Yamaha YZFR6W Owner'S Manual Download Page 62

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-12

To install the cowling

1. Fit the slot in cowling E over the

tab on the front cowling.

2. Install the bolts and the quick fas-

tener.

3. Place the wire harness in the orig-

inal position, and then close the
plastic fastener.

4. Install the cowling and the panel.

EAU39060

Panels A and B

To remove one of the panels
Remove the bolts, and then pull the
panel off as shown.

To install the panel
Place the panel in the original position,
and then install the bolts.

1. Cowling E
2. Bolt

3. Quick fastener

1. Cowling E
2. Slot

3. Front cowling

4. Tab

1. Panel B
2. Bolt

U2C011E0.book Page 12 Wednesday, July 12, 2006 10:13 AM

Summary of Contents for YZFR6W

Page 1: ...2C0 28199 11 OWNER S MANUAL YZFR6W C LIT 11626 20 43...

Page 2: ...EAU10041 U2C011E0 book Page 1 Wednesday July 12 2006 10 13 AM...

Page 3: ...cle 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 emiss...

Page 4: ...nsult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERAT...

Page 5: ...CHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications...

Page 6: ...tion U S A 1st edition July 2006 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 LI...

Page 7: ...l maintenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 9 Checking the spark plugs 6 13 Canister for California only 6 14 Engine oil and oil filter cartridge 6 14 Coolant...

Page 8: ...shooting charts 6 45 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Mo...

Page 9: ...s have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brig...

Page 10: ...ld or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing...

Page 11: ...ion when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo tha...

Page 12: ...quate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust sys...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2C011E0 book Page 5 Wednesday July 12 2006 10 13 AM...

Page 14: ...gasoline or solvent will damage windshield Use neutral detergent 5JW 00 California only California only California only HOWTO LAYOUT FUEL HOSES 1 2 3 4 FUEL DELIVERY FUEL PUMP FUEL FILTER PRESS REGULA...

Page 15: ...E ONLY 91 Min Pump Octane R M 2 5PW 2415E 11 WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 Cold tire normal pressure should be set as follows 3...

Page 16: ...Shock absorber assembly compression damping force adjusting screw for slow compression damping page 3 20 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw pag...

Page 17: ...use page 6 36 6 Battery page 6 35 7 Air filter element page 6 21 8 Front brake fluid reservoir page 6 27 9 Radiator cap page 6 17 10 Coolant reservoir page 6 17 11 Engine oil filler cap page 6 14 12 C...

Page 18: ...ver page 3 12 2 Left handlebar switches page 3 11 3 Main switch steering lock page 3 1 4 Multi function meter unit page 3 5 5 Right handlebar switches page 3 11 6 Brake lever page 3 12 7 Throttle grip...

Page 19: ...gine can be started The key cannot be re moved NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10660 OFF A...

Page 20: ...cator light This indicator light comes on when the high beam of the headlight is switched on EAU11250 Oil level warning light This warning light comes on when the engine oil level is low The electrica...

Page 21: ...then go off have a Yamaha dealer check the elec trical circuit NOTE This model is also equipped with a self diagnosis device for the fuel level de tection circuit If the fuel level detection circuit i...

Page 22: ...Go ahead with riding 117 134 C 243 274 F Temperature display flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not g...

Page 23: ...nform the rider when it is time to shift to the next higher gear The electrical circuit of the indicator light can be checked by turning the key to ON If the indicator light does not come on for a few...

Page 24: ...switch the speedometer and odometer tripmeter displays be tween kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the...

Page 25: ...ou do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km 3 mi Stopwatch mode To change th...

Page 26: ...mperature warning light comes on when the engine overheats When the key is turned to ON the coolant temperature is auto matically displayed even if the air intake temperature was displayed prior to tu...

Page 27: ...s This function allows you to adjust the brightness of the indicator light to suit your preference NOTE In this mode the right display shows the current setting for each function except the shift timi...

Page 28: ...eed The control mode changes to the shift timing indicator light deactiva tion function To set the shift timing indicator light de activation function NOTE The shift timing indicator light de activati...

Page 29: ...sound the horn EAU12660 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 vehicle overturns or when the...

Page 30: ...tion with the clutch lever when shifting the gears of the 6 speed con stant mesh transmission equipped on this motorcycle EAU33850 Brake lever The brake lever is located at the right handlebar grip To...

Page 31: ...he fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel ta...

Page 32: ...Avoid spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13380 CAUTION ECA...

Page 33: ...haust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire...

Page 34: ...e 2 Remove the key NOTE Make sure that the seats are properly secured before riding EAU39072 Helmet holding cable A helmet holding cable is provided in the owner s tool kit to secure two hel mets to t...

Page 35: ...nd then remove the cable from the helmet strap buck le 3 Install the passenger seat EAU38941 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing f...

Page 36: ...ping To increase the compression damping force and thereby harden the compres sion damping turn the adjusting bolt on each fork leg in direction a To de crease the compression damping force and thereb...

Page 37: ...nd 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 productio...

Page 38: ...with the position in dicator on the shock absorber Use the special wrench included in the owner s tool kit to make the ad justment Rebound damping force To increase the rebound damping force and there...

Page 39: ...ent it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary WARNING EWA10220 This shock absorber contains highly p...

Page 40: ...dealer service the shock absorber EAU38961 Luggage strap holders There are six luggage strap holders four on the bottom of the passenger seat and one on each passenger foot rest To use the luggage str...

Page 41: ...d or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See furth...

Page 42: ...clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is i...

Page 43: ...the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliabl...

Page 44: ...ences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used...

Page 45: ...t or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hy...

Page 46: ...sary 6 22 6 24 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pi...

