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PERIODIC MAINTENANCE AND MINOR REPAIR

6-27

6

EAU01356

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10–15 mm (0.4–0.6 in) as shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as fol-
lows.
To increase the clutch lever free play,
turn the adjusting bolt at the clutch le-
ver in direction

a

. To decrease the

clutch lever free play, turn the adjusting
bolt in direction

b

.

NOTE:

@

If 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 6-7

for cowling removal and installa-
tion procedures.)

3. Loosen the locknut at the crank-

case.

4. To increase the clutch lever free

play, turn the adjusting nut in di-
rection

a

. To decrease the clutch

lever free play, turn the adjusting
nut in direction

b

.

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

1. Clutch lever free play adjusting bolt
c. Clutch lever free play

1. Locknut
2. Clutch lever free play adjusting nut

(crank case)

E_5MT.book Page 27 Tuesday, August 28, 2001 2:05 PM

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Summary of Contents for YZF-R6P

Page 1: ...5MT 28199 11 LIT 11626 15 32 YZF R6P YZF R6PC OWNER S MANUAL PRINTED IN JAPAN 2001 7 4 0 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

Page 2: ...EAU03438 ...

Page 3: ...otorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these hi...

Page 4: ...t be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informa...

Page 5: ...PT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE E_5MT book Page 2 Tuesday August 28 2001 2 05 PM ...

Page 6: ...AL 2001 by Yamaha Motor Corporation U S A 1st edition July 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 15 32 E_5MT book Page 3 Tuesday August 28 2001 2 05 PM ...

Page 7: ...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 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 8: ...INFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 9: ...HANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle...

Page 10: ...rnering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the operator f...

Page 11: ...ation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your moto...

Page 12: ...ese items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories...

Page 13: ...ty therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not to spil...

Page 14: ...r an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or cl...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle E_5MT book Page 7 Tuesday August 28 2001 2 05 PM ...

Page 16: ...SAFETY INFORMATION 1 1 8 1 2 3 4 5 6 7 California only EMISSION HOSE ROUTING YAMAHA MOTOR CO LTD FROM FUEL TANK CARB TO ATMOSPHERE CANISTER E_5MT book Page 8 Tuesday August 28 2001 2 05 PM ...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 18: ...bolt page 3 16 4 Air filter element page 6 19 5 Shock absorber assembly compression damping force adjusting screw page 3 19 6 Shock absorber assembly spring preload adjusting ring page 3 18 7 Shock absorber assembly rebound damping force adjusting knob page 3 18 8 Shift pedal page 3 9 9 Coolant reservoir page 6 15 10 Engine oil filter cartridge page 6 13 E_5MT book Page 1 Tuesday August 28 2001 2 ...

Page 19: ... kit page 6 1 13 Fuses page 6 39 14 Rear brake fluid reservoir page 6 30 15 Radiator cap page 6 17 16 Front brake fluid reservoir page 6 30 17 Engine oil filler cap page 6 12 18 Engine oil dipstick page 6 12 19 Brake pedal page 3 10 E_5MT book Page 2 Tuesday August 28 2001 2 05 PM ...

Page 20: ...ndlebar switches page 3 7 3 Starter choke lever page 3 13 4 Speedometer unit page 3 5 5 Main switch steering lock page 3 1 6 Tachometer page 3 6 7 Right handlebar switches page 3 8 8 Throttle grip page 6 22 9 Brake lever page 3 9 E_5MT book Page 3 Tuesday August 28 2001 2 05 PM ...

Page 21: ... pedal 3 9 Brake lever 3 9 Brake pedal 3 10 Fuel tank cap 3 11 Fuel 3 11 Starter choke lever 3 13 Seats 3 13 Helmet holders 3 15 Storage compartment 3 15 Adjusting the front fork 3 16 Adjusting the shock absorber assembly 3 18 Matching the front and rear suspension settings 3 20 Luggage strap holders 3 21 Sidestand 3 21 Ignition circuit cut off system 3 22 E_5MT book Page 1 Tuesday August 28 2001 ...

