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PERIODIC MAINTENANCE AND MINOR REPAIR

6-42

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 reflectors by installing

the bolts.

6. Install the brake hose holders by

installing the bolts.

7. Secure the wheel axle by installing

the axle bolt, and then tightening
the wheel axle to the specified
torque.

NOTE:

While tightening the wheel axle, hold
the axle bolt to keep it from turning.

8. Tighten wheel axle pinch bolts A

and B to the specified torque.

9. Tap the outer side of the left fork

leg with a rubber mallet to align it
with the end of the wheel axle.

10. Tighten wheel axle pinch bolts C

and D to the specified torque.

11. While applying the front brake,

push down hard on the handlebar
several times to check for proper
fork operation.

Tightening torque:

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

Tightening torque:

Wheel axle:

91 Nm (9.1 m·kgf, 66 ft·lbf)

Tightening torque:

Wheel axle pinch bolt:

18 Nm (1.8 m·kgf, 13 ft·lbf)

Tightening torque:

Wheel axle pinch bolt:

18 Nm (1.8 m·kgf, 13 ft·lbf)

1. Front wheel axle pinch bolt A

2. Front wheel axle pinch bolt B

3. Front wheel axle pinch bolt C
4. Front wheel axle pinch bolt D

chapter6 Page 42 Thursday, August 7, 2003 5:58 PM

Содержание Moto matrix YZF-R6SC

Страница 1: ...PRINTED IN JAPAN 2003 08 3 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5SL 28199 11 LIT 11626 17 46 YZF R6S C OWNER S MANUAL ...

Страница 2: ...EAU10041 5SL11 book Page 1 Friday August 1 2003 5 20 PM ...

Страница 3: ...orcycle 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 emissions 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 high ...

Страница 4: ...e consult 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 OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow ...

Страница 5: ...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 RELIABILITY OF THIS MOTORCYCLE 5SL11 book Page 2 Friday August 1 2003 5 20 PM ...

Страница 6: ...poration U S A 1st edition July 2003 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 17 46 AFFIX DEALER LABEL HERE 5SL11 book Page 3 Friday August 1 2003 5 20 PM ...

Страница 7: ...neral maintenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 8 Checking the spark plugs 6 10 Canister for California only 6 11 Engine oil and oil filter cartridge 6 11 Coolant 6 14 Checking the air filter element 6 18 Air intake duct 6 21 Adjusting the throttle cable free play 6 21 Adjusting the valve clearance 6 21 Tires 6 22 Cast wheels 6 24 Accessories and replaceme...

Страница 8: ...g 6 44 Troubleshooting charts 6 45 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 5SL11 book Page 2 Friday August 1 2003 5 2...

Страница 9: ...cidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where ot...

Страница 10: ...e shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine ...

Страница 11: ...ose provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted t...

Страница 12: ...ycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transportin...

Страница 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 5SL11 book Page 5 Friday August 1 2003 5 20 PM ...

Страница 14: ...e R M 2 5PW 2415E 10 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 5SL11 book Page 6 Friday August 1 2003 5 20 PM ...

Страница 15: ...SAFETY INFORMATION 1 7 1 California only 9 California only 10 California only 8 5SL11 book Page 7 Friday August 1 2003 5 20 PM ...

Страница 16: ...pring preload adjusting ring page 3 17 6 Shock absorber assembly compression damping force adjusting screw page 3 17 7 Owner s tool kit page 6 1 8 Shock absorber assembly rebound damping force adjusting screw page 3 17 9 Shift pedal page 3 11 10 Engine oil drain bolt page 6 11 11 Engine oil filter cartridge page 6 11 12 Front fork compression damping force adjusting screw page 3 16 5SL11 book Page...

