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PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

EAU18781

Removing and installing
cowlings

The cowlings shown need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.
Refer to this section each time a cowl-
ing needs to be removed and installed.

EAU18912

Cowlings A and C

To remove one of the cowlings

1. Remove the screws.

2. Disconnect the turn signal light

lead connectors (and, for the left-
side cowling, also the auxiliary
light lead coupler), and then take
the cowling off.

1. Cowling A

2. Cowling B

1. Cowling C
2. Cowling D

1. Screw

U5AH19E0.book Page 8 Thursday, May 13, 2004 4:23 AM

Содержание YZF600RT

Страница 1: ...5AH 28199 19 LIT 11626 18 17 YZF600RT C OWNER S MANUAL...

Страница 2: ...EAU10041 U5AH19E0 book Page 1 Thursday May 13 2004 4 23 AM...

Страница 3: ...cycle 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 emi...

Страница 4: ...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 OPER...

Страница 5: ...INED 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 MOTOR...

Страница 6: ...oration U S A 1st edition May 2004 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...

Страница 7: ...E 6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing cowlings 6 8 Checking the spark plugs 6...

Страница 8: ...e motorcycle 6 38 Front wheel 6 38 Rear wheel 6 40 Troubleshooting 6 42 Troubleshooting charts 6 43 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Ide...

Страница 9: ...dents 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...

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

Страница 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...

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

Страница 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5AH19E0 book Page 5 Thursday May 13 2004 4 23 AM...

Страница 14: ...TY INFORMATION 1 6 1 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 1 2 3 4 5 6 7 U5AH19E0 book Page 6 Thursday May 13 2004 4 23...

Страница 15: ...ing ring page 3 12 4 Shock absorber assembly rebound damping force adjusting knob page 3 12 5 Shock absorber assembly compression damping force adjusting screw page 3 12 6 Storage compartment page 3 1...

Страница 16: ...fork spring preload adjusting bolt page 3 10 5 Front fork rebound damping force adjusting screw page 3 10 6 Radiator cap page 6 15 7 Front fork compression damping force adjusting screw page 3 10 8 E...

Страница 17: ...page 3 4 3 Starter choke lever page 3 8 4 Speedometer unit page 3 3 5 Tachometer page 3 3 6 Coolant temperature gauge page 3 4 7 Right handlebar switches page 3 4 8 Brake lever page 3 6 9 Throttle gr...

Страница 18: ...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 t...

Страница 19: ...have a Yamaha dealer check the electri cal circuit 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...

Страница 20: ...ne Red zone 13200 r min and above EAU11981 Self diagnosis device This model is equipped with a self diag nosis device for the following electrical circuits throttle position sensor fuel level warning...

Страница 21: ...ture of the coolant The coolant temperature varies with chang es in the weather and engine load If the needle reaches or enters the red zone stop the vehicle and let the en gine cool See page 6 43 CAU...

Страница 22: ...is 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 star...

Страница 23: ...uipped 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 s...

Страница 24: ...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 fue...

Страница 25: ...ontaining ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it c...

Страница 26: ...e key NOTE Make sure that the seat is properly se cured before riding EAU14290 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet ho...

Страница 27: ...wet When washing the vehicle be careful not to let any water enter the storage compartment EAU14741 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound da...

Страница 28: ...on damping turn the adjusting screw on each fork leg in direction a To de crease the compression damping force and thereby soften the compression damping turn the adjusting screw on each fork leg in d...

Страница 29: ...a spring preload adjust ing ring a rebound damping force ad justing knob and a compression damping force adjusting screw CAUTION ECA11220 Never attempt to turn the spring pre load and rebound damping...

Страница 30: ...ecrease the setting by turning the ad justing screw To soften the compres sion damping increase the setting by turning the adjusting screw Make sure that the position indicator is aligned with the app...

Страница 31: ...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 further down for an explanation of the...

Страница 32: ...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 r...

Страница 33: ...r 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 reliab...

Страница 34: ...quences 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 use...

Страница 35: ...ft 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 h...

Страница 36: ...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 pivoting points if necessary 6 31 Sides...

Страница 37: ...ulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 15 Never ride with th...

Страница 38: ...hing the start switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit 5 After starting the engine move the starter choke back halfway CA...

Страница 39: ...en 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 onl...

Страница 40: ...AU16740 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 l...

Страница 41: ...eter red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17200 Parking When parking stop the engine and then remove th...

Страница 42: ...IONS 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 RE...

Страница 43: ...RNING 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 U5AH...

Страница 44: ...ecessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance...

Страница 45: ...h 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...

Страница 46: ...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 Bra...

Страница 47: ...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 and meter cables Apply Yamaha chain and cable...