Page 22: ...n be removed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the ...

Page 23: ...ushed to the left or right EAU04303 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 5 L 0 8 Imp gal 0 9 US gal When this occurs refuel as soon as possible The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Turn the key to ON 2 If the warning light does not come on for a few seconds then go off have...

Page 24: ...oo high the warning light comes on and symbols and flash The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Turn the engine stop switch to and the key to ON 2 The warning light will come on and symbols and will appear in the display If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit ...

Page 25: ...temperature flash Warning light comes on Stop the motorcycle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See the Engine overheating section on page 6 48 for further instructions Above 284 F 140 C Symbol and message HI flash Warning light comes on Stop the engine and allow it to cool See the Engine overheating sec tion on page 6 4...

Page 26: ...etween the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO If the fuel level warning light comes on see page 3 2 the odometer display will automatically change to the fuel re serve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT button switches the dis play between the various tr...

Page 27: ...ESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock EAU00101 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range EC000003 CAUTION Do not operate the engine in the ta chometer red z...

Page 28: ...m 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 _ EAU00118 Handlebar switches EAU03888 Dimmer switch Set this switch to for the high beam and to for the low beam 0 r min for 3 seconds Circuit specific number of r min for 2 5 seconds Se...

Page 29: ...n EAU00129 Horn switch Press this switch to sound the horn EAU03890 Engine stop switch Set this switch to before 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 EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc ti...

Page 30: ...of the ignition circuit cut off system See page 3 22 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU00161 Brake lever The brake lever is located at the right hand...

Page 31: ...y from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever position adjusting dial 2 Arrow mark a Distance between brake lever and handlebar grip 1 Brake pedal E_5MT book Page 10...

Page 32: ... cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not ove...

Page 33: ...earch octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol contain...

Page 34: ...arter 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 EAU03814 Seats Rider seat To remove the rider seat Pull up the rear corners of the rider seat as shown remove the bolts and then pull the seat off 1 Sta...

Page 35: ...erclockwise 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 the seats are properly secured before riding _ 1 Projection 2 Seat hold...

Page 36: ...ay hit objects causing loss of control and possibly an accident _ To release the helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat EAU01242 Storage compartment The storage compartment is located under the passenger seat See page 3 14 for passenger seat opening and closing procedures EWA00005 WARNING _ Do not exceed the load lim...

Page 37: ...ease 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 bolt 1 Current setting ...

Page 38: ...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 39: ...ring in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber 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 Spr...

Page 40: ...ions as necessary 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 attempt to open the gas cylinder Do not subject the sho...

Page 41: ...conditions CI 05E EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Load condition Front fork adjustment Shock absorber assembly adjustment Spring preload Compression damping force Rebound damping force Spring preload Compression damping force Rebound damping force Rider only 1 8 1 9 1 10 1 7 4 12 3 20 With passenger 1 8 1 9 1 10 4 9 1 8 3 7 E_5MT...

Page 42: ...ition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system EW000044 WARNING The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss o...

Page 43: ...the 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 ...

Page 44: ...he clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shou...

Page 45: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 46: ... engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 6 12 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 15 6 16 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 ...

Page 47: ...peration is smooth Lubricate pedal pivoting points if necessary 6 35 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 34 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 35 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches ...

Page 48: ...pection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 WARNING If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle E_5MT book Page 3 Tuesday August 28 2001 2 05 PM ...

Page 49: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Engine break in 5 5 Parking 5 5 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 50: ...lowing 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 23 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop swi...

Page 51: ... starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 50 F 10 C require about 10 seconds of starter choke use and temperatur...

Page 52: ...while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU02988 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At...

Page 53: ...p the motorcycle 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU02989 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below CF 05E Acceleration shift point km h mi h Deceleration shift point km h mi h 1st 2nd 2nd 3rd 3rd 4th 4th 5th 5...

