Yamaha YZF-R6T(C) manual

PRINTED IN JAPAN 2004.08-2.7 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 5SL-28199-12 LIT-11626-18-45 YZF-R6T(C) OWNER’S MANUAL[...]

EAU10041 U5SL12E0.book Page 1 M onday, August 9, 2004 10:51 AM[...]

INTRODUCTION EAU10080 Cong ratul ations on you r pur chase of the Yam aha Y ZF-R 6(C). T his model i s the r esult of Yam aha’s vast e xperi ence i n the produ ction o f fine sporting, touri ng, and pace settin g raci ng mach ines. I t repr esents the high degre e of cra ftsmanship and reli ability that have made Yamah a a leader in these fiel ds[...]

IMPORTANT MANUAL INFORMATION EAU1013 0 Parti cularl y impor tant info rmati on is dist ingui shed in this manua l by the foll owing no tations : NOTE: ● This ma nual sho uld be co nsid ered a pe rmanent part of this motorc ycle and should remain w ith it e ven if th e motorc ycle is subs equently so ld. ● Yamaha continually s e eks a dvancem en[...]

IMPORTANT MANU AL INFORMATION AND UNTIL YOU HAVE BE EN TRAIN ED IN SAFE AN D PROPER RI DING TECHNI QUES. REGULAR I NSPECTIONS AND CAREFUL MAINTENAN CE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPAB ILITIES AND THE RELIA BILITY OF TH IS MOTORCYCLE . U5SL12E0.book Page 2 M onday, August 9, 2004 10:51 AM[...]

IMPORTANT MANUAL INFORMATION EAU10192 YZF-R6T(C) OW N E R ’ S MANU AL ©2004 by Y amaha Motor Corporation, U .S.A. 1st edition, A ugust 2004 All rights reserved. Any reprinting or unauthorized use without th e written permission of Y amaha Motor Corporation, U.S.A. is expressl y pr ohibited. Printed in Japan. P/N LIT -1162 6-18-4 5 AFFIX DEALER L[...]

TABLE OF CONTENTS SAFETY INFORMATION ............. ..... 1-1 Location of important lab els ........... 1-5 DESCRIPTION ............ ...................... 2-1 Left view ............... ...................... ..... 2-1 Right view .................. ................. ..... 2-2 Controls a nd instrumen ts ................2-3 INSTRUMENT AND CONTROL FUNC[...]

TABLE OF CONTENTS Replaci ng a turn s ignal li ght bulb ........ ...................... .............6-38 Replaci ng the li cense plate light bul b ............ ................. .......6-38 Supporting t he motorcycle ............6-39 Front wheel ...................... .............6-40 Rear wheel ................ ................. ..6-42 Troublesh[...]

1-1 1 SAFETY INFORMATION EAU10281 MOT ORCYC LES ARE SING LE TRAC K VE HIC LES. THEI R SAF E USE AND OPERATION AR E DEPEN- DENT UPON THE USE OF PROPER RID ING T ECH NIQU ES A S WEL L AS THE EXPERTISE OF THE OPERA- TOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS B EFORE RIDI NG THIS MOTOR CYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INST[...]

SAFETY INFORMATION 1-2 1 turn du e to EXCESSI VE SPEED or und ercorn ering ( insuff icient l ean angle for th e spee d). • Alway s obey the spee d lim it and never trav el fas ter t han war rant- ed by ro ad an d traffic condi tions. • Alway s signal be fore tur ning or chan ging lane s. Mak e su re that othe r motorists can see you. ● The po[...]

SAFETY INFORMATION 1-3 1 Loadin g The to tal weig ht of th e operat or, pas- senger, acce ssories and ca rgo must not exce ed the ma ximum loa d limit. When lo ading with in this weight limi t, keep the fol lowing in mind : ● Cargo and ac cess ory wei ght shoul d be kept as low and cl ose to the mo torcycl e as possible. Make sure t o distr ibute[...]

SAFETY INFORMATION 1-4 1 tor an d may limi t contro l ability, therefo re, such acce ssories are not re comm ended. ● Use ca utio n whe n addin g elect ri- cal accesso ries. If elect rical acces- sories e xceed t he cap acity o f the motor cycle ’ s elect rical system , an elec tric fa ilure coul d result, wh ich could cause a danger ous lo ss [...]

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Plea se read the f ollowing impor tant l abels carefu lly b efore o perat ing thi s veh icle. U5SL12E0.book Page 5 M onday, August 9, 2004 10:51 AM[...]

SAFETY INFORMATION 1-6 1 5 6 7 1 2 3 4 PREMIUM UNLEADED GASOLINE ONL Y 91 Min. Pump Octane (R+M) 2 5PW-2415E-11 CA UTION Cleaning with alkaline or acid cleaner , gasoline or solv en t 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 290 k[...]

