2000 YAMAHA YZF600 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6 3. Loosen the pinch bolt, wheel axle
and caliper bolts.
4. Elevate the wheel.
5. Remove the brake hose holders
and calipers.
NOTE:@ Do not depress the brake lever when
the calipers are off the discs as the
brake pads will be forced shut. @6. Remove the wheel axle and
speedometer gear unit. Make sure
the motorcycle is properly support-
ed.
EAU01469*
Front wheel installation1. Install the speedometer gear unit
into the wheel hub. Make sure the
wheel hub and the speedometer
gear unit are installed with the pro-
jections meshed into the slots.
2. Lift up the wheel between the front
fork legs. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork outer
tube.
3. Install the wheel axle and let the
motorcycle down.4. Install the calipers, caliper bolts
and brake hose holders. Make
sure there is enough gap between
the brake pads before installing
the calipers onto the brake discs.
5. Tighten the wheel axle, pinch bolt
and caliper bolts to the specified
torques.
6. Push down hard on the handle-
bars several times to check for
proper fork operation.
7. Install the speedometer cable.
8. Install the front fender and bolts.
1. Pinch bolt
2. Wheel axle
3. Caliper bolt (´ 2)
1. Speedometer gear unit
2. Slot
3. Stopper
Tightening torque:
Wheel axle:
65 Nm (6.5 m·kg)
Pinch bolt:
23 Nm (2.3 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)
E_4tv_Periodic.fm Page 36 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU01247*
Rear wheel removal
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so there is no danger of it
falling over.
@
1. Loosen the wheel axle nut, brake
torque rod bolt and caliper bolts.
2. Elevate the wheel.
3. Remove the wheel axle nut, left
wheel axle guide and caliper bolts,
and then remove the caliper.4. Loosen the locknuts and drive
chain adjusting nuts.
5. Push the wheel forward and re-
move the drive chain.
1. Wheel axle nut
2. Left wheel axle guide
3. Locknut (´ 2)
4. Drive chain adjusting nut (´ 2)
5. Wheel axle
1. Brake torque rod bolt
1. Caliper bolt (´ 2)
2. Right wheel axle guide
E_4tv_Periodic.fm Page 37 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6 6. Pull out the wheel axle along with
the right wheel axle guide, remove
the caliper bracket, and then the
wheel assembly by pulling back-
wards.
NOTE:@ l
Do not depress the brake pedal
when the caliper is off the disc as
the brake pads will be forced shut.
l
You do not have to disassemble
the chain in order to remove or in-
stall the wheel.
@
EAU01246*
Rear wheel installation1. Install the wheel assembly, right
wheel axle guide, caliper bracket,
and then insert the wheel axle.
2. Install the caliper and caliper bolts.
Make sure there is enough gap
between the brake pads before in-
stalling the caliper onto the brake
disc.
3. Tighten the brake torque rod bolt
to the specified torque.
4. Install and adjust the drive chain.
(See page 6-27 for details about
adjusting the drive chain slack.)5. Install the left wheel axle guide
and wheel axle nut and let the
motorcycle down.
6. Tighten the wheel axle nut and
caliper bolts to the specified
torques.
1. Caliper bracket
Tightening torque:
Brake torque rod bolt:
30 Nm (3.0 m·kg)
Axle nut:
117 Nm (11.7 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)
E_4tv_Periodic.fm Page 38 Wednesday, September 1, 1999 11:12 AM

MOTORCYCLE CARE AND STORAGE
7-2
7
ECA00010
CAUTION:@ l
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If you do use such
products for hard-to-remove
dirt, do not leave it on any long-
er than instructed, then thor-
oughly rinse it off with water,
immediately dry the area and
apply a corrosion protection
spray.
l
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.
l
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
l
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel bearings,
swingarm bearings, forks and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
l
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure they do not
leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
@After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on the
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)
E_4tv_Cleaning.fm Page 2 Wednesday, September 1, 1999 11:13 AM

MOTORCYCLE CARE AND STORAGE
7-3
71. Clean your motorcycle with cold
water and soap after the engine
has cooled down.
ECA00012
CAUTION:@ Do not use warm water since it in-
creases the corrosive action of the
salt. @2. Be sure to apply a corrosion pro-
tection spray on all (even chrome-
and nickel-plated) metal surfaces
to prevent corrosion.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 the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even chrome-
and nickel-plated) metal surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing it or covering it.
EWA00001
WA R N I N G
@ Make sure that there is no oil or wax
on the brakes and tires. If neces-
sary, clean the brake discs and lin-
ings with a regular brake disc
cleaner or acetone, and wash the
tires with warm water and mild soap.
Then, carefully test the motorcycle
for its braking performance and cor-
nering behavior. @
E_4tv_Cleaning.fm Page 3 Wednesday, September 1, 1999 11:13 AM