Page 54: ...r min 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 6 000 r min EC000052 CAUTION _ After 1 000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge replaced _ 1 600 km 1 000 mi and beyond The vehicle can now be operated nor mally EC000053 CAUTION _ Keep the engine speed out of the tachometer red zone If any engine trouble should oc cur during the engine ...

Page 55: ...justing the rear brake light switch 6 28 Checking the front and rear brake pads 6 29 Checking the brake fluid level 6 30 Changing the brake fluid 6 31 Drive chain slack 6 31 Lubricating the drive chain 6 33 Checking and lubricating the cables 6 34 Checking and lubricating the throttle grip and cable 6 34 Checking and lubricating the brake and clutch levers 6 34 Checking and lubricating the brake a...

Page 56: ...HE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO ...

Page 57: ...a particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ E_5MT book Page 2 Tuesday August 28 2001 2 05 PM ...

Page 58: ...very 26 600 mi 42 000 km 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses for cracks or damage Replace if necessary 5 Fuel filter Replace every 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system Check for...

Page 59: ... 13 000 km or 12 months 3 Air filter element Check condition and damage Replace if necessary 4 Cooling system Check hose for cracks or damage Replace if necessary Replace coolant every 24 months Ethylene glycol anti freeze coolant Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 6 Correct if necessary 6 Clutch Check operation Adjust or replace cable 7 Control ca...

Page 60: ...ased grease all purpose grease 14 Brake and shift pedal pivot shafts Apply chain lube lightly Lithium soap based grease all purpose grease 15 Drive chain Check chain slack alignment condition Adjust and lubricate chain thoroughly Special O ring chain lubricant Every 600 mi 1 000 km or after washing the motorcycle or riding in the rain 16 Wheel bearings Check bearings for smooth operation No ITEM R...

Page 61: ... calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged _ 17 Sidestand pivot Check operation and lubricate Apply chain lube lightly Lithium soap based grease all purpose grease 18 Sidestand switch Check and clean or replace if necessary 19 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary No ITEM ROUTINE INITIAL ODOMETER ...

Page 62: ...apter Refer to this section each time a cowling or the panel needs to be removed and installed EAU01602 Cowlings A and B To remove one of the cowlings Remove the screws slide the cowling forward for A or backward for B and then pull it off as shown 1 Cowling A right side Cowling B left side 2 Panel A 1 Screw 5 2 Cowling A Right side 1 Screw 6 2 Cowling B Left side E_5MT book Page 7 Tuesday August ...

Page 63: ...nd then slide the cowling into place 2 Place the cowling in the original position and then install the screws NOTE Make sure that the tabs at the front of each cowling fit side by side as shown and that all slots and projections fit to gether 1 Cowling A 2 Cowling B 1 Slot 2 2 Projection 2 1 Tab 2 E_5MT book Page 8 Tuesday August 28 2001 2 05 PM ...

Page 64: ...nd checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal col or when the motorcycle is ridden nor mally and all spark plugs installed in the engine should have the same color If an...

Page 65: ...rque 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 ECA00021 CAUTION Do not use any tools to remove or install the spark plug cap otherwise the ignition coil coupler may get damaged The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly To remove the spark plug cap simply tw...

Page 66: ...y clean it EAU04371 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE _ Make sure that the mo...

Page 67: ...the oil fill er cap and then add sufficient oil of the recommended type to raise it to the correct level 6 Insert and tighten the engine oil dipstick and then install and tight en the oil filler cap To change the engine oil with or without oil filter cartridge replace ment 1 Remove cowlings A and B See page 6 7 for cowling removal and installation procedures 2 Start the engine warm it up for sever...

Page 68: ..._ 5 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil 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 _ 1 Engine oil drain bolt Left side 1 Oil filter wrench 2 Oil filter cartridge Left side 1 O ring E_5MT book Page 13 Tuesday August 28 2001 2 0...

Page 69: ...NG II or higher Make sure that no foreign mate rial enters the crankcase _ 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficient _ 1 Torque wrench Tightening torque Oil f...