SAFETY INFORMATION 1-7 1 California onl y 9 California onl y 10 California onl y 8 U5SL12E0.book Page 7 M onday, August 9, 2004 10:51 AM[...]

DESC RIPTION 2-1 2 EAU1041 0 Left view 1. F ront f ork rebound damping force adjusting scre w (page 3-16) 2. F ront f ork spring preload adjusting bolt (page 3-16) 3. Fuse box 2 (page 6-35) 4. Coolant reser voir (page 6-14) 5. Shock absorber assembly spring preload adjusting ring (page 3-18) 6. Shock absorber assembly compression damping force adju[...]

DESCRIPTI O N 2-2 2 EAU10420 Right view 1. Luggage strap holder ( page 3-19) 2. Helmet holder (page 3-15) 3. Fuse box 1 (page 6-35) 4. Main fuse (page 6-35 ) 5. Battery (page 6-34) 6. Air filt er element (page 6-18) 7. F ront brake fl uid reser voir (page 6-27) 8. Radiator cap (page 6-14) 9. Coolant drain bolt (page 6-15) 10.Engine oil f iller cap [...]

DESC RIPTION 2-3 2 EAU1043 0 Controls and instruments 1. Clutch le ver (page 3-10) 2. Left handlebar s witches (page 3-9) 3. Multi-function display (page 3-6) 4. Main switch/steering lock (page 3-1) 5. T achom eter (page 3-5) 6. Right handlebar switches (page 3-9) 7. Throttle grip (page 6-20) 8. Brake le ver (page 3-11) U5SL12E0.book Page 3 M onday[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steer ing lock The main switch/st eering lo ck controls the igniti on and l ighti ng sys tems, and i s used t o lock t he st eering. The variou s posi tions ar e descri bed belo w. EAU26900 ON All el ectric al circ uits are s uppli ed with power, and the met er lig hting, tailli ght, lice [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-2 3 EAU11002 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The c orresp onding ind icator light flash- es when the tu rn signal sw itch is pus hed to th e left or ri ght. EAU11060 Neutral in dicator light “” This in dicat or li ght com es on w hen th e transm ission is i[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU11360 Fuel level warning light “” This w arning light comes on whe n the fuel level drops be low appr oximat ely 3.5 L ( 0.92 US gal) (0. 77 Imp.gal) . When th is occur s, refu el as soon as possible . The el ectri cal circ uit of the w arning light can be ch ecked by t urning t he key t o “ ON ” . [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-4 3 Coolant temp er atu re Disp lay Condi tions What to do Under 39 ° C (Under 103 ° F) Mess age “ LO ” is displa yed. OK. Go ahead with riding. 40 – 116 ° C (104 – 241 ° F) T emperature is display e d. OK. Go ahead with riding. 117 – 139 ° C (242 – 283 ° F) T emperature display flashes. W arnin[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 EAU11530 Engine trouble warning light “” This wa rning light co mes on or fla shes when an electr ical c ircuit m onitori ng the engine is defe ctive. When th is occurs, have a Yamaha dealer check the self - diagno sis system. (See page 3-6 for an expl anatio n of th e self -diagn osis de - vice.) The el e[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-6 3 EAU26920 Multi-function display The mu lti-fu nction d isplay is equi pped with th e followi ng: ● a speedo meter ( which sh ows the riding speed ) ● an od ometer (which show s the to - tal dist ance tra veled ) ● two tri pmeters (which s how the dista nce tra veled since they w ere last set to zero ) ?[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 3. Push the “ SEL ECT ” button, and the mi nute digit s will sta rt fla shing . 4. Push t he “ RESET ” button to set the mi nutes. 5. Push the “ SELEC T ” butto n and then rele ase it to s tart the clock. Self-diagnosis devi ces This m odel is equipp ed with a self -dia g- nosis d evice for variou [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-8 3 cedur e, only the sett ings ma de be- fore the “ SEL ECT ” button was la st pushed will be appli ed. ● In this mode, the mu lti- funct ion dis- play sho ws the current setting f or each fu nction ( excep t the shift tim- ing ind icator li ght activ ity func tion). To adju st the dis play bri ghtnes s 1.