Страница 17: ...36 4 Battery page 6 35 5 Air filter element page 6 18 6 Front brake fluid reservoir page 6 28 7 Radiator cap page 6 14 8 Coolant drain bolt page 6 15 9 Engine oil filler cap page 6 11 10 Brake pedal page 3 11 11 Dipstick page 6 11 12 Rear brake fluid reservoir page 6 28 5SL11 book Page 2 Friday August 1 2003 5 20 PM ...

Страница 18: ...age 3 10 2 Left handlebar switches page 3 9 3 Multi function display page 3 6 4 Main switch steering lock page 3 1 5 Tachometer page 3 5 6 Right handlebar switches page 3 9 7 Throttle grip page 6 21 8 Brake lever page 3 11 5SL11 book Page 3 Friday August 1 2003 5 20 PM ...

Страница 19: ... EAU10660 OFF All electrical systems are off The key can be removed EAU10680 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 ...

Страница 20: ...ha dealer check the electrical cir cuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a malfunction This model is also equipped with a self diagnosis device for the oil level detection circuit If the oil lev el detection circuit is defective the following cycle will be repeated un til the ...

Страница 21: ... fuel level detection circuit is defective the following cycle will be repeated until the malfunction is corrected The fuel level warning light will flash eight times then go off for 2 5 seconds If this occurs have a Yamaha dealer check the vehicle EAU11421 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow...

Страница 22: ...layed OK Go ahead with riding 117 139 C 242 283 F Temperature flashes Warning light comes on Stop the vehicle and allow it to idle until the coolant temperature goes down If the temperature does not go down stop the engine See page 6 45 Above 140 C Above 284 F Message HI flashes Warning light comes on Stop the engine and allow it to cool See page 6 45 5SL11 book Page 4 Friday August 1 2003 5 20 PM...

Страница 23: ...inform 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 seconds then go off have a Yamaha dealer check the electrical cir cuit See page 3 6 for a detailed expla nation of the function of this indicator light and on how to set it EAU11872 Tachometer The e...

Страница 24: ...P 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 F TRIP and start counting the distance traveled from that point In that case pushing the SELECT button switches the dis play between the various tripmeter and odometer modes in the following order F TRIP TRIP 1 TRIP 2 ODO F TRIP To reset a tripmete...

Страница 25: ...o make the fol lowing settings in the order listed be low Display brightness This function allows you to adjust the brightness of the multi function display to suit the outside lighting conditions Shift timing indicator light activity This function allows you to choose whether or not the indicator light should be activated and whether it should blink or stay on when acti vated Shift timing indicat...

Страница 26: ...en the indicator light flashes four times per second The indicator light is deacti vated in other words it will not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push the SELECT button to con firm the selected indicator light ac tivity The control mode changes to the shift timing indicator light acti vation function To set the shift timing indi...

Страница 27: ...the indicator light 2 Push the SELECT button to con firm the selected engine speed The control mode changes to the shift timing indicator light bright ness function To adjust the shift timing indicator light brightness 1 Push the RESET button to select the desired indicator light bright ness level 2 Push the SELECT button to con firm the selected indicator light brightness level The multi func tio...

Страница 28: ... this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull t...

Страница 29: ...equipped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear...

Страница 30: ...ck cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked WARNING EWA11090 Make sure that the fuel tank cap is properly closed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not ove...

Страница 31: ... if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13430 Catalytic converter This model is equipped with a catalytic converter in the exhaust chamber WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before...

Страница 32: ...e passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the front of the passenger seat and pull it forward To install the passenger seat 1 Insert the projection on the rear of the passenger seat into the seat holder as shown and then push the front of the seat down to lock it in place 2 Remove the key NOTE Make sure tha...

Страница 33: ...ontact the muf fler when secured to the right side helmet holder because of their size or shape Be sure that your helmet does not contact the muffler when it is secured to the helmet holder To release a helmet from a helmet holder Remove the passenger seat remove the helmet from the helmet holder and then install the seat EAU14461 Storage compartment The storage compartment is located under the pa...

Страница 34: ...E Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt Rebound damping force To increase the rebound damping force and thereby harden the rebound damp ing turn the adjusting screw on each fork leg in direction a To decrease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in di rection b 1 Spring ...

