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Yamaha Thundercat YZF600R, Owner'S Manual

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Yamaha Thundercat YZF600R Owner'S Manual Download Page 89

PERIODIC MAINTENANCE AND MINOR REPAIR

6-40

6

EAU03582

Front wheel 

To remove the front wheel 

EW000122

WARNING

_ 

●

It is advisable to have a Yamaha
dealer service the wheel.

●

Securely support the motor-
cycle so that there is no danger
of it falling over. 

_

1. Disconnect the speedometer ca-

ble from the front wheel.

2. Remove the front fender by re-

moving the bolts.

3. Loosen the front wheel axle pinch

bolt, then the wheel axle and the
brake caliper bolts.

4. Lift the front wheel off the ground

according to the procedure on
page 6-39.

5. Remove the brake hose holders

on each side by removing the
bolts.

6. Remove the brake calipers on

each side by removing the bolts.

7. Pull the wheel axle out, remove

the speedometer gear unit, and
then remove the wheel.

ECA00046

CAUTION:

_ 

Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. 

_

1. Speedometer cable
2. Bolt (

×

 2)

3. Front fender
4. Bolt (

×

 2)

5. Brake caliper
6. Brake hose holder

Left side

1. Front fender
2. Bolt (

×

 2)

3 Front wheel axle pinch bolt
4. Wheel axle
5. Bolt (

×

 2)

6. Brake caliper
7. Brake hose holder

Right side

U4TVE6.book  Page 40  Saturday, August 4, 2001  12:14 PM

Summary of Contents for Thundercat YZF600R

Page 1: ...4TV 28199 E6 OWNER S MANUAL YZF600R ...

Page 2: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 3: ...o enjoy all advantages of your YZF600R 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 deal...

Page 4: ...e 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 _ U4TVE6 book Page 2 Saturday August 4 2001 12 14 PM ...

Page 6: ...MANUAL 2001 by Yamaha Motor Co Ltd 1st edition May 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U4TVE6 book Page 3 Saturday August 4 2001 12 14 PM ...

Page 7: ...ENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 8: ...U4TVE6 book Page 2 Saturday August 4 2001 12 14 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 10: ... even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however shoul...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 12: ...ting ring page 3 15 4 Shock absorber assembly rebound damping force adjusting knob page 3 15 5 Shock absorber assembly compression damping force adjusting screw page 3 16 6 Storage compartment page 3 12 7 Helmet holder page 3 12 8 Grab bar 9 Shift pedal page 3 7 10 Radiator page 6 15 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 13: ...t fork spring preload adjusting bolt page 3 13 15 Front fork rebound damping force adjusting screw page 3 14 16 Radiator cap page 6 15 17 Front fork compression damping force adjusting screw page 3 14 18 Engine oil level check window page 6 10 19 Brake pedal page 3 8 20 Engine oil filler cap page 6 10 U4TVE6 book Page 2 Saturday August 4 2001 12 14 PM ...

Page 14: ...e 3 5 3 Starter choke lever page 3 11 4 Speedometer unit page 3 3 5 Tachometer page 3 4 6 Coolant temperature gauge page 3 5 7 Right handlebar switches page 3 6 8 Brake lever page 3 7 9 Throttle grip page 6 20 10 Main switch steering lock page 3 1 U4TVE6 book Page 3 Saturday August 4 2001 12 14 PM ...

Page 15: ... 7 Shift pedal 3 7 Brake lever 3 7 Brake pedal 3 8 Fuel tank cap 3 8 Fuel 3 9 Fuel tank breather hose for Germany only 3 10 Starter choke lever 3 11 Seat 3 11 Helmet holder 3 12 Storage compartment 3 12 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 15 Matching the front and rear suspension settings 3 17 Luggage strap holders 3 18 Sidestand 3 18 Ignition circuit cut off syst...

Page 16: ...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 while the motorcycle is movin...

Page 17: ...es on when the engine oil level is low The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clutch lever 3 Push the start switch If the warn ing light does not come on while pushing the start switch have a Yamaha dealer check the electri...