Page 47: ...Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 24 Never ride with the sidestand down 1 Turn the key to ON and mak...

Page 48: ...N ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly l...

Page 49: ...n EAU16740 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in th...

Page 50: ...the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 Since the eng...

Page 51: ...TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SE...

Page 52: ...NING EWA10340 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 U2C01...

Page 53: ...ssary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance when engine is cold Every 26600...

Page 54: ...utch Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leak...

Page 55: ...12 Chassis fasteners Check all chassis fitting and fas teners Correct if necessary 13 Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift...

Page 56: ...ce 22 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 23 Front and rear brake switches Check operation 24 C...

Page 57: ...disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal component...

Page 58: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 8 6 Replace the brake hoses every four years and if cracked or damaged U2C011E0 book Page 8 Wednesday July 12 2006 10 13 AM...

Page 59: ...cowling or panel needs to be re moved and installed EAU38970 Cowlings A and B To remove one of the cowlings Remove the bolts and the quick fasten er and then pull the cowling off as shown To install t...

Page 60: ...ing B if remov ing cowling D See page 6 9 2 Disconnect the turn signal light lead coupler 3 Remove the bolts quick fasteners and quick fastener screw and then take the cowling off 1 Cowling A 2 Tab 3...

Page 61: ...ing B to complete the installation of cowling D EAU39091 Cowling E To remove the cowling 1 Remove cowling B and panel B See page 6 9 2 Unfasten the wire harness by pressing on the tab to open the plas...

Page 62: ...tion and then close the plastic fastener 4 Install the cowling and the panel EAU39060 Panels A and B To remove one of the panels Remove the bolts and then pull the panel off as shown To install the pa...

Page 63: ...essive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean...

Page 64: ...chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A...

Page 65: ...he engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 5 11 if the oil filter cartridge is not being replaced 5 Remove the shift arm by removing the bolt 6 Pull th...

Page 66: ...on the shift arm with the match mark on the shift shaft and installing the bolt then tighten ing it to the specified torque CAUTION ECA15340 Be sure to align the match marks to ensure proper shifting...

Page 67: ...ha dealer check the vehicle 15 Turn the engine off and then check the oil level and correct it if necessary 16 Install the cowling EAU20070 Coolant The coolant level should be checked before each ride...

Page 68: ...have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator ca...

Page 69: ...e the coolant reservoir cap and then turn the coolant reservoir upside down to empty it 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install t...

Page 70: ...of the coolant will be reduced 15 Install the radiator cap start the engine let it idle for several min utes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator...

Page 71: ...uld mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance...

Page 72: ...shift Securely pack your heavi est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and...

Page 73: ...knowl edge and experience Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves WARNING EWA10480 The front and rear tires should be of the same make and de sign...

Page 74: ...il ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found...

Page 75: ...ories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held...

Page 76: ...lows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn...

Page 77: ...brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to chec...

Page 78: ...ubrication 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 seal...

Page 79: ...roper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this fr...

Page 80: ...hain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the drive chain as they may contain substances...

Page 81: ...should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be che...

Page 82: ...nd lubricating 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 WARNING EWA...

Page 83: ...EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on...

Page 84: ...support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dea...

Page 85: ...ompt 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 s...

Page 86: ...s 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Main fuse 2 Fuel injection system spare fuse 3 F...

Page 87: ...it counterclockwise 2 Disconnect the headlight coupler 3 Unhook the headlight bulb holder and then remove the defective bulb WARNING EWA10790 Headlight bulbs get very hot There fore keep flammable pr...

Page 88: ...hinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 5 Connect the headlight coupler 6 Install th...

Page 89: ...A11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket toget...

Page 90: ...ny maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional...

Page 91: ...rake caliper on each side by removing the bolts 5 Remove the axle bolt push the wheel axle out from the left side and then remove the wheel CAUTION ECA11050 Do not apply the brake after the brake cali...

Page 92: ...torque 9 Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle 10 Tighten wheel axle pinch bolt D and then tighten pinch bolt C to the specified torq...

Page 93: ...sprocket NOTE If the drive chain is difficult to re move remove the wheel axle first and then lift the wheel upward enough to remove the drive chain from the rear sprocket The drive chain cannot be d...

Page 94: ...y 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...

Page 95: ...here is no 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...

Page 96: ...d 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 recommen...

Page 97: ...the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly...

Page 98: ...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 are...

Page 99: ...com mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint...

Page 100: ...he electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps...

Page 101: ...eplacement 2 60 L 2 75 US qt 2 29 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 30 L 2 43 US qt 2...

Page 102: ...g 198 425 lb YZFR6WC 90 192 kg 198 423 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front whee...

Page 103: ...2 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature wa...

Page 104: ...ification 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 EAU26400 Vehicle identification num...

Page 105: ...affixed to the frame under the passenger seat See page 3 15 Record the information on this la bel in the space provided This informa tion will be needed when ordering spare parts from a Yamaha dealer...

Page 106: ...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...

Page 107: ...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...

Page 108: ...er that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 400...

Page 109: ...MATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U2C011E0 book Page 6 Wednesday July 12...

Page 110: ...arranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and re...

Page 111: ...ater date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can...

Page 112: ...repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is includ...

Page 113: ...protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help...

Page 114: ...t holding cable 3 16 High beam indicator light 3 2 Horn switch 3 11 I Identification numbers 9 1 Ignition circuit cut off system 3 24 Indicator and warning lights 3 2 K Key identification number 9 1 L...

Page 115: ...6 45 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 39 Turn signal switch 3 11 V Valve clearance 6 21 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9...

Page 116: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM...

Page 117: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM...

Page 118: ...PRINTED IN JAPAN 2006 07 5 2 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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