[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 the in dicato r light can be se t in in- crem ents of 500 r/ min. Fro m 12000 r /min to 1600 0 r/min, t he in - dicato r ligh t can be set in inc re- ments of 20 0 r/min. ● Be su re to set t he dea ctiva tion funct ion to a hi gher engi ne speed than fo r the acti vation functi on, otherw ise th e sh ift tim[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-10 3 EAU12400 Dimmer switch “ / ” Set th is swit ch to “” f or the high beam a nd to “” for the low bea m. EAU12460 Turn signal switch “ / ” To sign al a righ t-hand turn, pu sh thi s switch t o “” . To si gnal a left- hand turn, pu sh this s witch to “” . Wh en re- lease d, the s witch r [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 EAU12870 Shift pedal The s hift pe dal is locate d on th e left side of t he engi ne and is used in com- binati on with th e clutch leve r when shift ing the gears of the 6 -spee d con- stant-m esh transmissi on equipped on this motor cycle . EAU33850 Brake l ever The brake l ever is loc ated at the right han[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-12 3 EAU12941 Brake pedal The br ake peda l is on the rig ht side of the moto rcycle. To appl y the r ear brake , press dow n on the brak e peda l. EAU13070 Fuel tank cap To open the fuel tank c ap Open t h e fu el tank cap lock cover, in- sert the ke y into the lo ck, a nd th en turn it 1/ 4 turn clockwise. T he[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-13 3 EAU13210 Fuel Make sure that there is sufficien t fuel i n the ta nk. Fi ll the fuel tank to the b ottom of t he fil ler tube as sh own. W ARNING EWA10880 ● Do not overfill the fuel ta nk, oth- erwise it may overfl ow wh en the fuel warms up and expands. ● Avoid spilling fuel on the hot en- gine. CAUTION:[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-14 3 EAU13440 Catalytic conve rter This v ehicl e is eq uipp ed with a cat alytic conve rter in the mu ffler . W ARNING EWA10860 The exhaust system is hot after op- erati on. Make sure th at the exhaust system has cooled down before do- ing any maintenance work. CAUTION: ECA10700 The following precautions must be[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-15 3 2. W hile holding the key in that pos i- tion, l ift th e fron t of th e passe nger seat and pu ll it forwar d. To instal l the passenger seat 1. Insert th e proj ection on the re ar of the p assen ger seat into the se at hold er as s hown , and t hen push the fro nt of the seat d own to loc k it in pl ace. 2[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-16 3 EAU14461 Storage compartment The st orage com par tment is locate d under the pa sseng er se at. (S ee pag e 3-14.) W ARNING EWA10961 ● Do not ex ceed the lo ad limi t of 3 kg (7 lb) for the storage com- partment. ● Do not exce ed the maximum load o f 191 k g (421 lb) (CAL) 192 kg (423 lb) (U49) for the [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-17 3 Rebound damping force To in crea se the r eboun d dam ping fo rce and ther eby h arden the rebo und da mp- ing , turn t he ad just ing sc rew on each fork le g in direct ion (a ). To decr ease the rebo und damp ing fo rce and th ereby softe n the rebo und damp ing, tu rn the adjus ting s crew on ea ch fork le[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-18 3 EAU15051 Adjusti ng the shock ab sorber assem bly This shoc k abso rber assem bly is equipp ed wit h a sprin g prelo ad adjus t- ing rin g and rebo und and co mpres sion dampin g forc e adj usting screws . CAUTION: ECA10100 Never a ttempt t o turn an adju sting mechanism beyond the maximum or minimum setting[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-19 3 in dir ectio n (a). To de crease the com - pres sion damp ing for ce and th ereby softe n the com pressi on damp ing, tur n the adj u stin g screw in di recti on (b). N O TE: Altho ugh the tota l numb er of c licks o f a dampin g force adjus ting mec hanism may not e xactly match the above spec- ific ations d[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-20 3 EAU15300 Sidestand The si destan d is lo cated on the left side of th e fram e. Rai se the si destand or lower it with yo ur foot while ho ldin g the vehicle upright . NOTE: The bu ilt-i n side stand s wit ch is p art of the igni tion circ uit cu t-off syst em, whic h cuts t he igni tion in cer tain s ituati[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-21 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T ur n the key on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep the [...]

PRE-OPERATION CH ECKS 4-1 4 EAU15591 The con dition of a vehicl e is the owner ’ s responsibi lity. Vital components can start to de terior ate q uickly an d unex pectedly, even if th e vehi cle rema ins unused (for example , as a resu lt of e xposur e to t he elem ents). Any damage, fl uid leakag e or loss of tir e air p ressure could have s eri[...]

PRE-OPERATION CHE CKS 4-2 4 EAU15603 Pre-operation check list ITEM CHECKS P A GE Fuel • Check fuel le vel in fuel tank. • Refuel if necessar y . • Check fuel line for leakage. 3-13 Engine oil • Check oil le vel in engine. • If necessar y , add recommended oil to specified le vel. • Check vehicle f or oil leakage. 6-11 Coolant • Check [...]

