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PERIODIC MAINTENANCE AND MINOR REPAIR

6-38

6

EAU24350

Supporting the motorcycle

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 up-
right. 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 un-
der the frame in front of the rear
wheel.

2. Raise the front wheel off the

ground by using a motorcycle
stand.

To service the rear wheel

Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle 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.

1. Quick fastener

2. Pin

1

2

5SL21.book Page 38 Tuesday, August 19, 2003 11:00 AM

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Summary of Contents for 2004 YZF-R6S

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 08 0 3 1 CR E 5SL 28199 21 YZF R6S OWNER S MANUAL ...

Page 2: ...5SL21 book Page 2 Tuesday August 19 2003 11 00 AM ...

Page 3: ... to enjoy all advantages of your YZF R6 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dea...

Page 4: ... your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 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 motor cycle operator a ...

Page 5: ...ANUAL 2003 by Yamaha Motor Co Ltd 1st edition August 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan 5SL21 book Page 2 Tuesday August 19 2003 11 00 AM ...

Page 6: ...ntenance and lubrication chart 6 2 Removing and installing cowlings and panels 6 6 Checking the spark plugs 6 8 Engine oil and oil filter cartridge 6 9 Coolant 6 12 Checking the air filter element 6 16 Air intake duct 6 18 Adjusting the engine idling speed 6 18 Adjusting the throttle cable free play 6 19 Adjusting the valve clearance 6 19 Tires 6 19 Cast wheels 6 22 Adjusting the clutch lever free...

Page 7: ...6 37 Supporting the motorcycle 6 38 Front wheel 6 39 Rear wheel 6 41 Troubleshooting 6 42 Troubleshooting charts 6 43 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 5SL21 book Page 2 Tuesday August 19 2003 11 00 AM ...

Page 8: ...nts 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 Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other mo...

Page 9: ...hield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or ...

Page 10: ...under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully 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 ob scure lights or reflectors Accessories fitted to the handle ...

Page 11: ...le note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting ...

Page 12: ...AFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3 4 5SL21 book Page 5 Tuesday August 19 2003 11 00 AM ...

Page 13: ...SAFETY INFORMATION 1 6 1 4 1 2 3 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 E0 UNLEADED FUEL ONLY 5SL21 book Page 6 Tuesday August 19 2003 11 00 AM ...

Page 14: ...pring preload adjusting ring page 3 20 6 Shock absorber assembly compression damping force adjusting screw page 3 20 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw page 3 20 9 Shift pedal page 3 14 10 Engine oil drain bolt page 6 9 11 Engine oil filter cartridge page 6 9 12 Front fork compression damping force adjusting screw page 3 19 5SL21 book Page 1...

Page 15: ...attery page 6 32 6 Throttle stop screw page 6 18 7 Air filter element page 6 16 8 Front brake fluid reservoir page 6 25 9 Radiator cap page 6 12 10 Coolant drain bolt page 6 13 11 Engine oil filler cap page 6 9 12 Brake pedal page 3 14 13 Dipstick page 6 9 14 Rear brake fluid reservoir page 6 25 5SL21 book Page 2 Tuesday August 19 2003 11 00 AM ...

Page 16: ...e 3 13 2 Left handlebar switches page 3 12 3 Multi function display page 3 8 4 Main switch steering lock page 3 2 5 Tachometer page 3 8 6 Right handlebar switches page 3 12 7 Throttle grip page 6 19 8 Brake lever page 3 14 5SL21 book Page 3 Tuesday August 19 2003 11 00 AM ...

Page 17: ... IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re regis t...

Page 18: ...ighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlights come on automatically when the engine is started and stay on until the key is turned to OFF even if the engine stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are of...

Page 19: ...auxiliary lights are on The hazard light and turn signal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11001 Indicator and warning lights 1 Push 2 Turn 1 Right turn signal indica...

Page 20: ...tection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the malfunction is corrected The oil level warning light will flash ten times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11360 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 5 L 0 92 US gal 0 77 ...

