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Yamaha 2001 YZF-R6N, Owner'S Manual, Page: 82 / 124

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Yamaha 2001 YZF-R6N Owner'S Manual Download Page 82

PERIODIC MAINTENANCE AND MINOR REPAIR

6-27

6

2. Remove cowling A. (See page 6-6

for cowling removal and installa-
tion procedures.)

3. Loosen the locknut at the crank-

case.

4. To increase the clutch lever free

play, turn the adjusting nut in di-
rection 

a

. To decrease the clutch

lever free play, turn the adjusting
nut in direction 

b

.

5. Tighten the locknut.
6. Install the cowling.

EAU00713

Adjusting the rear brake light 
switch 

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction 

a

. To

make the brake light come on later,
turn the adjusting nut in direction 

b

. 

EAU00721

Checking the front and rear 
brake pads 

The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. 

1. Locknut
2. Clutch lever free play adjusting nut

1. Rear brake light switch
2. Rear brake light switch adjusting nut

1. Front brake pad wear indicator groove

Front

E_5mt.book  Page 27  Thursday, October 5, 2000  3:24 PM

Summary of Contents for 2001 YZF-R6N

Page 1: ...PRINTED IN JAPAN 2000 9 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5MT 28199 20 YZF R6N OWNER S MANUAL ...

Page 2: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 3: ...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 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 4: ... 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 informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5mt book Page 2 Thursday October 5 2000 3 24 PM ...

Page 6: ...ANUAL 2000 by Yamaha Motor Co Ltd 1st Edition August 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5mt book Page 3 Thursday October 5 2000 3 24 PM ...

Page 7: ...ND 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 EAU00009 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 8: ...E_5mt book Page 2 Thursday October 5 2000 3 24 PM ...

Page 9: ...NFORMATION 1 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 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 10: ...ANICAL 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 ...

Page 11: ...rnering 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 f...

Page 12: ...ation 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 moto...

Page 13: ...ing such cargo 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 caut...

Page 14: ...ty 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 spil...

Page 15: ... 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 motor cycle 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 clo...

Page 16: ...ETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 2 E_5mt_Safety fm Page 7 Thursday October 5 2000 4 05 PM ...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 18: ...preload adjusting bolt page 3 15 4 Air filter element page 6 19 5 Shock absorber compression damping force adjusting screw page 3 18 6 Shock absorber spring preload adjusting ring page 3 17 7 Shock absorber rebound damping force adjusting knob page 3 18 8 Shift pedal page 3 8 9 Coolant reservoir page 6 15 10 Engine oil filter page 6 11 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 19: ...gage strap holders page 3 21 12 Owner s tool kit page 6 1 13 Fuses page 6 39 14 Rear brake fluid reservoir 15 Radiator cap page 6 16 16 Front brake fluid reservoir 17 Brake pedal page 3 9 E_5mt book Page 2 Thursday October 5 2000 3 24 PM ...

Page 20: ...ar switches page 3 7 3 Starter choke lever page 3 11 4 Digital speedometer unit page 3 5 5 Main switch steering lock page 3 1 6 Tachometer page 3 6 7 Right handlebar switches page 3 7 8 Throttle grip page 6 22 9 Brake lever page 3 9 E_5mt book Page 3 Thursday October 5 2000 3 24 PM ...

Page 21: ... pedal 3 8 Brake lever 3 9 Brake pedal 3 9 Fuel tank cap 3 10 Fuel 3 11 Starter choke lever 3 11 Seats 3 12 Helmet holders 3 13 Storage compartment 3 14 Adjusting the front fork 3 15 Adjusting the shock absorber assembly 3 17 Matching the front and rear suspension settings 3 20 Luggage strap holders 3 21 Sidestand 3 21 Ignition circuit cut off system 3 22 E_5mt book Page 1 Thursday October 5 2000 ...

Page 22: ...LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK whi...

Page 23: ...he turn signal switch is pushed to the left or right EAU03284 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 5 L When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Turn the key to ON 2 If the warning light does not come on have a Yamaha dealer check the ...