Page 70: ...ied in the periodic maintenance and lubrication chart To check the coolant level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE _ The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false r...

Page 71: ...e cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ 4 Close the reservoir cap and then install the coolant reserv...

Page 72: ...gine is hot _ 5 Remove the coolant drain bolt to drain the engine 6 Loosen the clamp screw and then disconnect the radiator hose to drain the radiator 7 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 8 Connect the radiator hose and then tighten the clamp screw 9 Install the coolant drain bolt and then tighten it to the specified torque NOTE _ Chec...

Page 73: ...ecommended coolant into the reservoir to the maximum level mark and then install the cap and cover 15 Pour the recommended coolant into the radiator until it is full 1 Screw 2 Left side 1 Bolt 2 Left side Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhib itors for aluminum engines Coolant quantity Total amount 2 15 L 1 89 ...

Page 74: ...le for several min utes and then turn it off 17 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 18 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 19 Install the panel and the cowlings ...

Page 75: ... 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 5 Remove the air filter case cover by removing the screws 1 Fuel cock 2 Hose 2 3 Fuel sender coupler 1 Screw 6 2 Air filter case cover E_5MT book Page 20 Tuesday August 28 2001 2 05 PM ...

Page 76: ...cover by installing the screws 10 Connect the fuel sender coupler and the hoses turn the fuel cock lever to ON place the fuel tank in the original position and then in stall the bolts 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 ...

Page 77: ...able free play The throttle cable free play should measure 6 8 mm 0 2 0 3 in at the throttle grip Periodically check the throttle cable free play and if neces sary 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 78: ...y loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dlebags etc if appr...

Page 79: ...en a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately 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 _ Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves 1 Tire sidewall 2 Tire wear indicator a...

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

Page 81: ...to develop its optimal characteris tics EAU00691 Accessories and replacement parts EW000098 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine ...

Page 82: ...r 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 7 for cowling removal and installa tion procedures 3 Loosen the locknut at the crank case 4 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free pl...

Page 83: ... hydraulic system will diminish the braking performance which may result in loss of control and an accident _ 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 t...

Page 84: ... point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU04396 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake Check the brake pad wear as follows 1 Remove the brake caliper bolt and then tilt the caliper forward to inspect ...

Page 85: ... to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quali ty 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 c...

Page 86: ...rvals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU00744 Drive chain slack The drive chain slack should be checked befor...

Page 87: ...l iper bracket bolt and the locknut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward a Drive chain slack Drive chain slack 40 50 mm 1 6 2 0 in 1 Axle nut 2 Drive chain slack adjusting bolt 3...

Page 88: ...e 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 the drive ch...

Page 89: ...bles 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 EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clut...

Page 90: ...ting the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grea...

Page 91: ...on EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds ...

Page 92: ... support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the 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 cha...

Page 93: ...s and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek pr...

Page 94: ... MF battery a special constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have ac cess to a sealed type MF bat tery charger have a Yamaha dealer charge your battery EAU04375 Replacing the fuses The main fuse and the fuse box which contains the fuses for the individual cir cuits are located under the rider seat See page 3 13 for r...

Page 95: ...the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Main fuse 2 Spare main fuse Specified fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 15 A Radiator fan fuse 7 5 A Ignition fuse 15 A Backup fuse odometer and clock 7 5 A E_5MT book Page 40 Tuesday Augus...

Page 96: ... secure it with the bulb holder EC000104 CAUTION _ 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 glass the luminosi ty 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 ...

Page 97: ...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 the lens by installing the screw ECA00065 CAUTION Do not overtighten the screw other wise the lens may break 1 Screw E_5MT book Page 42 Tue...

Page 98: ...lacing 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 EAU01824 Front wheel To re...

Page 99: ...nt wheel so that it is on the ground 4 Install the brake calipers and re flectors by installing the bolts NOTE _ Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs _ 5 Install the brake hose holders by installing the bolts 6 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques...