Page 21: ...engine immediately and allow the engine to cool The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit CAUTION ECA10020 Do not operate the engine if it is overheated 5SL21 book Page 5 Tuesday August 19 2003 11 00 AM ...

Page 22: ...yed OK Go ahead with riding 117 139 C 242 283 F Temperature flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 43 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 43 5SL21 book Page 6 Tuesday August 19 2003 11 00 A...

Page 23: ... for a few seconds then go off have a Yamaha dealer check the electrical cir cuit See page 3 8 for a detailed expla nation of the function of this indicator light and on how to set it EAU26871 Immobilizer system indicator light The electrical circuit of the indicator light can be checked by turning the key to ON If the indicator light does not come on for a few seconds then go off have a Yamaha de...

Page 24: ...e distance traveled since the fuel level warning light came on a clock a self diagnosis device a display brightness and shift tim ing indicator light control mode NOTE Be sure to turn the key to ON before using the SELECT and RESET but tons Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the foll...

Page 25: ...de e g 11 12 13 This model is also equipped with a self diagnosis device for the immobilizer system If any of the immobilizer system circuits are defective the immobilizer system indicator light will flash and then the multi function display will indicate a two digit error code e g 51 52 53 NOTE If the multi function display indicates er ror code 52 this could be caused by transponder interference...

Page 26: ...ming indicator light bright ness This function allows you to adjust the brightness of the indicator light to suit your preference NOTE To make any settings in this mode you have to cycle through all of its functions However if the key is turned to OFF or the engine is started before completing the pro cedure only the settings made be fore the SELECT button was last pushed will be applied In this m...

Page 27: ...he indicator light can be set in increments of 200 r min 1 Push the RESET button to select the desired engine speed for acti vating the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light deactiva tion function To set the shift timing indicator light de activation function NOTE The indicator light deactivation ...

Page 28: ... Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard switch 1 Engine stop switch 2...

Page 29: ... the ON or posi tion use this switch to turn on the haz ard light simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10060 Do not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU12820 Clutch lever The clutch le...

Page 30: ...quipped with a po sition adjusting dial To adjust the dis tance 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 EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear ...

Page 31: ...k 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 WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not over...

Page 32: ...AU13430 Catalytic converter This model is equipped with a catalytic converter in the exhaust chamber WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasolin...

Page 33: ... passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward To install the passenger seat 1 Insert the projection on the rear of the passenger seat into the seat holder as shown and then push the front of the seat down to lock it in place 2 Remove the key NOTE Make sure that...

Page 34: ...ets may contact the muf fler when secured to the right side helmet holder because of their size or shape Be sure that your helmet does not contact the muffler when it is secured to the helmet holder To release a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat EAU14461 Storage compartment The storage compartment is located und...

Page 35: ...Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing 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 di rection b 1 Spring pr...

Page 36: ...sents 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 EAU15051 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and rebound and compression damping force adjusting screws CAUTION E...

Page 37: ...E Although the total number of clicks 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 ...

Page 38: ...eat unhook the straps from the hooks and then install the seat with the straps hanging out from under the passenger seat See page 3 17 EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in c...

Page 39: ... in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EW...

Page 40: ...er 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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle s...

Page 41: ...equences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle 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 WARNING EWA11150 If any item in the Pre operation check list is not ...

Page 42: ...ha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 24 6 25 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fl...

Page 43: ...s Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 29 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 30 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights sig...

Page 44: ...stand up WARNING EWA10290 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 CAUTION ECA11730 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning...

Page 45: ... NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 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 dis tances The transmission is properly lubricated only when the engine ...

Page 46: ...ully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17091 0 1000 km 0 600 mi Avoid prolonged operation above 7000 r min 1000 16...

Page 47: ...he engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials 5SL21 book Page 4 Tuesday August 19 2003 11 00 AM ...

Page 48: ...ith mainte nance work have a Yamaha dealer do it for you EAU17490 Owner s tool kit The owner s tool kit is located inside the storage compartment under the pas senger seat See page 3 17 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 How ever additional tools suc...

Page 49: ...NCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limi...