Page 24: ...s too high the warning light flashes and symbols and come on To check that the warning light is work ing properly Put the transmission in neutral or apply the clutch lever Turn the engine stop switch to and the key to ON The warning light will come on and symbols and will ap pear in the display If the warning light does not come on have a Yamaha dealer inspect the electrical circuit EC000118 CAUTI...

Page 25: ... flash Warning light comes on Stop the motorcycle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See the Engine overheating section on page 6 48 for further instructions Above 140 C Symbol and message HI flash Warning light comes on Stop the engine and allow it to cool See the Engine overheating sec tion on page 6 48 for further ins...

Page 26: ...he dis play between the various tripmeter and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F To reset a tripmeter select it by push ing the SELECT button and then push the RESET button for at least one second If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5...

Page 27: ...lay the following error code CB 11E Use the table below to identify the faulty electrical circuit CB 28E If the tachometer displays such an er ror code note the circuit specific num ber 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 _ 1 Tac...

Page 28: ...signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU00138 Engine stop switch Set this switch to to stop the en gine 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 pa...

Page 29: ...tch operation The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 20 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on thi...

Page 30: ... 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 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 Brake lever 1 Brake lever position adjusting dial 2 Arrow mark a Di...

Page 31: ...the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding...

Page 32: ...fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU00192 EAU02973 Starter choke lever 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 1 Fuel tank fller tube 2 Fuel level Recommended fue...

Page 33: ...occurs turn off the starter choke EAU01890 Seats Rider seat To remove the rider seat Lift up the rear corners of the rider seat as shown remove the bolts and then pull the seat off To install the rider seat Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original position and then install the bolts 1 Bolt 2 1 Projection 2 Seat holder E_5mt b...

Page 34: ...nd then push the front of the seat down to lock it in place 2 Remove the key NOTE Make sure that the seats are properly secured before riding EAU03159 Helmet holders The helmet holders are located on the bottom of the passenger seat To secure a helmet to a helmet holder 1 Remove the passenger seat See page 3 12 for removal and instal lation procedures 2 Attach the helmet to a helmet holder and the...

Page 35: ... LOCK Other locks may not fit EWA00005 WARNING _ Do not exceed the load limit of 3 kg for the storage compart ment Do not exceed the maximum load of 189 kg for the vehicle _ To place a U LOCK in the storage compartment 1 Remove the rubber cap from the hole at the bottom of the storage compartment and then store it in a safe place to prevent losing the cap 2 Insert the ends of the U LOCK bar into t...

Page 36: ...justing screws and com pression damping force adjusting screws EW000035 WARNING Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bol...

Page 37: ...crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in direction b CI 02E 1 Current setting 2 Front fork cap bolt CI 18E Maximum hard Adjusting position 1 2 3 4 5 6 7 8 Standard Minimum soft 1 Rebound damping force adjusting screw Minimum soft 9 clicks in direction b Standard 6 clicks in direction b Maximum hard 1 click in direc...

Page 38: ...sembly This shock absorber assembly is equipped with a spring preload adjust ing ring a rebound damping force ad justing knob and a compression damping force adjusting screw EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To de ...

Page 39: ...s of a damping force adjusting mechanism may not exactly match the above spec ifications 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 num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary 1 Rebound damping force ad...

Page 40: ...r 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 ab sorber 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 per formance Always have a Yamaha dealer servic...

Page 41: ...conditions CI 05E EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 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 9 1 7 4 12 3 20 With passenger 1 8 1 10 1 9 4 9 1 8 3 7 E_5mt...

Page 42: ...tion circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system 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 oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of...

Page 43: ...he clutch lever is not pulled It prevents starting when the trans mission 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 EW000045 WARNING _ If a malfunction is noted have a...

Page 44: ...he clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall 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 The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shou...

Page 45: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 46: ...e If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 6 14 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 15 6 18 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 spe...

Page 47: ...ake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 34 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 33 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 Ins...