Page 18: ...U00057 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right EAU00063 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows t...

Page 19: ...splay the following error code CB 11E Use the table below to identify the faulty electrical circuit CB 12E 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 T...

Page 20: ...2 CAUTION _ Do not operate the engine if it is overheated _ EAU00109 Anti theft alarm optional This motorcycle can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information EAU00118 Handlebar switches EAU00120 Pass switch PASS Press this switch to flash the headlight EAU03888 Dimmer switch Set this switch to for the high beam and to for the low b...

Page 21: ...fore starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU03898 Light switch Set this switch to to turn on the auxiliary light meter lighting and tail light Set the switch to to turn on the headlight also Set the switch to to turn off all the lights EAU00143 Start switch Push this switch to ...

Page 22: ...ion with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU00161 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handlebar grip The brake lever is equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn t...

Page 23: ...k cap can be opened To close the fuel tank cap 1 Push the fuel tank cap into posi tion with the key inserted in the lock 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE _ The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked _ EWA00025 WARNING _ Make ...

Page 24: ... of the same spe cial design as the original _ EAU04255 ECA00104 CAUTION _ Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs ...

Page 25: ...e motorcycle Check the fuel tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary 1 Fuel tank breather hose U4TVE6 book Page 10 Saturday August 4 2001 12 14 PM ...

Page 26: ...f the starter choke ECA00038 CAUTION _ Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke _ EAU04158 Seat To remove the seat 1 Insert the key into the helmet hold er lock and then turn it as shown 2 Pull the seat off 1 Starter choke...

Page 27: ...it objects causing loss of control and possibly an accident _ EAU04275 Storage compartment This storage compartment is designed to hold an optional genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage com partment securely fasten it with the straps When the U LOCK is not in the storage compartment be sure to se cure the straps to prevent losing them When storing the o...

Page 28: ...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 groove on the ad justing mechanism with the top of the front fork cap bolt _ CI 10E 1 Spring preload adjusting b...

Page 29: ...nism beyond the maximum or minimum settings _ NOTE _ Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above 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 jus...

Page 30: ... de crease the spring preload and thereby soften the suspension turn the adjust ing ring in direction b CI 10E Rebound damping force To increase the rebound damping force and thereby harden the rebound damping turn the adjusting knob in di rection a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting knob in direction b CI 03E 1 Spring preload adjusting ...

Page 31: ...t the position indicator is aligned with the appropriate setting CI 10E EAU00315 WARNING _ This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or...

Page 32: ...itions 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 10 1 5 1 6 3 25 With passenger 1 8 1 10 1 10 3 7 1 4 3 10 U4T...

Page 33: ...n 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 control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling...

Page 34: ...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 35: ...e 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 shoul...

Page 36: ...U4TVE6 book Page 21 Saturday August 4 2001 12 14 PM ...

Page 37: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 38: ...n engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 10 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 13 6 14 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 s...

Page 39: ...tion is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 32 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Chec...

Page 40: ...tion 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 _ U4TVE6 book Page 3 Saturday August 4 2001 12 14 PM ...

Page 41: ... 5 Starting the engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 5 Parking 5 6 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 42: ... starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 20 Never ride with the sidestand down _ 1 Turn the key to ON and make s...

Page 43: ...rning light does not come on when push ing the start switch or if it does not go off after starting with suf ficient engine oil have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come on...

Page 44: ... press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it _ EC000048 CAUTION _ Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the tran...

Page 45: ...rgely on your riding style Consider the following tips to reduce fuel consumption Thoroughly warm up the engine Turn the starter choke off as soon as possible Shift up swiftly and avoid high en gine speeds during acceleration Do not rev the engine while shift ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of t...

Page 46: ...ged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU03749 0 1 000 km Avoid prolonged operation above 6 500 r min 1 000 1 600 km Avoid prolonged operation above 8 000 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 nor ...