Страница 35: ...esents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary EAU15051 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring and rebound and compression damping force adjusting screws CAUTION ...

Страница 36: ...OTE Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications a...

Страница 37: ...seat unhook the straps from the hooks and then install the seat with the straps hanging out from under the passenger seat See page 3 14 EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in ...

Страница 38: ...s in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING E...

Страница 39: ...fter the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle...

Страница 40: ...sequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not...

Страница 41: ...maha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 27 6 28 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check ...

Страница 42: ...ls Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 32 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 33 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 33 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights si...

Страница 43: ...290 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 sure that the engine stop switch is set to CAUTION ECA11830 The following warning lights and in dicator light should come on for a few seconds then go off Oil level warning light Fuel level warn...

Страница 44: ...UTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train ...

Страница 45: ...me on 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 the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on ...

Страница 46: ...ing the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17211 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 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 vehicle may overturn C...

Страница 47: ...ONS 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 SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES EAU1748...

Страница 48: ... WARNING 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 5SL11 book Page 2 Friday August 1 2003 5 20 PM ...

Страница 49: ...s 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 mi 42000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Electronic fuel in jection Check and adjust engine idle speed and synchronization 6 Exhaust system Check for leaka...

Страница 50: ...2 Clutch 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 leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for dam a...

Страница 51: ...nths Repack 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 ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand s...

Страница 52: ...lace 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 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable No...

Страница 53: ...nusually wet or dusty areas Hydraulic brake service After 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 components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 5SL1...

Страница 54: ...bs described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU19010 Cowlings A and B To remove one of the cowlings Remove the bolts slide the cowling for ward for A or backward for B and then pull it off as shown 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 1 Bolt 1 Bolt 2 Cowling A 5SL11 book Page 8 Friday August 1 2003 5 20 PM ...

Страница 55: ...iginal position and then install the bolts NOTE Make sure that the tabs at the front of each cowling fit side by side as shown and that all slots and projections fit to gether EAU19460 Panels A and B To remove one of the panels Remove the bolts slide the panel for ward and then take it off 1 Bolt 2 Cowling B 1 Cowling A 2 Cowling B 1 Slot 2 Projection 1 Tab 1 Bolt chapter6 Page 9 Thursday August 7...

Страница 56: ...hen the vehicle is ridden normally and all spark plugs installed in the en gine should have the same color If any spark plug shows a distinctly different color the engine could be defective Do not attempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Be...

Страница 57: ...charging of fuel vapor into the atmosphere Before operating this vehicle make sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged Make sure that the canister breath er is not blocked and if necessary clean it EAU19930 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the ...

Страница 58: ...ne 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 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 10 if the oil filter cart...

Страница 59: ...h an oil filter wrench and then tighten it to the specified torque with a torque wrench 9 Install the cowling 10 Install the coolant reservoir cover by installing the bolts 11 Install the engine oil drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary 1 Oil filter wrench 2 Engine oil filter cartridge 1 O ring 1 Torque wrench Tightenin...

Страница 60: ... immediately turn the engine off and have a Yamaha dealer check the vehicle 14 Turn the engine off and then check the oil level and correct it if necessary EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart EAU20111 To check the coolant level 1 Place the vehicle ...

Страница 61: ...ant 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 cap when the engine is hot 4 Install the reservoir cap and then install the coolant reservoir cover by installing the bolts NOTE The radiator fan is automatically switched on or off according to the...

Страница 62: ...diator cap when the engine is hot 6 Remove the coolant drain bolt to drain the cooling system 7 Loosen the clamp screw and then disconnect the radiator hose to drain the radiator 8 Remove the coolant reservoir cov er by removing the bolts 9 Remove cowling B See page 6 8 10 Pull the fuel hoses upward to re move them from the guide 1 Clamp screw 2 Air intake duct 1 Radiator cap 1 Coolant drain bolt ...