Page 100: ...e bolts 4 Loosen the locknut on each side of the swingarm 5 Turn the drive chain slack adjust ing bolts fully in direction a 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 rear wheel _ 7 Pull the wheel axle out and then remove the wheel ECA00119 CAUTION _ Do not apply the bra...

Page 101: ...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 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 deale...

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

Page 103: ... hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check ...

Page 104: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 105: ...ectrical 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 106: ...leaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a...

Page 107: ...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 thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use ...

Page 108: ... a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OF...

Page 109: ...to ground the spark plug electrodes while turning the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires fr...

Page 110: ...SPECIFICATIONS 8 Specifications 8 1 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 111: ...o 12 4 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 5 L 2 2 Imp qt 2 6 US qt With oil filter cartridge replacement 2 7 L 2 4 Imp qt 2 9 US qt Total amount dry engine 3 5 L 3 1 Imp qt 3 7 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE ...

Page 112: ...sc Transmission Primary reduction system Spur gear Primary reduction ratio 1 955 Secondary reduction system Chain drive Number of drive chain sprocket teeth front rear YZF R6 16 48 YZF R6C 16 46 Secondary reduction ratio YZF R6 3 000 YZF R6C 2 875 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 846 2nd 1 947 3rd 1 556 4th 1 333 5th 1 190 6th 1 083 Chassis Frame type Di...

Page 113: ...a 2 90 kgf cm2 42 psi High speed riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 250 kPa 2 50 kgf cm2 36 psi 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 50 17 M C MT 5 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4...

Page 114: ...ake light 13 5 V 0 6 6 1 W 2 LED Front turn signal position light 12 V 27 8 W 2 Rear turn signal light 12 V 27 W 2 Licence plate light 12 V 5 W 1 Meter lighting 12 V 1 4 W 2 Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Oil level coolant temperature warning light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling system f...

Page 115: ...number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 Street and enduro motorcycle limited warranty 9 7 Yamaha extended service 9 9 E_5MT book Page 1 Tuesday August 28 2001 2 05 PM ...

Page 116: ...01E 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 ...

Page 117: ...e under the passenger seat See page 3 14 for seat removal and installation procedures Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_5MT book Page 2 Tuesday August 28 2001 2 05 PM ...

Page 118: ...estigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tr...

Page 119: ...e for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 0...

Page 120: ... printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi...

Page 121: ... or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks E_5MT book Page 6 Tuesday August 28 2001 2 05 PM ...

Page 122: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY E_5MT book Page 7 Tuesday August 28 2001 2 05 PM ...

Page 123: ...CONSUMER INFORMATION 9 8 9 E_5MT book Page 8 Tuesday August 28 2001 2 05 PM ...

Page 124: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S E_5MT book Page 9 Tuesday August 28 2001 2 05 PM ...

Page 125: ...CONSUMER INFORMATION 9 10 9 E_5MT book Page 10 Tuesday August 28 2001 2 05 PM ...

Page 126: ... stop switch 3 8 F Front and rear suspension settings 3 20 Front fork adjusting 3 16 Front fork checking 6 36 Fuel 3 11 Fuel level warning light 3 2 Fuel tank cap 3 11 Fuses replacing 6 39 H Handlebar switches 3 7 Headlight bulb replacing 6 41 Helmet holders 3 15 High beam indicator light 3 2 Horn switch 3 8 I Identification numbers 9 1 Ignition circuit cut off system 3 22 Indicator and warning li...

Page 127: ...3 15 Supporting the motorcycle 6 43 T Tachometer 3 6 Tail brake light 6 42 Throttle cable free play adjusting 6 22 Throttle grip and cable checking and lubricating 6 34 Tires 6 23 Tool kit 6 1 Troubleshooting 6 46 Troubleshooting charts 6 47 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 42 Turn signal switch 3 8 V Valve clearance adjusting 6 22 Vehicle identification number 9 ...

Page 128: ...5MT 28199 11 LIT 11626 15 32 YZF R6P YZF R6PC OWNER S MANUAL PRINTED IN JAPAN 2001 7 4 0 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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