Page 47: ...e key from the main switch EW000058 WARNING _ Since the 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 motorcycle may overturn _ U4TVE6 book Page 6 Saturday August 4 2001 12 14 PM ...

Page 48: ...U4TVE6 book Page 7 Saturday August 4 2001 12 14 PM ...

Page 49: ... rear brake pads 6 27 Checking the brake fluid level 6 27 Changing the brake fluid 6 28 Drive chain slack 6 29 Lubricating the drive chain 6 30 Checking and lubricating the cables 6 31 Checking and lubricating the throttle grip and cable 6 31 Checking and lubricating the brake and shift pedals 6 31 Checking and lubricating the brake and clutch levers 6 32 Checking and lubricating the sidestand 6 3...

Page 50: ...e maintenance work have a Yamaha dealer do it for you _ EAU01299 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 11 for seat removal procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever addi...

Page 51: ...ANCE JOB ODOMETER READING 1 000 km ANNUAL 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 52: ... or riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 50 000 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 Shock absorber assembly Check operation ...

Page 53: ...d Replace the brake hoses every four years and if cracked or damaged _ 23 Engine oil Change Check oil level and vehicle for oil leakage 24 Engine oil filter cartridge Replace 25 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Lights signals and switches Check operation A...

Page 54: ...erform some of the main tenance jobs described in this chapter Refer to this section each time a cowl ing needs to be removed and installed EAU04277 Cowlings A and C To remove one of the cowlings 1 Remove the bolts 1 Cowling A 2 Cowling B 1 Cowling C 2 Cowling D 1 Bolt 3 on each side U4TVE6 book Page 5 Saturday August 4 2001 12 14 PM ...

Page 55: ...cowling off To install the cowling 1 Connect the turn signal connec tors and for the left side cowling also the auxiliary light coupler 2 Place the cowling in the original position and then install the bolts Bolt 6 Bolt 7 Left side Right side 1 Bolt 5 on each side 1 Auxiliary light coupler 2 Turn signal connector 2 U4TVE6 book Page 6 Saturday August 4 2001 12 14 PM ...

Page 56: ...n install the screws 2 Install the seat EAU04278 Cowling D To remove the cowling 1 Remove the seat and cowling B See pages 3 11 and 6 7 for seat and cowling removal and installa tion procedures 2 Remove the grab bar by removing the bolts 3 Remove the screw and then pull the cowling off as shown To install the cowling 1 Place the cowling in the original position and then install the screw 2 Install...

Page 57: ...g cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medi um to light tan the ideal color when the motorcycle is ridden nor mally 2 Check that all spark plugs installed in the engine have the same color NOTE _ If any spark plug shows a dis...

Page 58: ...grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE _ If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ 4 Install the spark plug cap Specif...

Page 59: ...d then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil w...

Page 60: ... filter wrench is available at a Yamaha dealer _ 6 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE _ Make sure that the O ring is properly seated _ 7 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench 1 Engine oil drain bolt Left side 1 Oil filter cartridge 2 Oil filter wrench 1 O ring Tightening torque Oil filt...

Page 61: ...dle 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 check the vehicle _ ...

Page 62: ...mum level mark remove the seat See page 3 11 for seat re moval and installation proce dures and then open the coolant reservoir cap 4 Add coolant or distilled water to raise the coolant to the specified level close the coolant reservoir cap and then install the seat EC000080 CAUTION _ If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water sinc...

Page 63: ...al and installation procedures 3 Remove cowling D See page 6 7 for cowling removal and installa tion procedures 4 Remove the coolant reservoir by removing the bolts 5 Drain the coolant from the coolant reservoir 6 Remove cowlings A and C See page 6 5 for cowling removal and installation procedures 7 Remove the fuel tank bolts and then lift the fuel tank Do not re move the fuel hoses EW000071 WARNI...