Page 48: ...ection 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 E_5mt book Page 3 Thursday October 5 2000 3 24 PM ...

Page 49: ...ANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Tips for reducing fuel consumption 5 3 Engine break in 5 4 Parking 5 4 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 50: ...ust 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 igni tion circuit cut off system ac cording to the procedure described on page 3 23 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to ECA00...

Page 51: ...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 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 EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine ...

Page 52: ... Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Thoroughly warm up the engi...

Page 53: ... 000 r min 1 000 1 600 km Avoid prolonged operation above 6 000 r min EC000052 CAUTION After 1 000 km of operation the en gine oil must be changed and the oil filter cartridge replaced 1 600 km and beyond The vehicle can now be operated normally EC000053 CAUTION Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately ha...

Page 54: ...E_5mt book Page 5 Thursday October 5 2000 3 24 PM ...

Page 55: ...rear brake pads 6 27 Checking the brake fluid level 6 29 Changing the brake fluid 6 30 Drive chain slack 6 30 Lubricating the drive chain 6 31 Checking and lubricating the cables 6 32 Checking and lubricating the throttle grip and cable 6 33 Checking and lubricating the brake and clutch levers 6 33 Lubricating the brake pedal 6 34 Checking and lubricating the sidestand 6 34 Lubricating the rear su...

Page 56: ... BE SHORT ENED EW000060 WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU01296 CAUTION Do not test this motorcycle on a dy namometer stand for an extended period of time otherwise heat in duced discoloration of the fiber con structed muffler may occur EAU03713 Owner s tool kit The tool kit is located under the pas senger seat See page 3 13 for...

Page 57: ...uired for a particular job have a Yamaha dealer perform it for you _ EW000063 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle unsafe for use Consult a Yamaha dealer be fore attempting any changes _ E_5mt book Page 2 Thursday October 5 2000 3 24 PM ...

Page 58: ...CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn...

Page 59: ...g for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assembly Check operation and shock absorber for oil leakage 21 Rear suspension relay arm and c...

Page 60: ...omponents of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 25 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 ...

Page 61: ...apter Refer to this section each time a cowling or panel needs to be re moved and installed EAU01602 Cowlings A and B To remove one of the cowlings Remove the screws slide the cowling forward for A or backward for B and then pull it off as shown 1 Cowling A right side Cowling B left side 2 Panel C 1 Screw 5 2 Cowling A Right side 1 Screw 6 2 Cowling B Left side E_5mt book Page 6 Thursday October 5...

Page 62: ...d then slide the cowling into place 2 Place the cowling in the original position and then install the screws NOTE Make sure that the tabs at the front of each cowling fit side by side as shown and that all slots and projections fit to gether 1 Cowling A 2 Cowling B 1 Slot 2 2 Projection 2 1 Tab 2 E_5mt book Page 7 Thursday October 5 2000 3 24 PM ...

Page 63: ...01315 Panel C To remove the panel Remove the screws and then take the panel off To install the panel Place the panel in the original position and then install the screws 1 Screw 2 1 Projection 2 Slot E_5mt book Page 8 Thursday October 5 2000 3 24 PM ...

Page 64: ...f ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clea...

Page 65: ...he ignition coil coupler may get damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply twist it back and forth while pulling it out to install it twist it back and forth while pushing it in E_5mt book Page 10 Thursday October 5 2000 3 24 PM ...

Page 66: ...the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 4 If the en...

Page 67: ...n oil pan under the engine to collect the used oil 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 5 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 1 Engine oil filler cap Right side 1 Engine oil drain plug Left side 1 Oil ...

Page 68: ...t and then tighten it to the specified torque 9 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kg Tightening torque Engine oil drain bolt 43 Nm 4 3 m kg Left side Recommended engine oil See page 8 1 Oil quantity Without oil filter cartridge replacement 2 5 L With oil ...

Page 69: ... 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 deal er c...