Page 50: ...ssis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Sidestand Check operation Lubricate 16 Sidestand switch Check operation 17 Front fork Check operation and for oil leakage 18 Shock absorber assem bly Check operation and shock absorber for oil leakage 19 Rear suspension relay arm and connecting arm pivoting points Check operation 20 Electronic fuel injection Adjust e...

Page 51: ...otorcycle or riding in the rain 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 28 Air induction system Check the air cut off valve reed valve and hose for dam age Replace any damaged parts if necessar...

Page 52: ...6 5 6 Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 5SL21 book Page 5 Tuesday August 19 2003 11 00 AM ...

Page 53: ... described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU19010 Cowlings A and B To remove one of the cowlings Remove the bolts slide the cowling for ward for A or backward for B and then pull it off as shown 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 1 Bolt 1 Bolt 2 Cowling A 5SL21 book Page 6 Tuesday August 19 2003 11 00 AM ...

Page 54: ...inal position and then install the bolts 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 EAU19461 Panels A and B To remove one of the panels Remove the bolts slide the panel for ward and then take it off 1 Bolt 2 Cowling B 1 Cowling A 2 Cowling B 1 Slot 2 Projection 1 Tab 1 Bolt 5SL21 book Page 7 Tuesday August 19...

Page 55: ...en the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color 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 deal er check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Bef...

Page 56: ...d oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when...

Page 57: ...al minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 10 if the oil filter cartridge is not being replaced 4 Remove the coolant reservoir cov er by removing the bolts 5 Remove cowling B See page 6 6 6 Remove the oil filter cartridge with an oil filter wrench...

Page 58: ... cap CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 1 O ring 1 Torque wrench Tightening torq...

Page 59: ...at the intervals specified in the periodic maintenance and lubrication chart EAU20111 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the s...

Page 60: ...e engine is hot 4 Install the reservoir cap and then install the coolant reservoir cover by installing the bolts NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 43 for further instructions EAU20342 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 R...

Page 61: ...olant reservoir cap and then turn the coolant reservoir upside down to empty it 13 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 14 Install the coolant reservoir by in stalling the bolts 15 Connect the radiator hose and then tighten the clamp screw 16 Install the coolant drain bolt and then tighten it to the specified torque 1 Radiator cap 1 Cool...

Page 62: ...eeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 22 Install the radiator cap start the engine let it idle for several min utes and then turn it off 23 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 24 Start the...

Page 63: ... Before disconnecting the fuel tank breather hose and fuel tank overflow hose 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 case and then support the tank as shown WARNING EWA10410 Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the...

Page 64: ...and fuel tank overflow hose to the fuel tank 11 Place the fuel tank in the original position and then install the bolts WARNING EWA11360 Before placing the fuel tank in the original position make sure that the fuel hoses are not dam aged If any fuel hose is dam aged 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 ...

Page 65: ...m before making this adjustment NOTE The engine is warm when it quickly re sponds to the throttle Check the engine idling speed and if necessary adjust it to specification by turning the throttle stop screw To in crease the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as des...

Page 66: ...ervals specified in the periodic maintenance and lubrication chart EAU21780 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires ...

Page 67: ... minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced WARNING EWA10470 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and bra...

Page 68: ...th super high speed tires Note the following points in order to 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 ti...

Page 69: ...EAU22060 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows To increase the clutch lever free play turn the adjusting bolt at the clutch lever in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE If the spe...

Page 70: ...ion and if necessary have a Yamaha dealer ad just it WARNING EWA10690 A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an acci dent...

Page 71: ...ified in the periodic maintenance and lubrication chart EAU22410 Front brake pads Each front brake pad is provided with a wear indicator which allows you to check the brake pad wear without hav ing 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 bra...

Page 72: ...he recommended quality brake fluid otherwise the 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 a...

Page 73: ...n upright po sition 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 by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect ad...

Page 74: ...icated 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 Service the drive chain as follows CAUTION ECA10580 The drive chain must be lubricated after washing the motorcycle or riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damagin...

Page 75: ...ble is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked befo...

Page 76: ...he pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease 5SL21 book Page 29 Tuesday August 19 2003 11 00 AM ...

