2000 YAMAHA YZF600 check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician.
EAU00658
TiresTo ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
WARNING
@ Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed. @
CE-33EMaximum load*180 kg (except for A, CH, S)
178 kg (for A, CH, S)
Cold tire pressure Front Rear
Up to 90 kg load*225 kPa
(2.25 kg/cm
2,
2.25 bar)250 kPa
(2.50 kg/cm
2,
2.50 bar)
90 kg Maximum load*250 kPa
(2.50 kg/cm
2,
2.50 bar)290 kPa
(2.90 kg/cm
2,
2.90 bar)
High speed riding250 kPa
(2.50 kg/cm
2,
2.50 bar)290 kPa
(2.90 kg/cm
2,
2.90 bar)
* Load is the total weight of cargo, rider, passenger
and accessories.
E_4tv_Periodic.fm Page 19 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU00744
Drive chain slack checkNOTE:@ Spin the wheel several times and find
the tightest position of the chain. Check
and/or adjust the chain slack while it’s
in this tightest position. @To check the chain slack the motor-
cycle must be held straight up with both
wheels on the ground and without rider.
Check the slack at the position shown
in the illustration. Normal slack is ap-
proximately 20 ~ 30 mm. If the slack
exceeds 30 mm, adjust.
EAU00762
Drive chain slack adjustment1. Loosen the axle nut.
2. Loosen the locknuts on each side.
To tighten the chain, turn the chain
adjusting nuts in direction a
. To
loosen the chain, turn the adjusting
nuts in direction b
and push the
wheel forward. Turn each adjust-
ing nut exactly the same amount to
maintain correct axle alignment.
There are marks on each side of
the swingarm. Use these marks to
align the rear wheel.
EC000096
CAUTION:@ Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits. @3. After adjusting, tighten the lock-
nuts. Then tighten the axle nut to
the specified torque.
a. Chain slack
1. Axle nut
2. Alignment marks
3. Adjusting nut
4. Locknut
5. Wheel axle guide
Tightening torque:
Axle nut:
115 Nm (11.5 m·kg)
E_4tv_Periodic.fm Page 27 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
WA R N I N G
@ If the sidestand does not move
smoothly, consult a Yamaha dealer. @
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
E_4tv_Periodic.fm Page 29 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
EAU02990*
Troubleshooting chart
EW000125
WARNING
@ Never check the fuel system while smoking or in the vicinity of an open flame. @
Check if there is fuel
in the fuel tank.1. Fuel
Enough fuel.
No fuel.
Go to compression check.
Supply fuel.
Engine doesn’t start, go to compression check.
Use the electric starter.2. Compression
There is compression.
No compression.
Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark plugs
and check electrodes.3. Ignition
Wet.
Dry.
Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, ask a Yamaha
dealer to inspect.Engine doesn’t start, go to battery
check.Open throttle half-way and start
the engine.
Use the electric starter.4. Battery
Engine turns over
quickly.
Engine turns over
slowly.
Battery good.Check connections or
recharge.
E_4tv_Periodic.fm Page 40 Wednesday, September 1, 1999 11:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
Engine overheating
EW000070
WARNING
@ Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown
out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. @NOTE:@ If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible. @
Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.
E_4tv_Periodic.fm Page 41 Wednesday, September 1, 1999 11:12 AM

MOTORCYCLE CARE AND STORAGE
7-5
7a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs and place the spark
plugs on the cylinder head so that
the electrodes are grounded. (This
will limit sparking during the next
step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, install the spark
plugs and then the spark plug
caps.
EWA00003
WARNING
@ When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking. @
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, then raise the
motorcycle so that both of its
wheels 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 up the muffler outlet with a
plastic bag to prevent moisture
from entering.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
(less than 0 °C or more than
30 °C). For more information, see
“Battery storage” in the chapter
“PERIODIC MAINTENANCE AND
MINOR REPAIRS”.
NOTE:@ Make any necessary repairs before
storing the motorcycle. @
E_4tv_Cleaning.fm Page 5 Wednesday, September 1, 1999 11:13 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

INDEX
MMain switch/steering lock ......................... 3-1
Model label .............................................. 9-2NNeutral indicator light ............................... 3-2OOil level indicator circuit check ................. 3-4
Oil level indicator light .............................. 3-2PParking .................................................... 5-6
Pass switch ............................................. 3-8
Periodic maintenance and lubrication ...... 6-2
Pre-operation check list ........................... 4-1RRear brake pedal ................................... 3-10
Rear brake pedal height adjustment ...... 6-23
Rear shock absorber adjustment ........... 3-18
Rear suspension lubrication................... 6-30
Rear wheel installation........................... 6-38
Rear wheel removal............................... 6-37
Recommended combinations of the
front fork and the rear shock
absorber settings................................. 3-20
Recommended shift points
(for Switzerland only)............................. 5-5
Right view................................................ 2-2
SSeat ...................................................... 3-14
Shifting .................................................... 5-4
Shift pedal ............................................. 3-10
Sidestand .............................................. 3-21
Sidestand/clutch switch operation
check .................................................. 3-22
Sidestand lubrication ............................. 6-29
Spark plugs ............................................. 6-7
Specifications .......................................... 8-1
Speedometer .......................................... 3-6
Starter (choke) “ ” ............................. 3-13
Starting a warm engine ........................... 5-4
Starting the engine .................................. 5-1
Start switch ............................................. 3-9
Steering inspection................................ 6-31
Storage ................................................... 7-4
Storage compartment............................ 3-15TTachometer............................................. 3-6
Tail/brake light bulb replacement ........... 6-35
Throttle cable and grip lubrication.......... 6-28
Throttle cable free play inspection ......... 6-18
Tips for reducing fuel consumption .......... 5-5
Tires...................................................... 6-19
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-39
Troubleshooting chart ........................... 6-40
Turn indicator light................................... 3-3
Turn signal light bulb replacement ......... 6-35
Turn signal switch ................................... 3-8
VValve clearance adjustment ................... 6-19
Vehicle identification number ................... 9-1WWheel bearings...................................... 6-31
Wheels .................................................. 6-22
E_4tvIX.fm Page 2 Wednesday, September 1, 1999 11:15 AM