PRE-OPERATION CH ECKS 4-3 4 Thr ottle grip • Make sure that oper ation is smooth. • Check cable free pla y . • If necessar y , have Y am aha dealer adjust cabl e free play and lubricat e cable and grip housing. 6-20, 6-30 Contr ol cables • Make sure that oper ation is smooth. • Lubricate if nece ssary . 6-30 Drive chain • Check chain sl[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-1 5 EAU15950 W ARNING EWA10270 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it i n a clo sed area fo r any length of ti[...]

OPERATION AND IM PORTANT RIDING POINTS 5-2 5 CAUTION: ECA11130 For maximum engine li fe, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The e ngine is warm when it quickly re- sponds to the throttl e. EAU16671 Shifting Shifti ng gear s let s you c ontrol the amount of engine po wer ava ilable for[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-3 5 4. At the r ecom mend ed shi ft poin ts sho wn in the fo llow ing tabl e, clos e the thr ottle, and at the same time, quickl y pull th e clutch lever in. 5. Shif t the transm issio n int o se cond gear. (M ake su re not t o shift the transm ission int o the neut ral posi- tion.) 6. Open the thr ottle par[...]

OPERATION AND IM PORTANT RIDING POINTS 5-4 5 CAUTION: ECA10301 After 1000 km (600 mi) of operation, the engine oil must be changed and the o il fil ter c artrid ge or elemen t re- plac ed. 1600 km (1000 mi) and beyo nd The vehi cle can now be operat ed nor- mally . CAUTION: ECA10310 ● Keep the engine speed out of the tachometer red zone. ● If a[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-1 6 EAU17231 Safety is an obliga tion of the o wner . Pe- riod ic insp ection , adju stment and lu bri- cation will keep your vehi cle in th e safest and most eff icient co ndition po s- sible. The mos t impo rtant po ints of motor cycle inspectio n, adjus tment, an d lubri cation a re explai ned on t he fo[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-2 6 W ARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor- mance, excess ive em issio ns, and render the ve hicle un safe fo r use. Consult a Yamaha dealer before at- tem pting an y cha nges. U5SL12E0.book Page 2 M onday, August 9, 2004 10:51 AM[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-3 6 EAU17600 Periodi c mainte nance char t for th e emissi on control sy stem * Since t hese it ems req uire special tools, dat a and technical s kills, hav e a Yama ha dealer perform t he serv ice. No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 8000 mi[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-4 6 EAU32183 General maintenance and lubrication chart No. ITEM ROUTINE INITIAL ODOMETER READINGS 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 mo nths 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter elem[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-5 6 9 * Swingar m piv ot beari ngs • Check bearing assemblies f or looseness. • Moderately repack with lithium- soap-based grease. √ Repack. 10 Drive chain • Check chain slack, ali gnment and condition. • Adjust and lubr icate chain with a special O-ring c hain lubricant thoroughly . Every 500 mi [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-6 6 * Since these items re quire spe cial tools, da ta and technica l skills, have a Yamaha deale r perform the ser vice. 17 * Fron t f ork • Check operation and for oil leak- age. • Replace if necessar y . √√√√√ 18 * Shock absorber as- semb ly • Check operation and for oil leak- age. • R[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-7 6 NOTE: From 24 000 mi (3700 0 km) or 36 m onths, repeat th e mainte nance interv als star ting fr om 8000 mi (1300 0 km) or 12 m onths . EAU17630 NOTE: ● The ai r filte r need s mor e freq uent s ervice if yo u are ridi ng in u nusual ly we t or du sty a reas. ● Hydrau lic brake servic e • After di[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-8 6 EAU18711 Removing and installing cowlings and panels The cow lings and pane ls shown ne ed to be rem oved to perform some of th e main tenanc e jobs de scri bed in thi s chapte r. Refer to this secti on each tim e a cowli ng or pane l needs to be re- moved and instal led. EAU19012 Cowlings A and B To r[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-9 6 To instal l the cowl ing 1. Fit the s lots an d projecti ons at the rear bot tom o f each c owlin g to- geth er, an d then slide th e cowlin g into pl ace. 2. Place the cowl ing in th e orig inal posit ion, and then in stall th e bolts and qu ick fa sten ers. NOTE: Make s ure that the tabs at the fr ont[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-10 6 To ins tall the pa nel 1. Fit t he tabs on the pan el in to the slots and slid e it backw ard. 2. Insta ll the bolt s. EAU19651 Checki ng the spark pl ugs The spa rk plugs are importan t engine compon ents, wh ich sho uld be che cked perio dical ly, pr eferab ly by a Yamah a dealer . Since he at and d[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-11 6 NOTE: If a tor que wre nch is not ava ilabl e when install ing a spark plug, a go od estima te of the c orrec t torque i s 1/4 – 1/2 tu rn past fi nger tight . Howe ver, t he spark plug s hould be tightene d to the speci - fied torq ue as soon as po ssibl e. CAUTION: ECA10840 Do not use any tools to [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-12 6 4. Remove the en gine oi l dipstick a nd wipe i t clean, insert it back into th e hole (witho ut scr ewing it in), and then r emov e it ag ain to chec k the oil level . NOTE: The en gine o il shoul d be be tween th e minimu m and maximum le vel mar ks. 5. If the engine oi l is at or below the mini mum[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-13 6 6. Rem ove the oil filt er cartri dge with an oil filter wrench. NOTE: An oi l fil ter wre nch i s av ailable at a Yama ha de aler. 7. Apply a thin coat of engine o il to the O-r ing o f the new oi l fil ter car - tridge . NOTE: Make s ure that th e O-ri ng is prop erly seated . 