Страница 48: ...sually 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...

Страница 49: ...ction each time a cowl ing needs to be removed and installed EAU18912 Cowlings A and C To remove one of the cowlings 1 Remove the screws 2 Disconnect the turn signal light lead connectors and for the...

Страница 50: ...o install the cowling 1 Place the cowling in the original position and then install the screws 2 Install the seat EAU19020 Cowling D To remove the cowling 1 Remove the seat and cowling B See pages 3 9...

Страница 51: ...that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the e...

Страница 52: ...n past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap EAU19672 Canister for California only This model is equipped wi...

Страница 53: ...king the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then c...

Страница 54: ...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...

Страница 55: ...let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warn...

Страница 56: ...el mark open the coolant reservoir cap 5 Add coolant or distilled water to raise the coolant to the specified level close the coolant reservoir cap and then install the seat CAUTION ECA10470 If coolan...

Страница 57: ...he fuel hoses WARNING EWA10410 Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage 5 Remove...

Страница 58: ...ard water or salt water is harmful to the engine You may use soft water if you can t get distilled water 17 Start the engine let it idle for sev eral minutes and then turn it off 18 Remove the radiato...

Страница 59: ...nt The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually we...

Страница 60: ...he air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 9 Install the air filter case cover by in stalling the screws and bolt 10 Place the fuel tank in t...

Страница 61: ...the air vent hose removed EAU21210 Air intake duct Check that the screen of the intake duct is not blocked Clean the screen if nec essary EAU21270 Adjusting the carburetors The carburetors are import...

Страница 62: ...rvals specified in the periodic maintenance and lubrication chart EAU21750 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the...

Страница 63: ...tire damage an accident or even injury Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass...

Страница 64: ...this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflat...

Страница 65: ...hanged or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face...

Страница 66: ...follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in dir...

Страница 67: ...ecking the front and rear brake pads Front brake Rear brake The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each br...

Страница 68: ...e recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmfu...

Страница 69: ...upright po sition NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned straight up and there should be no weight on it 2 Shift the transmission into the neu tral...

Страница 70: ...cated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows C...

Страница 71: ...ove smoothly have a Yamaha dealer check or replace it WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged...

Страница 72: ...hould be lu bricated if necessary EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact s...

Страница 73: ...tion WARNING 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...

Страница 74: ...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 de...

Страница 75: ...an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mi...

Страница 76: ...not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in q...

Страница 77: ...nd then secure it with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise...

Страница 78: ...urn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU24201 Replacing a turn signal light bulb 1...

Страница 79: ...by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using...

Страница 80: ...4851 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that the sl...

Страница 81: ...a dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Loosen the wheel axle nut and the brake caliper bolts 2 Remove the cotter pin and then loose...

Страница 82: ...ot apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU25651 To install the rear wheel 1 Install the wheel right wheel axle gu...

Страница 83: ...hooting 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 hav...

Страница 84: ...mpression 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...

Страница 85: ...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...

Страница 86: ...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...

Страница 87: ...on 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...

Страница 88: ...chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel d...

Страница 89: ...eels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent mo...

Страница 90: ...tridge replacement 2 90 L 3 07 US qt 2 55 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt Radiator capacity including all routes 1 95 L 2 06...

Страница 91: ...al weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading...

Страница 92: ...b voltage wattage x quantity Headlight 12 V 60 W 55 0 W 1 Tail brake light 12 V 8 0 27 0 W 1 Front turn signal position light 12 V 27 W 8 0 W 2 Rear turn signal light 12 V 27 0 W 2 Meter lighting 12 V...

Страница 93: ...tification 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 nu...

Страница 94: ...abel is affixed to the frame under the seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Mod...

Страница 95: ...tigation 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 deale...

Страница 96: ...cle 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 o...

Страница 97: ...inder 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...

Страница 98: ...RMATION 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 U5AH19E0 book Page 6 Thursday May 13...

Страница 99: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5AH19E0 book Page 7 Thursday May 13 2004 4 23 AM...

Страница 100: ...CONSUMER INFORMATION 9 8 9 U5AH19E0 book Page 8 Thursday May 13 2004 4 23 AM...

Страница 101: ...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 inclu...

Страница 102: ...ed 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 hel...

Страница 103: ...gh beam indicator light 3 2 Horn switch 3 5 I Identification numbers 9 1 Ignition circuit cut off system 3 15 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5...

Страница 104: ...3 Turn signal indicator light 3 2 Turn signal light bulb replacing 6 37 Turn signal switch 3 5 V Valve clearance adjusting 6 21 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limit...

Страница 105: ...PRINTED IN JAPAN 2004 05 1 0 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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