Page 70: ...ts open the reservoir cap add coolant to the maximum level mark close the reservoir cap and then install the reservoir cover and bolts EC000080 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 cool ant as soon as possible other wise the en...

Page 71: ...lings A and B See page 6 6 for panel and cowling removal and installa tion procedures 3 Place a container under the en gine to collect the used coolant 4 Remove the radiator cap EW000067 WARNING Never attempt to remove the radia tor cap when the engine is hot 5 Remove the water pump drain bolt to drain the water pump housing 6 Loosen the clamp screw and then disconnect the radiator hose to drain t...

Page 72: ...ove the coolant reservoir by removing the bolts 12 Remove the coolant reservoir cap and then turn the reservoir upside down to empty it 13 Install the coolant reservoir by in stalling the bolts 14 Pour the recommended coolant into the reservoir to the maximum level mark and then install the cap and cover 15 Pour the recommended coolant into the radiator until it is full Tightening torque Coolant d...

Page 73: ...veness of the coolant will be reduced 16 Install the radiator cap start the engine let it idle for several min utes and then turn it off 17 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 18 Start the engine and then check the vehicle for coolant leakage If coolant is ...

Page 74: ... rider seat removal and in stallation procedures 2 Remove the fuel tank bolts and lift the fuel tank as shown 3 Turn the fuel cock lever to OFF and then disconnect the hoses and the fuel sender coupler NOTE _ Before removing the hoses mark them to ensure that they will be reinstalled in their correct positions _ 4 Tilt the front of the fuel tank back to position the tank away from the air filter c...

Page 75: ...p erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn _ 9 Install the air filter case cover by installing the screws 10 Connect the fuel sender coupler and the hoses turn the fuel cock lever to ON place the fuel tank in the original position and then in stall the bolts EW000131 WARNING _ Make sure that the fuel hoses and vacuum hose...

Page 76: ...f routine maintenance EC000095 CAUTION The carburetors have been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU00632 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic ...

Page 77: ...usting the throttle cable free play The throttle cable free play should measure 6 8 mm at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be ad...

Page 78: ...fety Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dle...

Page 79: ...rn tires decreases riding sta bility and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience CE 20E NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations Tire information This motorcycle is equipped w...

Page 80: ... make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a new tire...

Page 81: ... tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteristics EAU01356 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 15 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows To increase the clutch lever free play turn the adjusting ...

Page 82: ...ght 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 EAU00721 Checking the front and rear brake pads The front and rear brake...

Page 83: ... wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake Check the brake pad wear as follows 1 Remove the rear brake caliper by removing the bolt and then tilt the caliper forward to inspect the wear indicator groove If a brake pad has worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer re place the brake...

Page 84: ...e rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter 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 det...

Page 85: ...rive 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 2 Shift the transmission into the neu tral position 3 Move the rear wheel b...

Page 86: ...this from occurring keep the drive chain slack within the specified limits _ 3 Tighten the locknuts and then tighten the axle nut to the specified torque EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Serv...

Page 87: ...The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 WARNING Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damage...

Page 88: ...rottle cable and then apply several drops of oil to the cable allowing it to trickle into the sheaths 3 Grease the inside of the throttle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install the grip by installing the screws EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before e...

Page 89: ... 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 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 all purpose grease Recommended lubricant Lithium soap based grease all purpose gre...

Page 90: ...5 WARNING Securely support the motorcycle so that there is no danger of it falling over 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 handle bars several times to check if the front fork compresses and re bounds smoothly E...

Page 91: ... support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion char...

Page 92: ...s and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek pr...

Page 93: ...ry before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals EC000102 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you d...

Page 94: ...er age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 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 fuse 2 Radiator fan fuse 3 Ignition fuse 4 Signaling system fuse 5 Odometer fuse 6 Spare fu...

Page 95: ... coupler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new bulb into position and then secure it with the bulb holder 1 Headlight coupler 2 Headlight bulb cover 1...

Page 96: ...he headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the head light lens Do not use a headlight bulb of a wattage higher than speci fied 5 Install the bulb cover and then connect the coupler 6 Install the panel 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU03730 Tail brake light This motorcycle is e...