8. Inst all th e new oi[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-14 6 12. Add t he s pecif ied am ount of the reco mmende d engi ne oil, an d then insta ll and tighten th e oil fill er cap. CAUTION: ECA11620 ● In order to pre vent clutch slip- page (since the engine oi l also lubricates the clutch), do not mix a ny ch emica l addi tive s. Do not use oil s with a diese[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-15 6 3. If th e coolan t is at or be low the mini mum le vel mar k, remo ve the coolant reservo ir cover by remov- ing th e bolts, remov e the res ervoi r cap , and the n add coola nt to th e maximu m level mark. CAUTION: ECA10470 ● If coolant is not available , use distilled water or soft tap water inste[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-16 6 2. Remove pa nel A, an d cowlin gs A and B. ( See page 6-8.) 3. Plac e a cont ainer under t he engin e to co llect the us ed coo lant. 4. Loosen the cl amp screw, and then disconn ect the air inta ke duct. 5. Remove the radia tor ca p. W ARNING EWA10380 Never attem pt to re move the rad iator cap when[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-17 6 10. Remov e the c oolan t reser voir by removi ng the bo lts. 11. Rem ove th e cool ant re servoi r cap , and then tu rn the c oolant reservoi r ups ide down to empt y it. 12. Afte r the co olant is comp letely drain ed, thor oughl y flus h the co ol- ing s ystem with clean tap wate r. 13. Insta ll the[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-18 6 CAUTION: ECA10470 ● If coolant is not available, use distilled water or s oft tap water instead. Do not use har d water or sal t wate r since it is ha rmful to the engine. ● If wat er ha s been u sed in stea d of coolant, replace it with cool- ant as soon as possible, other- wise the engine ma y n[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-19 6 W ARNING EWA10410 ● Make su re that th e fuel tank is well supported. ● Do not tilt or pull the fuel tank too much, otherwise the fuel hos es ma y come loose, which could cause fuel l eakag e. 4. Remove the air fi lter ca se cov er by removi ng the screws . 5. Pul l the ai r filt er elem ent out . [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-20 6 ● Be sur e to place t he fuel ta nk brea ther ho se an d the fue l tank overflow hose i n the orig inal po- sition. 10. Insta ll the rid er seat . EAU21210 Air intake duct Check that t he screen of the inta ke duct is not block ed. Cl ean the scr een if nec- essary. EAU21381 Checki ng the throttle c[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-21 6 EAU21401 Valv e clear ance The v alve cl earance chan ges with use, resultin g in improp er air-fue l mixtu re and/o r engine no ise. T o prev ent th is from o ccurr ing, th e valve c learan ce must be adjus ted by a Yama ha dealer at th e inte rvals s pecified in the period ic mainte nance and lu bric[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-22 6 est item s clo se to th e cen ter of t he vehicle, and distribute the weight evenl y from sid e to side. P roper ly adjust the susp ension for you r load, and check the condition and pres- sure of your tires. NEVER OVER- LOAD YOUR V EHICLE. Ma ke sure that the total weight of the cargo, rid- er, passe[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-23 6 This moto rcycl e is equip ped with cast whee ls and tubeles s tire s with v alves. W ARNING EWA10480 ● The front and rear tires should be of the sam e make and de- sign, otherwise the handling char acte ristics of the m otor- cycle cannot be guaranteed. ● After ext ensive tests , only the tires li[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-24 6 EAU21960 Cast wheels To max imize t he pe rform ance, d urabi l- ity, an d safe operat ion of your vehi cle, note t he fo llowing point s re garding the spec ified wh eels. ● The wh eel ri ms shou ld be checked for cracks, bends or w arpage be- fore ea ch ride . If any dama ge is found, hav e a Yama[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-25 6 EAU22060 Adjusti ng the cl utch leve r free play The c lutch le ver fr ee play s hould mea- sure 10 .0 – 15 .0 mm (0 .39 – 0.59 in) as shown. Period ically ch eck the clut ch le- ver free p lay an d, if ne cess ary, adj ust it as fo llow s. To increa se the clutch le ver free play, turn th e adjus [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-26 6 EAU22270 Adjusting the rear brake light switch The re ar brake light sw itch, which is ac- tivate d by the bra ke pedal , is prop erly adjus ted wh en the b rake light co mes on jus t befo re bra king takes e ffect. If necessary, adjust t he bra ke light swit ch as follo ws. Turn the adj usting nut wh[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-27 6 EAU22580 Checking the brake fluid level Front brake Rear b rake Insuf ficient b rake fluid may allow ai r to enter the b rake s ystem, possibly caus- ing it to become inef fective. Befor e ridin g, check that the b rake f luid is above the minimu m level mar k and repl enish if necess ary. A low brak e[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-28 6 EAU22730 Changing the brake fluid Have a Y amaha deal er chang e the brak e fluid a t the in tervals speci fied in the NO TE afte r the period ic ma inte- nance a nd lubr ication chart. In additio n, have the oi l seals of the mast er cylin- ders and cali pers as well as th e brak e hoses replace d at[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-29 6 NOTE: Using the a lignmen t mark s on ea ch side of th e swinga rm, make sure t hat both c hain pull ers are in th e same pos i- tion for proper whe el alignm ent. CAUTION: