 V, 27/8 W × 2
Rear turn signal light
12 V, 27 W × 2
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 × 1
8
8-4
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
Identification numbers ....................................................................... 9-1
Key identification number .................................................................. 9-1
Vehicle identification number ............................................................. 9-1
Model label ........................................................................................ 9-2
Reporting safety defects ................................................................... 9-3
Motorcycle noise regulation .............................................................. 9-4
Maintenance record .......................................................................... 9-5
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND
ENDURO MOTORCYCLE LIMITED WARRANTY .......................... 9-7
YAMAHA EXTENDED SERVICE (Y.E.S.) ......................................... 9-9
9
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
EAU01039
9-
EAU02944
Identification numbers
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
1. Key identification number
1. KEY IDENTIFICATION NUMBER:
CA-02E
2. VEHICLE IDENTIFICATION
NUMBER:
EAU01043
EAU01041
Key identification number
Vehicle identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space
provided.
CA-02E
9
1. Vehicle identification number
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in
your area.
@
3. MODEL LABEL INFORMATION:
CA-01E
@
9-1
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
1. Model label
EAU01050
Model label
The model label is affixed to the frame
under the seat. (See page 3-9 for seat
removal and installation procedures.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
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U5AH16.book Page 3 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
EAU01051
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
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U5AH16.book Page 4 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
EAU01053
Motorcycle noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
CL-01E
Exhaust system
Muffler
Exhaust pipe
Silencer
Intake system
Air cleaner case
Air cleaner element
Intake duct
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U5AH16.book Page 5 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
EAU01874
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
CL-04E
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
600 mi
(1,000 km) or
1 month
4,000 mi
( 7,000 km) or
6 months
8,000 mi
(13,000 km) or
12 months
12,000 mi
(19,000 km) or
18 months
16,000 mi
(25,000 km) or
24 months
9
20,000 mi
(31,000 km) or
30 months
24,000 mi
(37,000 km) or
36 months
9-5
Remarks
U5AH16.book Page 6 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
Remarks
28,000 mi
(43,000 km) or
42 months
32,000 mi
(49,000 km) or
48 months
36,000 mi
(55,000 km) or
54 months
40,000 mi
(61,000 km) or
60 months
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U5AH16.book Page 7 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
EAU02918
YAMAHA MOTOR CORPORATION, U.S.A.
STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY
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U5AH16.book Page 8 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
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U5AH16.book Page 9 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
EAU01063
YAMAHA EXTENDED SERVICE (Y.E.S.)
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U5AH16.book Page 10 Wednesday, May 8, 2002 9:16 AM
CONSUMER INFORMATION
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9-10
U5AH16.book Page 1 Wednesday, May 8, 2002 9:16 AM
INDEX
10-
A
D
L
Accessories and replacement parts .......6-26
Air filter element, cleaning ......................6-19
Air intake duct ........................................6-21
Air vent hose, checking ..........................6-21
Dimmer switch......................................... 3-5
Drive chain, lubricating .......................... 6-32
Drive chain slack ................................... 6-31
Adjusting .......................................... 6-31
Checking.......................................... 6-31
Labels, location ........................................1-7
Luggage strap holders ...........................3-17
B
Battery ...................................................6-37
Brake and clutch levers, checking and
lubricating ............................................6-34
Brake and shift pedals, checking and
lubricating ............................................6-33
Brake fluid, changing .............................6-30
Brake fluid level, checking......................6-29
Brake lever...............................................3-6
Brake light switch (rear), adjusting .........6-28
Brake pads, checking.............................6-29
Brake pedal..............................................3-7
Brake pedal position, adjusting ..............6-27
C
Cables, checking and lubricating............6-33
Canister (for California only)...................6-12
Carburetors, adjusting............................6-22
Care.........................................................7-1
Clutch lever..............................................3-6
Clutch lever free play, adjusting .............6-27
Coolant ..................................................6-16
Changing..........................................6-17
Checking ..........................................6-16
Coolant temperature gauge .....................3-4
Cowlings, removing and installing ............6-7
M
Engine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............. 6-13
Engine stop switch................................... 3-5
Main switch/steering lock .........................3-1
Maintenance and lubrication, periodic ......6-4
Maintenance, emission control system.....6-3
Maintenance, periodic ..............................6-1
Maintenance record .................................9-5
Model label ..............................................9-2
F
N
Front and rear suspension settings........ 3-16
Front fork, adjusting............................... 3-11
Front fork, checking ............................... 6-35
Fuel ......................................................... 3-8
Fuel level warning light ............................ 3-2
Fuel tank cap........................................... 3-7
Fuses, replacing .................................... 6-38
Neutral indicator light ...............................3-2
Noise regulation .......................................9-4
E
H
Handlebar switches ................................. 3-5
Headlight bulb, replacing ....................... 6-39
Helmet holder ........................................ 3-10
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-5
I
Identification numbers ............................. 9-1
Ignition circuit cut-off system.................. 3-18
Indicator and warning lights ..................... 3-2
K
Key identification number ........................ 9-1
O
Oil level warning light ...............................3-2
P
Parking.....................................................5-6
Part locations ...........................................2-1
Pre-operation check list............................4-1
R
Rear suspension, lubricating ..................6-34
S
Safety defects, reporting ..........................9-3
Safety information ....................................1-1
Seat .........................................................3-9
Self-diagnosis device ...............................3-3
Shifting.....................................................5-3
Decelerating .......................................5-4
Shift points..........................................5-5
Starting out and accelerating ..............5-4
U5AH16.book Page 2 Wednesday, May 8, 2002 9:16 AM
INDEX
Shift pedal ............................................... 3-6
Shock absorber assembly, adjusting ..... 3-13
Sidestand .............................................. 3-17
Sidestand, checking and lubricating....... 6-34
Spark plugs, checking ........................... 6-10
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever ................................ 3-9
Starting and warming up a cold engine.... 5-1
Starting a warm engine............................ 5-3
Start switch.............................................. 3-5
Steering, checking ................................. 6-35
Storage.................................................... 7-4
Storage compartment ............................ 3-11
Supporting the motorcycle ..................... 6-41
T
Tachometer ............................................. 3-3
Tail/brake light bulb, replacing ............... 6-40
Throttle cable free play, adjusting .......... 6-22
Throttle grip and cable, checking and
lubricating............................................ 6-33
Tires ...................................................... 6-23
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-45
Troubleshooting charts .......................... 6-46
Turn signal indicator light ......................... 3-2
Turn signal light bulb, replacing ............. 6-41
Turn signal switch.................................... 3-5
V
Valve clearance, adjusting..................... 6-22
Vehicle identification number ................... 9-1
W
Warranty, extended................................. 9-9
Warranty limited ...................................... 9-7
Wheel bearings, checking ..................... 6-36
Wheel (front) ......................................... 6-42
Installing .......................................... 6-43
Removing ........................................ 6-42
Wheel (rear) .......................................... 6-43
Installing .......................................... 6-45
Removing ........................................ 6-43
Wheels.................................................. 6-26
OWNER’S MANUAL
YZF600RR
YZF600RRC
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2002.04-1.2×1 CR
(E)
LIT-11626-16-10
5AH-28199-16