Page 97: ... mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der 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 un der the fr...

Page 98: ...ke after the brake calipers have been removed otherwise the brake pads will be forced shut EAU01638 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground 4 Push down hard on the handlebar several times to check for proper fork operation 5 Install the brake calipers by install ing the bolts NOTE Make sure tha...

Page 99: ... procedure on page 6 42 3 Remove the axle nut and then re move the brake caliper by remov ing the bolts 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain adjusting bolts fully in direction a 6 Push the wheel forward and then remove the drive chain from the rear sprocket Tightening torques Wheel axle 72 Nm 7 2 m kg Front wheel axle pinch bolt 20 Nm 2 0 m kg Brake caliper bolt...

Page 100: ... from the left hand side 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 30 for drive chain slack adjustment pro cedures 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Install the brake caliper by install ing the bolts NOTE _ Make sure that there is enough space between the brake pads before install ing the brake...

Page 101: ... troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often infer...

Page 102: ...ompression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Operate the electric starter 4 Battery The engine turns over quickly The engine tur...

Page 103: ... hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap 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 Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check ...

Page 104: ...E_5mt book Page 49 Thursday October 5 2000 3 24 PM ...

Page 105: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 106: ...ctrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners e...

Page 107: ...l hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal 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 eas...

Page 108: ...n duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry ...

Page 109: ...ter and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for 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 posi tion Turn the fuel cock lever to OFF ...

Page 110: ...ile turning the engine over 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 Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cov...

Page 111: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 112: ...lectric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter cartridge replacement 2 5 L With oil filter cartridge replacement 2 7 L Total amount dry engine 3 5 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain an...

Page 113: ...tem Spur gear Primary reduction ratio 1 955 Secondary reduction system Chain drive Secondary reduction ratio 3 000 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 846 2nd 1 947 3rd 1 556 4th 1 333 5th 1 190 6th 1 083 Chassis Frame type Diamond Caster angle 24 Trail 81 mm Tires Front Type Tubeless tire Size 120 60 ZR17 55 W Manufacturer model MICHELIN Pilot SPORT B Dunl...

Page 114: ...e Cast wheel Size 17 MT 3 50 Rear Type Cast wheel Size 17 MT 5 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspension Spring shock absorbers Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 130 mm Rear 120 mm Electrical system Ign...

Page 115: ... 4 Meter lighting 12 V 1 4 W 2 Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Oil level coolant temperature warning light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 15 A Radiator fan fuse 7 5 A Ignition fuse 15 A Odometer fuse 7 5 A E_5mt book Page 4 Thursday October 5 2000 3 24 PM ...

Page 116: ...etric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55...

Page 117: ...ORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Motorcycle noise regulation for Australia 9 2 E_5mt book Page 1 Thursday October 5 2000 3 24 PM ...

Page 118: ...1E EAU01041 Key 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 EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify y...

Page 119: ...TH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive 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 pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the ve...

Page 120: ...usting 3 15 Front fork checking 6 35 Fuel 3 11 Fuel consumption tips for reducing 5 3 Fuel level warning light 3 2 Fuel tank cap 3 10 Fuses replacing 6 39 H Handlebar switches 3 7 Headlight bulb replacing 6 40 Helmet holders 3 13 High beam indicator light 3 2 Horn switch 3 7 I Identification numbers 9 1 Idling speed adjusting 6 21 Ignition circuit cut off system 3 22 Indicator and warning lights 3...

Page 121: ...Tachometer 3 6 Tail brake light 6 41 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 46 Troubleshooting charts 6 47 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 42 Turn signal switch 3 7 V Valve clearance adjusting 6 22 Vehicle identification number 9 1 W Wheel bearings checking 6 36 Wheel...

Page 122: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 123: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 124: ...PRINTED IN JAPAN 2000 9 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5MT 28199 20 YZF R6N OWNER S MANUAL ...

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