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Yamaha 2005 YZF-R6T, Owner'S Manual

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Yamaha 2005 YZF-R6T Owner'S Manual Download Page 75

PERIODIC MAINTENANCE AND MINOR REPAIR

6-28

6

EAU23131

Checking and lubricating the 
brake and shift pedals 

The operation of the brake and shift
pedals should be checked before each
ride, and the 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)

U5SL22E0.book  Page 28  Monday, August 9, 2004  3:22 PM

Summary of Contents for 2005 YZF-R6T

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 09 0 3 1 CR E 5SL 28199 22 YZF R6T OWNER S MANUAL ...

Page 2: ...U5SL22E0 book Page 2 Monday August 9 2004 3 22 PM ...

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 motorcycle operator a b...

Page 5: ...MANUAL 2004 by Yamaha Motor Co Ltd 1st edition July 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5SL22E0 book Page 2 Monday August 9 2004 3 22 PM ...

Page 6: ...iodic maintenance 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 17 Adjusting the engine idling speed 6 18 Checking the throttle cable free play 6 18 Valve clearance 6 19 Tires 6 19 Cast wheels 6 21 Adjusting the clutch lever free play ...

Page 7: ...6 36 Supporting the motorcycle 6 37 Front wheel 6 38 Rear wheel 6 40 Troubleshooting 6 41 Troubleshooting charts 6 42 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 U5SL22E0 book Page 2 Monday August 9 2004 3 22 PM ...

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: ... Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided 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 clear...

Page 11: ... equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle 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 ...

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 4 3 U5SL22E0 book Page 5 Monday August 9 2004 3 22 PM ...

Page 13: ...te il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5PA 21568 00 01 290 kPa 2 90 kgf cm2 42psi 5VY 21668 00 U5SL22E0 book Page 6 Monday August 9 2004 3 22 PM ...

Page 14: ...pring preload adjusting ring page 3 21 6 Shock absorber assembly compression damping force adjusting screw page 3 21 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw page 3 21 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 U5SL22E0 book Pag...

Page 15: ...attery page 6 31 6 Idle adjusting screw page 6 18 7 Air filter element page 6 16 8 Front brake fluid reservoir page 6 24 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 15 13 Dipstick page 6 9 14 Rear brake fluid reservoir page 6 24 U5SL22E0 book Page 2 Monday August 9 2004 3 22 PM ...

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 18 8 Brake lever page 3 14 U5SL22E0 book Page 3 Monday August 9 2004 3 22 PM ...

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 EAU11002 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 U5SL22E0 book Page 5 Monday August 9 2004 3 22 PM ...

Page 22: ...OK Go ahead with riding 117 139 C 242 283 F Temperature display 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 42 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 42 U5SL22E0 book Page 6 Monday August 9 2004 3 ...

Page 23: ...or 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 EAU26872 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 deal...

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: ...e pull the lever toward the handle bar grip The brake lever is equipped with a po sition adjusting knob To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting knob while holding the lever pushed away from the handlebar grip When the de sired position is obtained be sure to set it by aligning a groove on the adjusting knob with the mark on the brake lever 1 Shift ...

Page 31: ...l 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 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 WARNING EWA11090 Make su...

Page 32: ...d 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 Your Yamaha engine has been de signed to use premium unleaded gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduc...

Page 33: ...ter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU14091 Seats Rider seat To remove the rider seat Pull back the rear 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 plac...

Page 34: ...1 Remove the passenger seat See page 3 17 2 Attach the helmet to a helmet hold er and then securely install the passenger seat WARNING EWA11040 Never ride with a helmet attached to a helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident CAUTION ECA11600 Some helmets may contact the muf fler when secured to the right side helmet holder because of their siz...

Page 35: ... WARNING EWA10180 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 bolt on each fork leg in direction b NOTE Align the appropriate g...

Page 36: ... settings NOTE 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 speci...

Page 37: ...ping force and thereby harden the rebound damp ing turn the adjusting screw in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw in di rection b Compression damping force To increase the compression damping force and thereby harden the compres sion damping turn the adjusting screw 1 Spring preload adjusting ring 2 Special wrench 3 Pos...

Page 38: ... held re sponsible 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 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...

Page 39: ...g the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tra...

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: ...oft or spongy have Yamaha dealer bleed hydraulic system 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 23 6 24 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reserv...

Page 43: ...s Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 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 U5SL22E0 book Page 4 Monday August 9 2004 3 22 PM ...

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: ...e or riding in the rain 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation...

Page 51: ...5 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 necessary 29 Muffler and exhaust pipe Che...

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 U5SL22E0 book Page 5 Monday August 9 2004 3 22 PM ...