Page 64: ...11 Remove the water pump drain bolt to drain the cooling system 12 Remove the cylinder drain bolts to drain the cooling system 13 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 14 Install the water pump drain bolt and cylinder drain bolts and then tighten them to the specified torques 1 Clamp screw 2 2 Right air intake duct 1 Radiator cap 1 Water ...

Page 65: ...the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 20 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 21 Install the right air intake duct and then tighten the clamp screws 22 Place the fuel tank in the original position a...

Page 66: ...ank bolts 3 Lift the fuel tank to position it away from the air filter case Do not dis connect the fuel hoses EW000071 WARNING _ Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage _ 4 Remove the air filter case cover by removing the screws 5 Pull the air filter element out 6 Clean the air ...

Page 67: ...ews 10 Place the fuel tank in the original position and then install the bolts EW000072 WARNING _ Before installing the fuel tank make sure that the fuel hoses are not damaged If any fuel hose is damaged do not start the engine but have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched _ 11 Install the seat EAU...

Page 68: ...part of 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...

Page 69: ...e throttle cable free play The throttle cable free play should measure 3 7 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 adjusted by...

Page 70: ...andling braking performance and safety characteris tics of your motorcycle you should keep the following precautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry...

Page 71: ...ed have a Yamaha dealer replace the tire immediately CE 08E NOTE _ The tire tread depth limits may differ from country to country Always comply with the local regulations _ EW000079 WARNING _ Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control The replacement of al...

Page 72: ...ores listed below to avoid tire deflation during a high speed ride _ CE 10E CE 14E 1 Tire air valve 2 Tire valve core 3 Tire valve cap with seal FRONT Manufacturer Size Model Dunlop 120 60 ZR17 55W D204F 120 60 ZR17 M C 55W Metzeler 120 60 ZR17 55W MEZ1 FRONT 120 60 ZR17 M C 55W Bridgestone 120 60 ZR17 55W BT57F 120 60 ZR17 M C 55W Michelin 120 60 ZR17 55W MACADAM 90X 120 60 ZR17 M C 55W REAR Manu...

Page 73: ...ure according to the operating conditions _ EAU03773 Cast wheels To maximize the performance durabil ity and safe operation of your motor cycle 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 not attempt even the smallest repair to the wheel A de...

Page 74: ... direction b 3 Tighten the locknut NOTE _ If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism _ EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 42 mm below the top of the footrest as shown Peri odically check the brake pedal po...

Page 75: ...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 directio...

Page 76: ...int that the wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU03294 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate wor...

Page 77: ...rake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE afte...

Page 78: ...ng 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 adjust it as follows EAU03752 To adjust the drive chain slack 1 Loosen the axle nut then loosen the locknut at each end of the swingarm 2 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en t...

Page 79: ...d 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 EC000097 CAUTION _ 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 ECA00053 CAUTION _ To prevent damaging the O rings do not clean...

Page 80: ...st Replace a damaged cable as soon as possible to prevent unsafe conditions _ EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03370 Checking and lubricating the brake and shift pedals The operatio...

Page 81: ...al 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 _ EAU04282 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based gr...

Page 82: ... 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 EC000098 CAUTION _ If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be ...

Page 83: ...ha dealer check or repair the steer ing 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 chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U4TVE6 book Page 34 Saturday August 4 2001 12 14 PM ...

Page 84: ...mpt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN _ 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 ...

Page 85: ...r cuits are located under the seat See page 3 11 for seat removal and instal lation procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage...

Page 86: ...ctrical system EAU04160 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder U4TVE6 book Page 37 Saturday Augu...

Page 87: ...adlight 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 _ 4 Install the headlight bulb cover and then connect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU01623 Replacing the tail brake light bulb 1 Remove the t...

Page 88: ...er 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 ...

Page 89: ... the ground according to the procedure on page 6 39 5 Remove the brake hose holders on each side by removing the bolts 6 Remove the brake calipers on each side by removing the bolts 7 Pull the wheel axle out remove the speedometer gear unit and then remove the wheel ECA00046 CAUTION _ Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut _ 1...