ECA10570 Improp er drive chai n slack will ov er- load the engine as well as other vital parts of the motorcycle and can lead to c[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-30 6 CAUTION: ECA11110 Do not use engine oil or any other lu- bric ants for the d rive ch ain, as they may contain substances that could damage the O-rings. EAU23090 Checki ng and lubricat ing the cables The o peratio n of al l contr ol cable s and the co nditio n of t he cabl es shoul d be checked before [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-31 6 EAU23131 Checking and lubricating the brake and shift pedals The op erati on of the b rake a nd shif t pedals sh ould be che cked bef ore each ride , and the peda l pivo ts shou ld be lu- bricat ed if ne cessary. EAU23140 Checking and lubricating the brake and clutch levers Brake le ver Clutch lever Th[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-32 6 EAU23200 Checki ng and lubricat ing the sidest and The o peratio n of th e sidest and shou ld be ch ecked before each ride , and the sidest and pivot a nd metal-t o-metal contac t surf aces s hould be lub rica ted if necessary. W ARNING EWA10730 If the sidestand does not move up and down smoothly, hav[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-33 6 EAU23271 Checking the front fork The c ondit ion a nd oper ation of th e fron t fork must be ch ecke d as f ollows at the inter vals specifi ed in the pe riodic main - ten ance and lu bric ation ch art . To check the condition W ARNING EWA10750 Securely support the vehicle so that there is no danger of[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-34 6 EAU23290 Checki ng the whe el bearings The f ront an d rear whe el beari ngs must be chec ked a t the in terval s spe cifie d in the pe riodi c mainte nance and lubr ica- tion ch art. If t here i s play in the wh eel hub or if th e wheel do es not turn smoot hly, h ave a Ya maha de aler ch eck the w h[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-35 6 • INTERNAL: D rink large qua n- tities of water or milk and im- medi ately ca ll a physi cian. • EYES: Flush with water for 15 minutes and seek prompt medical attention. ● Batteries produce explos ive hy- drogen gas. Therefore, keep spar ks, f lames , ciga rette s, etc., away from the battery and[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-36 6 If a fuse is blow n, repla ce it as follow s. 1. Turn the key t o “ OFF ” and turn o ff the el ectric al cir cuit in questi on. 2. Re move th e blow n fuse, and the n install a new fuse of the spe cifi ed amper age. CAUTION: ECA10640 Do not use a fuse of a higher amper- age rating than recommended[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-37 6 4. Unho ok the h eadlig ht bulb hold er, and the n remo ve the defe ctive bulb . W ARNING EWA10790 Headlight bulbs get very hot. There - fore, keep flamma ble products away from a lit headlight bulb, and do not touch the bulb until it ha s cooled down. 5. Place a new headli ght bulb in to po - sition, [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-38 6 EAU24180 Tail/brake light This m odel i s equipp ed with an LED type o f tail/ brake l ight. If th e tai l/brake light does not come on, have a Yama ha dealer check it. EAU24201 Replacing a turn signal light bulb 1. Remove t he turn signal light lens by rem oving the sc rew. 2. Remove t h e de fective[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-39 6 3. Rem ove the defec tive bu lb by pu ll- ing it ou t. 4. Ins ert a new bu lb into the socket . 5. Ins tall the s ocke t (toge ther w ith the bulb ) by pushin g it in. 6. Ins tall the l icense plate l ight u nit by insta lling t he scre ws. EAU24350 Supporting the motorcycle Sinc e this mo del is no t [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-40 6 EAU24360 Front wheel EAU34591 To remove the f ront wheel W ARNING EWA10820 ● It is adv isable to have a Yama ha deale r serv ice the whe el. ● Securely support the motor- cycle so that th ere is no danger of it falling over. 1. Loosen the wheel axle p inch bolts, the axl e bolt, an d then the brak[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-41 6 NOTE: Make su re that the re is en ough space betwe en the brak e pads before inst all- ing the brake cal ipers on to the bra ke discs. 5. Ins tall the b rake hos e ho lders a nd reflect ors by instal ling th e bolts and nut s. 6. Secur e the wheel ax le by i nstal ling the ax le bol t, and then tighte[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-42 6 EAU25080 Rear wheel EAU25311 To remove t he rear whee l W ARNING EWA10820 ● It is adv isable to have a Yama ha deale r serv ice the whe el. ● Securely support the motor- cycle so that th ere is no danger of it falling over. 1. Loos en the axl e nut. 2. Lift the rea r wh eel of f th e ground accord[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-43 6 NOTE: ● Be su re to in sert t he retai ner on the bra ke calipe r bracket int o the s lot in th e swin gar m. ● Make sure th at ther e is en ough space betw een the brak e pad s be- fore in stallin g the whee l. 2. Ins tall th e driv e chain on to the rear sprocket. 3. Ins tall th e axle n ut, and [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-44 6 EAU25911 Troubleshooting charts Starting problems or poor engine performance W ARNING EWA10840 Keep away open fla mes and do not sm oke while checking or working on the fuel s ystem. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fu[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-45 6 Engine overheating W ARNING EWA10400 ● Do not remove the radiator cap when the e ngine and radiator are hot. Scalding hot fluid and steam may be blown out under pressur e, which could cause serious injury. Be sure to wait unti l the engine has c ooled. ● After removing the radiator cap retaining bo[...]