SPECIFICATIONS
8-3
8
Rear
Ty p e Tu b e l e s s
Size 160/60 ZR17 (69 W)
Manufacturer/model Bridgestone / BT57
Dunlop / D204
Metzeler / MEZ1
Michelin / MACADAM 90X
Maximum load* 180 kg (except for A, CH, S)
178 kg (for A, CH, S)
Air pressure (cold tire)
Up to 90 kg load*
Front 225 kPa (2.25 kg/cm
2, 2.25 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
90 kg load ~ maximum
load*
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
High speed riding
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
* Load is total weight of cargo, rider, passenger and accessories.Wheels
Fr on t
Ty p e C a s t
Size 17 ´ MT 3.50
Rear
Ty p e C a s t
Size 17 ´ MT 5.00
Brakes
Fr on t
Type Dual disc brake
Operation Right hand operation
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot operation
Fluid DOT 4
Suspension
Fr on t
Ty p e Te l e s c o p i c f o r k
Rear
Type Swingarm (link suspension)
Shock absorbers
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
E_4tv_Spec.fm Page 3 Wednesday, September 1, 1999 11:14 AM

SPECIFICATIONS
8-4
8
Wheel travel
Front 130 mm
Rear 120 mm
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 18.5 A @ 5,000 r/min
Battery
Type YTX12-BS
Voltage, capacity 12 V, 10 AH
Headlight type
Quartz bulb (halogen)
Bulb voltage, wattage
´ quantity
Headlight 12 V, 60/55 W ´ 1
Tail/brake light 12 V, 5/21 W ´ 1
Auxiliary light 12 V, 4 W ´ 1
Turn signal light 12 V, 21 W ´ 4
Meter light 12 V, 1.7 W ´ 4
Neutral indicator light 12 V, 3.4 W ´ 1
High beam indicator light 12 V, 3.4 W ´ 1
Oil level indicator light 12 V, 3.4 W ´ 1
Turn indicator light 12 V, 3.4 W ´ 1
Fuel indicator light 12 V, 3.4 W ´ 1Fuses
Main fuse 30 A
Headlight fuse 20 A
Signaling system fuse 15 A
Fan fuse 7.5 A
Ignition fuse 7.5 A
E_4tv_Spec.fm Page 4 Wednesday, September 1, 1999 11:14 AM

10-INDEXAAir filter ..................................................6-15
Air intake duct ........................................6-17
Air vent hose .......................................... 6-17
Antitheft alarm (optional) .......................... 3-7BBattery ................................................... 6-32
Brake and clutch lever lubrication........... 6-29
Brake and shift pedal lubrication ............ 6-29
Brake fluid replacement ......................... 6-26
Brake light switch adjustment ................. 6-24CCable inspection and lubrication ............ 6-28
Carburetor adjustment ...........................6-17
Care.........................................................7-1
Changing the coolant ............................. 6-13
Checking the front and
rear brake pads ................................... 6-25
Clutch lever .............................................. 3-9
Clutch lever free play adjustment ........... 6-23
Controls/Instruments ................................2-3
Coolant temperature gauge ..................... 3-8
Cooling system ...................................... 6-12
Cowling A and B ......................................6-5
Cowling C ................................................6-7
Cowling and panel removal and
installation .............................................6-5
DDiagnosis device ..................................... 3-7
Dimmer switch ......................................... 3-8
Drive chain lubrication ........................... 6-28
Drive chain slack adjustment ................. 6-27
Drive chain slack check ......................... 6-27EEngine break-in ....................................... 5-5
Engine oil ................................................ 6-9
Engine stop switch................................... 3-9FFront brake lever ................................... 3-10
Front fork adjustment............................. 3-16
Front fork inspection .............................. 6-30
Front wheel installation .......................... 6-36
Front wheel removal .............................. 6-35
Fuel ....................................................... 3-11
Fuel indicator circuit check....................... 3-5
Fuel indicator light ................................... 3-2
Fuel tank breather hose
(for Germany only) .............................. 3-13
Fuel tank cap ......................................... 3-11
Fuse replacement.................................. 6-33GGive safety the right of way ..................... 1-1
HHandlebar switches ..................................3-8
Dimmer switch ....................................3-8
Engine stop switch..............................3-9
Horn switch.........................................3-8
Lights switch .......................................3-9
Pass switch ........................................3-8
Start switch .........................................3-9
Turn signal switch ...............................3-8
Headlight bulb replacement....................6-33
Helmet holder.........................................3-15
High beam indicator light ..........................3-3
Horn switch ..............................................3-8IIdentification number records ...................9-1
Idle speed adjustment ............................6-18
Indicator lights ..........................................3-2
Fuel indicator light...............................3-2
High beam indicator light ....................3-3
Neutral indicator light ..........................3-2
Oil level indicator light .........................3-2
Turn indicator light ..............................3-3
Inspecting the brake fluid level ...............6-25KKey identification number .........................9-1LLeft view...................................................2-1
Lights switch ............................................3-9
Luggage strap holders ...........................3-21
E_4tvIX.fm Page 1 Wednesday, September 1, 1999 11:15 AM