Page 90: ... axle pinch bolt and the brake caliper bolts to the specified torques 7 Install the brake hose holders by installing the bolts 8 Connect the speedometer cable 9 Install the front fender by installing the bolts 10 Push down hard on the handlebar several times to check for proper fork operation EAU04197 Rear wheel To remove the rear wheel EW000122 WARNING _ It is advisable to have a Yamaha dealer se...

Page 91: ... and the drive chain slack adjusting nut on both sides of the swingarm 6 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE _ The drive chain does not need to be disassembled in order to remove and install the wheel _ 7 Pull the wheel axle out along with the right wheel axle guide remove the brake caliper bracket and then remove the wheel ECA00048 CAUTION _ Do not a...

Page 92: ...new cotter pin into the brake torque rod bolt EWA00051 WARNING _ Always use a new cotter pin for the brake torque rod bolt _ EAU03087 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the 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...

Page 93: ...compression 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 tu...

Page 94: ...ss 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 Che...

Page 95: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 96: ...trical 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 ...

Page 97: ...f 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 easily if the area is covered with a wet cloth for a few minutes before cleaning ...

Page 98: ...damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING _ Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before operating the motor cycle test its b...

Page 99: ...ent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore...

Page 100: ...every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see ...

Page 101: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 102: ...Compression ratio 12 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 6 L With oil filter cartridge replacement 2 9 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 us...

Page 103: ...em Spur gear Primary reduction ratio 1 708 Secondary reduction system Chain drive Secondary reduction ratio 3 133 Number of drive chain sprocket teeth front rear 15 47 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 846 2nd 1 947 3rd 1 545 4th 1 333 5th 1 190 6th 1 074 Chassis Frame type Diamond Caster angle 25 Trail 97 mm Tires Front Type Tubeless tire Size 120 60 ZR1...

Page 104: ...0 kPa 2 90 kgf cm2 2 90 bar High speed riding Front 250 kPa 2 50 kgf cm2 2 50 bar Rear 290 kPa 2 90 kgf cm2 2 90 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3 50 17 M C MT 3 50 Rear Type Cast wheel Size 17 MT 5 00 17 M C MT 5 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot F...

Page 105: ... Headlight 12 V 60 55 W 1 Tail brake light 12 V 5 21 W 1 Turn signal light 12 V 21 W 4 Auxiliary light 12 V 4 W 1 Meter lighting 12 V 1 7 W 4 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Oil level warning light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 1 Fuel level warning light 12 V 3 4 W 1 Fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 15 ...

Page 106: ...MPERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 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 k...

Page 107: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 U4TVE6 book Page 1 Saturday August 4 2001 12 14 PM ...

Page 108: ... 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 109: ... frame under the seat See page 3 11 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U4TVE6 book Page 2 Saturday August 4 2001 12 14 PM ...

Page 110: ...eak in 5 5 Engine oil and oil filter cartridge 6 10 Engine stop switch 3 6 F Front and rear suspension settings 3 17 Front fork adjusting 3 13 Front fork checking 6 33 Fuel 3 9 Fuel consumption tips for reducing 5 4 Fuel level warning light 3 3 Fuel tank breather hose Germany only 3 10 Fuel tank cap 3 8 Fuses replacing 6 36 H Handlebar switches 3 5 Headlight bulb replacing 6 37 Helmet holder 3 12 ...

Page 111: ...cle 6 39 Suspension rear lubricating 6 32 T Tachometer 3 4 Tail brake light bulb replacing 6 38 Throttle cable free play adjusting 6 20 Throttle grip and cable checking and lubricating 6 31 Tires 6 21 Tool kit 6 1 Troubleshooting 6 43 Troubleshooting charts 6 44 Turn signal indicator light 3 3 Turn signal light bulb replacing 6 39 Turn signal switch 3 6 V Valve clearance adjusting 6 20 Vehicle ide...

Page 112: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 113: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM ...

Page 114: ...PRINTED IN JAPAN 2001 6 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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