MOTORCYCLE CARE A ND ST ORAGE 7-1 7 EAU26030 Care While the open desi gn of a mo torcyc le reveal s the a ttracti venes s of th e tech- nology , it al so makes it m ore vul n era - ble. Rust and cor rosion can d evel op even if high-q uality compon ents ar e used. A rusty ex haust pipe m a y go un- notic ed on a car, howeve r, it detract s fro m th[...]

MOTORCYCLE CAR E AND STORAGE 7-2 7 After normal use Remov e dirt with warm wate r, a mild det ergent , and a so ft, cle an spon ge, and th en rinse th oroughly with cl ean wate r. Use a toot hbrus h or bott lebrush for h ard-t o-reac h areas. Stub born dirt and inse cts will com e off more e a sily if the ar ea is co vered wi th a wet c loth fo r a[...]

MOTORCYCLE CARE A ND ST ORAGE 7-3 7 CAUTION: ECA10800 ● Apply spray oil and wax spa r- ingly and make sure to wipe off any ex cess. ● Never apply oil or wax to any rubber and plastic parts , but treat them with a suit able care product. ● Avoid using abrasive polishing compounds as they will wear away the p aint. NOTE: Consul t a Yama ha deal[...]

MOTORCYCLE CAR E AND STORAGE 7-4 7 4. Lu brica te all control cabl es and the pivoting point s of all lev ers and pedals as we ll as of the side - stan d/cent ersta nd. 5. Check an d, if necessa ry, correct the t ire air pressur e, and t hen lift the motor cycle so that both of its whee ls are off th e gro und. Al terna- tively, turn t he whee ls a[...]

SPECI FIC ATIO NS 8-1 8 Dimensions: Overa ll length: 2045 mm (80.5 in) Overa ll width: 690 mm (27.2 in ) Overa ll height: 1105 mm (43.5 in) Seat hei ght: 830 mm (32.7 in ) Wheel bas e: 1385 mm (54.5 in) Gro und clear ance: 145 mm (5.71 in ) Minimu m turni ng radius : 3800 mm (149. 6 in) Weight: With oil a nd fuel: 183.0 kg (403 lb) (U49) 184. 0 kg [...]

SPECIFICATIONS 8-2 8 2nd: 37/1 9 (1 .947 ) 3rd: 28/1 8 (1 .556 ) 4th: 32/2 4 (1 .333 ) 5th: 25/2 1 (1 .190 ) 6th: 26/2 4 (1 .083 ) Chassis: Frame type: Diamo nd Caste r angle: 24.50 ° Trail: 95. 0 mm (3.74 in) Front tire: Type: Tubeless Size: 120/70 ZR 17M/C (58W) Manuf acturer/m odel: DUNLOP/ D218F M Rea r tir e: Type: Tubeless Size: 180/55 ZR 17[...]