Страница 63: ...washer for damage and re place it if necessary 17 Pour the recommended coolant into the reservoir to the maximum level mark and then install the coolant reservoir cap 18 Install the coolant reservoir cover by installing the bolts 19 Insert the fuel hoses into the guide and place them in their original po sition 20 Install cowling B 21 Pour the recommended coolant into the radiator until it is full...

Страница 64: ...e radiator cap 24 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system 25 Connect the air intake duct and then tighten the clamp screw 26 Install the panel and the cowling EAU21161 Checking the air filter element The air filter element should be checked at the intervals specified in the periodic maintenance and lubricat...

Страница 65: ...e the air filter case cover by removing the screws 6 Pull the air filter element out 7 Check the condition of the air filter element and replace it if it is dam aged or excessively dusty 8 Insert the element into the air filter case CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment ...

Страница 66: ...If any fuel hose is dam aged do not start the engine but have a Yamaha dealer replace the hose otherwise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose and the fuel tank overflow hose in the original po sition 12 Install the rider seat 1 Fuel tank breather hose except for California 2 Fuel tank overflow hos...

Страница 67: ...rip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21400 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 a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart ...

Страница 68: ...ms that can 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 pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does n...

Страница 69: ...onal 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 otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always m...

Страница 70: ...ation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha dealer re place the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed o...

Страница 71: ...ed accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts manufactured by other companies Yamaha cannot be held liable for any consequences caused by the use of items which have not been approved by Yamaha EAU22060 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 ...

Страница 72: ... b 5 Tighten the locknut 6 Install the cowling EAU22251 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 11 0 mm 0 43 in below the bottom of the foot rest bracket as shown Periodically check the brake pedal position and if necessary have a Yamaha dealer ad just it WARNING EWA10690 A soft or spongy feeling in the brake pedal can indicate the presence ...

Страница 73: ... come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU22410 Front brake pads Each front brake pad is provided with a wear indicator which a...

Страница 74: ...the 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 check the brake pads for wear and the brake system 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 recommen...

Страница 75: ...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 EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22770 To check the drive chain slack 1 Place the motorcycl...

Страница 76: ... the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper 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 from occurring keep the drive chain slack within the specified limits 3 Tighten the loc...

Страница 77: ...y 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 that could damage the O rings EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable en...

Страница 78: ...ould be lubricated or replaced 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 checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease 5SL11 book Page 32 Friday August 1 2003 5 20...

Страница 79: ...ng and 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 EWA10730 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 pur pose grease Recommended lubricant Lithium ...

Страница 80: ...s to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubri...

Страница 81: ... need to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes s...

Страница 82: ...eck it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery cha...

Страница 83: ...stem EAU23940 Replacing a headlight bulb This model is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Remove panel B if replacing the left headlight bulb or panel A if re placing the right headlight bulb See page 6 8 2 Remove the headlight bulb cover by turning it counterclockwise 3 Disconnect the headlight coupler 1 Headlight fuse 2 Radiator fan fuse 3 ...

Страница 84: ...free from oil otherwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 6 Co...

Страница 85: ...hing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU24310 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the socket together with the ...

Страница 86: ... in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motor...

Страница 87: ...ove the brake caliper and re flector on each side by removing the bolts 5 Remove the axle bolt pull the wheel axle out and then remove the wheel CAUTION ECA11050 Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut EAU25041 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel s...

Страница 88: ...ed torque 9 Tap the outer side of the left fork leg with a rubber mallet to align it with the end of the wheel axle 10 Tighten wheel axle pinch bolts C and D to the specified torque 11 While applying the front brake push down hard on the handlebar several times to check for proper fork operation Tightening torque Brake caliper bolt 40 Nm 4 0 m kgf 29 ft lbf Tightening torque Wheel axle 91 Nm 9 1 m...