Page 77: ...tervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle 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 vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard ...

Page 78: ...g must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle 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 Yam...

Page 79: ...t 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 prompt medical attention ...

Page 80: ...ealer charge your battery EAU23701 Replacing the fuses The main fuse and fuse box 1 are locat ed under the rider seat See page 3 17 Fuse box 2 is located under panel B See page 6 6 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 1 Spare main fuse 2 Main fuse ...

Page 81: ...his model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Remove panel B if replacing the left headlight bulb or panel A if re placing the right headlight bulb See page 6 6 2 Remove the headlight bulb cover by turning it counterclockwise 3 Disconnect the headlight coupler Specified fuses Main fuse 40 0 A Fuse box 1 Electronic fuel injection fuse 15 0 A...

Page 82: ...ee from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the 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 headlight lens Do not use a headlight bulb of a wattage higher than specified 6 Conn...

Page 83: ...ng it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the bu...

Page 84: ...er pin in with a screwdriver then pulling the fastener out 2 Remove the socket together with the bulb by pulling it out 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the socket together with the bulb by pushing it in 6 Install the auxiliary light bulb cover by installing the quick fastener NOTE To install the quick fastener push the center pin out so ...

Page 85: ...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 frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cyc...

Page 86: ...e bolt 4 Remove the brake caliper on each side by removing the bolts 5 Remove the axle bolt pull the wheel axle out and then remove the wheel CAUTION ECA11050 Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut EAU25031 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 t...

Page 87: ...side of the left fork leg with a rubber mallet to align it with the end of the wheel axle 10 Tighten wheel axle pinch bolt D and then tighten pinch bolt C to the specified torque 11 Retighten pinch bolt D to the spec ified torque 12 While applying the front brake push down hard on the handlebar several times to check for proper fork operation Tightening torque Brake caliper bolt 40 Nm 4 0 m kgf 29...

Page 88: ... the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the rear wheel 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU25660 To install the rear wheel 1 In...

Page 89: ...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 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 motorcy...

Page 90: ...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 The engine does not start Check the battery Operate the electric starter 4 Battery ...

Page 91: ... hissing 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 t...

Page 92: ... dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion 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 Do not use any harsh chemical products on ...

Page 93: ...r drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion 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 stainless steel parts including the exhaust system Even the...

Page 94: ...fore storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful ...

Page 95: ...ery month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 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 ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the batt...

Page 96: ...oil filter cartridge replacement 2 60 L 2 75 US qt 2 29 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 15 L 2 27 US qt 1 89 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 0 L 4 49 US gal 3 74 Imp gal Fuel reserve amount 3...

Page 97: ...6 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 193 kg 198 425 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right...

Page 98: ...2 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature indicator light LED Engine trouble warning light LED Immobilizer system indicator light LED Shift timing indicator light LED Fuses Main fuse 40 0 A Headlight fuse 20 0 A Signaling system fuse 15 0 A Ign...

Page 99: ...ntification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 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 your motorcycle and may be used to register your m...

Page 100: ...YSTEM 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 vehicle after such de...

Page 101: ...bar switches 3 12 Hazard switch 3 13 Headlight bulb replacing 6 34 Helmet holders 3 18 High beam indicator light 3 4 Horn switch 3 13 I Identification numbers 9 1 Ignition circuit cut off system 3 23 Immobilizer system 3 1 Immobilizer system indicator light 3 7 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 36 Luggage ...

Page 102: ...leshooting 6 42 Troubleshooting charts 6 43 Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 36 Turn signal switch 3 12 V Valve clearance adjusting 6 19 Vehicle identification number 9 1 W Wheel bearings checking 6 32 Wheel front 6 39 Wheel rear 6 41 Wheels 6 22 5SL21 book Page 2 Tuesday August 19 2003 11 00 AM ...

Page 103: ...5SL21 book Page 3 Tuesday August 19 2003 11 00 AM ...

Page 104: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 08 0 3 1 CR E 5SL 28199 21 YZF R6S OWNER S MANUAL ...

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