Page 53: ...this chapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU19012 Cowlings A and B To remove one of the cowlings Remove the bolts and quick fasteners slide the cowling forward for B or backward for A and then pull it off as shown 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 1 Quick fastener 1 Bolt 2 Cowling A U5SL22E0 book Page 6 Monday August 9 2004 3 22 P...

Page 54: ...ion and then install the bolts and quick fasteners 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 U5SL22E0 book Page 7 Mond...

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: ... filter cartridge replace ment 1 Start the engine warm it up for several 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 cowling B See page 6 6 5 Remove the coolant reservoir cov er by removing...

Page 58: ...the recommended engine oil and then install and tighten the oil filler 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 m...

Page 59: ...at the intervals specified in the periodic maintenance and lubrication chart EAU20112 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: ...ine is hot 4 Install the reservoir cap and then install the coolant reservoir cover by installing the bolts NOTE The radiator fans are automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 42 for further instructions EAU20343 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remo...

Page 61: ...ap and then turn the coolant reservoir upside down to empty it 12 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 13 Install the coolant reservoir by in stalling the bolts 14 Connect the radiator hose and then tighten the clamp screw 15 Install the coolant drain bolt and then tighten it to the specified torque 1 Radiator cap 1 Coolant drain bolt 2 ...

Page 62: ...nt of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 19 Install the radiator cap start the engine let it idle for several min utes and then turn it off 20 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 21 Start the engine an...

Page 63: ... tilt it back and away from the air filter case Do not disconnect the fuel hoses WARNING EWA10410 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 4 Remove the air filter case cover by removing the screws 5 Pull the air filter element out 6 Check the condition of the air filter element a...

Page 64: ...lacing 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 connected and routed and not pinched Be sure to place the fuel tank breather hose and the fuel tank overflow hose in the original po sition 10 In...

Page 65: ...ing the idle adjusting 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 described above have a Yamaha dealer make the adjustment EAU21381 Checking the throttle cable free play The throttle cable free play should mea sure 6 0 8 0 mm 0 24 0 31 in at the t...

Page 66: ... ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely...

Page 67: ... 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 brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience NOTE The tire tread depth limits may differ fr...

Page 68: ... before a high speed run Always adjust the tire air pres sure according to the operating conditions EAU21960 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do no...

Page 69: ... the specified clutch lever free play cannot be obtained as described above proceed as follows 1 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 2 Remove cowling A See page 6 6 3 Loosen the locknut at the crank case 4 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le ver free play turn the adjusting ...

Page 70: ...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 71: ...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 72: ...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 73: ... 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 ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not c...

Page 74: ...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 75: ...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 U5SL22E0 book Page 28 Monday August 9 2004 3 22 PM ...

Page 76: ...sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed at the intervals specified in the peri odic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubrican...

Page 77: ...to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrica...

Page 78: ...eed to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes sev...

Page 79: ...a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Usin...

Page 80: ...ectrical 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 Fuse box 2 2 Headlight fuse 3 Parking lighting fuse 4 Ignition fuse 5 Signaling system fuse 6 Backup fuse for odometer clock and immo bilizer system 7 Electronic fuel injection fuse 8 Spare fuse Specified fuses Main fuse 40 0 A Fuse box 1 Radiator fa...

Page 81: ...ery hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 5 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transpar ency of the glas...

Page 82: ... equipped with an LED type of tail brake light If the tail brake light does not come on have a Yamaha dealer check it EAU24201 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 counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install th...

Page 83: ...light unit by installing the screws EAU24342 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Remove the auxiliary light bulb cover by removing the quick fas tener NOTE Remove the quick fastener by pushing the center pin in with a screwdriver then pulling the fastener out 2 Remove the socket together wi...

Page 84: ...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 ...

Page 85: ...brake caliper on each side by removing the bolts 5 Remove the axle bolt push the wheel axle out from the left side 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 EAU33931 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 th...

Page 86: ...e 9 Tap the outer side of the right 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...

Page 87: ...ear sprocket NOTE If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be disas sembled 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 th...

Page 88: ...factory trouble may occur dur ing 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 your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools ex...

Page 89: ...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 90: ... 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 91: ... 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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...g 198 423 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 290 kPa 42 psi 2 90 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 hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Op...

Page 97: ...ral 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 warning 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 Ignition fuse 15 0 A Parking lighting fu...

Page 98: ...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 99: ...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 100: ...placing 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 strap holders 3 22 M Main switch steering lock 3 2 Mod...

Page 101: ... Troubleshooting charts 6 42 Turn signal indicator lights 3 4 Turn signal light bulb replacing 6 35 Turn signal switch 3 12 V Valve clearance 6 19 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheel front 6 38 Wheel rear 6 40 Wheels 6 21 U5SL22E0 book Page 2 Monday August 9 2004 3 22 PM ...

Page 102: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 103: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 104: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 09 0 3 1 CR E 5SL 28199 22 YZF R6T OWNER S MANUAL ...

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