Страница 89: ...om the rear sprocket NOTE The drive chain does not need to be disassembled in order to remove and install the rear wheel 7 While supporting the brake caliper bracket pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU25660 To install the rear wheel 1 ...

Страница 90: ... Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorc...

Страница 91: ...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 The engine does not start Check the battery Operate the electric starter 4 Battery...

Страница 92: ...he hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check...

Страница 93: ...e dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on...

Страница 94: ...ter drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even t...

Страница 95: ...Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonfu...

Страница 96: ...very month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more in formation on storing the ba...

Страница 97: ...ment 2 60 L 2 75 US qt 2 29 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 2 15 L 2 27 US qt 1 89 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 0 L 4 49 US gal 3 74 Imp gal Fuel reserve amount 3 5 L 0 92 US gal 0 77 Imp ga...

Страница 98: ...m Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 192 kg 198 423 lb CAL 90 193 kg 198 425 lb U49 Front 250 kPa 36 psi 2 50 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 17M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Op...

Страница 99: ... 0 W 2 Licence plate light 12 V 5 0 W 1 Meter lighting LED Neutral indicator light LED High beam indicator light LED Oil level warning light LED Turn signal indicator light LED Fuel level warning light LED Coolant temperature indicator light LED Engine trouble warning light LED Shift timing indicator light LED Fuses Main fuse 40 0 A Headlight fuse 20 0 A Signaling system fuse 15 0 A Ignition fuse ...

Страница 100: ...dentification 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 number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle an...

Страница 101: ...bel is affixed to the frame under the rider seat See page 3 14 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 5SL11 book Page 2 Friday August 1 2003 5 20 PM ...

Страница 102: ...vestigation 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 T...

Страница 103: ...hicle 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 ...

Страница 104: ...eminder 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 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 k...

Страница 105: ...NFORMATION 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 5SL11 book Page 6 Friday August 1 2003 5 20 PM ...

Страница 106: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5SL11 book Page 7 Friday August 1 2003 5 20 PM ...

Страница 107: ...CONSUMER INFORMATION 9 8 9 5SL11 book Page 8 Friday August 1 2003 5 20 PM ...

Страница 108: ...red 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 included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towin...

Страница 109: ...cked 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 you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 5SL11 book Page 10 Friday August 1 2003 5 20 PM ...

Страница 110: ...H Handlebar switches 3 9 Headlight bulb replacing 6 37 Helmet holders 3 15 High beam indicator light 3 2 Horn switch 3 10 I Identification numbers 9 1 Ignition circuit cut off system 3 20 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 39 Luggage strap holders 3 19 M Main switch steering lock 3 1 Maintenance and lubrica...

Страница 111: ...eshooting 6 44 Troubleshooting charts 6 45 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 39 Turn signal switch 3 10 V Valve clearance adjusting 6 21 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 35 Wheel front 6 41 Wheel rear 6 43 Wheels 6 24 5SL11 book Page 2 Friday August 1 2003 5 20 PM ...

Страница 112: ...0 31 3 15 63 6 19 95 8 1 0 0 0 0 0 0 0 0 32 3 16 64 6 20 96 8 2 0 0 0 0 0 0 0 0 1 E intro 1 33 3 17 65 6 21 97 8 3 0 0 0 0 0 0 0 0 2 E info 1 34 3 18 66 6 22 98 9 1 0 0 0 0 0 0 0 0 3 E info 2 35 3 19 67 6 23 99 9 2 0 0 0 0 0 0 0 0 4 E Copyright 36 3 20 68 6 24 100 9 3 0 0 0 0 0 0 0 0 5 E Contents 1 37 3 21 69 6 25 101 9 4 0 0 0 0 0 0 0 0 6 E Contents 2 38 4 1 70 6 26 102 9 5 0 0 0 0 0 0 0 0 7 1 1 ...

Страница 113: ...PRINTED IN JAPAN 2003 08 3 5 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5SL 28199 11 LIT 11626 17 46 YZF R6S C OWNER S MANUAL ...

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