SPECI FIC ATIO NS 8-3 8 Char ging system : AC magn eto Battery: Model : GT9B-4 Voltag e , capa city: 12 V, 8.0 Ah Headlight: Bulb type: Halo gen bulb Bulb voltage, wattage x quantity: Headlig ht: 12 V, 55.0 W × 2 Tail/br ake light: LED Fron t turn sig nal/posit ion light: 12 V, 21 W/5 .0 W × 2 Rear tur n signal lig ht: 12 V, 21.0 W × 2 Licenc e [...]

CONSUMER INFORMATI ON 9-1 9 EAU26351 Identification numbers Recor d the key iden tificatio n numb er, vehic le ide ntifica tion number and mo d- el labe l informa tion in the s p aces pro- vided bel ow for a ssistan ce when order ing spar e par ts from a Y amaha deal er or f or re feren ce in ca se the vehi - cle is stole n. KEY IDENTIFICATION NUMB[...]

CONSUMER INFORMA T ION 9-2 9 EAU26470 Model label The mod el label is affixe d to the fram e under the rider seat. (See pa ge 3-14.) Record the informa tion on this labe l in the sp ace prov ide d. This in form ation will b e need ed when order ing sp are part s from a Y amaha dealer . 1. Model label U5SL12E0.book Page 2 M onday, August 9, 2004 10:[...]

CONSUMER INFORMATI ON 9-3 9 EAU26550 Reporting safety defects If you be lieve that you r vehicl e has a def ect whic h could cause a cra sh or co uld cause injury or death, yo u sho uld imme diatel y infor m the Na tional Highw ay Traf fic Safety Ad minis trati on (NHT SA) in ad diti on to not ifyi ng Yama ha Motor Co rpora tion , U.S .A. If NHTSA [...]

CONSUMER INFORMA T ION 9-4 9 EAU26560 Motorcycle noise regulation TAMPERIN G WITH NOISE C ONTROL SY STEM PROHI BITED: Federa l law pro hibits the followi ng acts or the caus ing there of: (1) The remov al or rend ering in operat ive by any perso n other than f or purpo ses of m ainten ance, r epair, or replac ement o f any d evice or eleme nt of de[...]

CONSUMER INFORMATI ON 9-5 9 EAU26632 Maintenance record Copie s of wor k orde rs an d/or rec eip ts for pa rts p urchas ed and i nstal led on your vehic le will be req uired to doc ument th at maint enan ce has b een com plete d in acco rdanc e with the emiss ions warr anty. The cha rt belo w is prin ted only as a remin der that ma intenance w o rk[...]

CONSUMER INFORMA T ION 9-6 9 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Maintenance interval Date of service Mile age Servicing dealer name and add ress Remarks U5SL12E0.book Page 6 M onday, August 9, 2004 10:51 AM[...]

CONSUMER INFORMATI ON 9-7 9 EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5SL12E0.book Page 7 M onday, August 9, 2004 10:51 AM[...]

CONSUMER INFORMA T ION 9-8 9 U5SL12E0.book Page 8 M onday, August 9, 2004 10:51 AM[...]

CONSUMER INFORMATI ON 9-9 9 EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) K eep your Y amaha protected even after y our warranty expires with gen uine Y amaha Extended Ser vice (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co ver age for e xtra [...]

CONSUMER INFORMA T ION 9-10 9 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right aw ay , and you ’ ll rest easy knowing you ’ ll hav e strong factory-backed protection e ven after your Y amaha Limited W arranty expires. A special note: If visiting your dealer isn ’ t con venient, contact Y amaha with your[...]

INDEX A Accessories and replacement parts ..... 6-24 Air filter element, checking . .................. 6-18 Air intake duct ...... ....... ...... .......... ......... . 6-20 B Batter y ....... ........ ...... ........... ........ ....... ... 6-34 Brake and clutch levers, checking and lubricating ..... ...... ....... ... 6 -31 Brake and shift pedals[...]

INDEX Tires ..... ....... .... ...... ....... ........ ...... ........... 6 -21 Tool k it ...... .... ...... .... ....... ...... ........ ....... .... 6-1 Troubleshooting . .............. ..................... 6-43 Troubleshooting charts ...... ................... 6-44 Turn si gnal indicator lights ..... ........ ....... .. 3-2 Turn signal light bu[...]

PRINTED IN JAPAN 2004.08-2.7 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 5SL-28199-12 LIT-11626-18-45 YZF-R6T(C) OWNER’S MANUAL[...]