2000 YAMAHA YZF600 air filter

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-2
Cowling and panel removal and installation.......... 6-5
Cowling A and B ................................................... 6-5
Cowling C ............................................................. 6-7
Spark plugs........................................................... 6-7
Engine oil .............................................................. 6-9
Cooling system ................................................... 6-12
Changing the coolant.......................................... 6-13
Air filter ............................................................... 6-15
Air vent hose ....................................................... 6-17
Air intake duct ..................................................... 6-17
Carburetor adjustment ........................................ 6-17
Idle speed adjustment ........................................ 6-18
Throttle cable free play inspection ...................... 6-18
Valve clearance adjustment ................................ 6-19
Tires .................................................................... 6-19
Wheels................................................................ 6-22
Clutch lever free play adjustment........................ 6-23
Rear brake pedal height adjustment ................... 6-23
Brake light switch adjustment ............................. 6-24
Checking the front and rear brake pads.............. 6-25
Inspecting the brake fluid level............................ 6-25
Brake fluid replacement ...................................... 6-26Drive chain slack check...................................... 6-27
Drive chain slack adjustment ............................. 6-27
Drive chain lubrication........................................ 6-28
Cable inspection and lubrication ........................ 6-28
Throttle cable and grip lubrication ...................... 6-28
Brake and shift pedal lubrication ........................ 6-29
Brake and clutch lever lubrication ...................... 6-29
Sidestand lubrication.......................................... 6-29
Rear suspension lubrication............................... 6-30
Front fork inspection ........................................... 6-30
Steering inspection ............................................ 6-31
Wheel bearings .................................................. 6-31
Battery................................................................ 6-32
Fuse replacement .............................................. 6-33
Headlight bulb replacement ............................... 6-33
Tail/brake light bulb replacement ........................ 6-35
Turn signal light bulb replacement...................... 6-35
Front wheel removal ........................................... 6-35
Front wheel installation ...................................... 6-36
Rear wheel removal ........................................... 6-37
Rear wheel installation ....................................... 6-38
Troubleshooting .................................................. 6-39
Troubleshooting chart......................................... 6-40
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
CP-01ENO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.
• Replace if necessary.ÖÖ
2*Fuel filter• Check condition.
• Replace if necessary.Ö
3 Spark plugs• Check condition.
• Clean, regap or replace if necessary.ÖÖÖ
4*Valves• Check valve clearance.
• Adjust if necessary.Every 42,000 km or 42 months
(whichever comes first)
5 Air filter
• Clean or replace if necessary.ÖÖ
6Clutch• Check operation.
• Adjust or replace cable.ÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
9*Wheels• Check balance, runout and for damage.
• Rebalance or replace if necessary.ÖÖ
10*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖ
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970*
NOTE:@ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@21
*Carburetors• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.ÖÖÖ
22 Engine oil• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)ÖÖÖ
23 Engine oil filter cartridge
• Replace.ÖÖ
24*Cooling system• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km or 24 months (whichever comes
first).ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.
NOTE:@ Wait a few minutes until the oil level
settles before checking. @3. The oil level should be between
maximum and minimum marks. If
the level is low, fill the engine with
sufficient oil to reach the specified
level.Engine oil and oil filter cartridge re-
placement
1. Remove cowling A. (See page 6-5
for removal and installation proce-
dures.)
2. Remove the cowling stay.
3. Warm up the engine for several
minutes.
4. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
5. Remove the drain bolt and drain
the oil.6. Remove the oil filter by using an oil
filter wrench.
NOTE:@ An oil filter wrench is available at a
nearby Yamaha dealer. @7. Reinstall the drain bolt and tighten
it to the specified torque.
1. Engine oil filler cap
1. Engine oil drain boltLeft side view
1. Oil filter cartridge
2. Oil filter wrenchTightening torque:
Drain bolt:
43 Nm (4.3 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
68. Apply a light coat of engine oil to
the O-ring of the new oil filter.
NOTE:@ Make sure the O-ring is seated proper-
ly. @9. Install the oil filter and tighten it to
the specified torque with an oil fil-
ter wrench.NOTE:When installing the oil filter, tighten it to
the proper torque by using a torque
wrench.
10. Fill the engine with sufficient oil to
reach the specified level. Install
the oil filler cap and tighten it.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@
11. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.NOTE:@ After the engine is started, the oil level
indicator light should go off if the oil is at
the specified level. @
EC000067
CAUTION:@ If the indicator light flickers or re-
mains on, immediately stop the en-
gine and consult with a Yamaha
dealer. @12. Install the cowling stay and cowl-
ing.
1. O-ring
Tightening torque:
Oil filter:
17 Nm (1.7 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
3.5 L
Periodic oil change:
2.6 L
With oil filter replacement:
2.9 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
NOTE:@ If you find any leaks, ask a Yamaha
dealer to inspect. @18. Install the right air intake duct, then
install and tighten the screw
clamps.
19. Install the fuel tank and fuel tank
bolts.
20. Install the coolant reservoir and
bolts.
21. Fill the coolant reservoir with the
recommended coolant to the
specified level.
22. Install cowlings A and B.
23. Install cowling C.
24. Install the seat.
EAU01475
Air filterThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat.
2. Remove the bolts holding the fuel
tank.
3. Lift the fuel tank upward and posi-
tion it away from the air filter case.
(Do not remove the fuel hoses.)
EW000071
WA R N I N G
@ l
Support the fuel tank carefully
during this procedure.
l
Do not tilt the fuel tank too
much or pull it too hard because
the fuel hose connections may
become loose causing fuel
leakage.
@4. Remove the screws holding the air
filter case cover.
1. Bolt (´ 2)
1. Air filter case cover
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 5. Pull out the air filter.
6. Remove the air filter from its guide
and clean it with solvent. After
cleaning, squeeze the air filter to
remove the remaining solvent.7. Apply recommended oil to the en-
tire surface of the filter and
squeeze out the excess oil. The air
filter should be wet but not drip-
ping.
EC000082
CAUTION:@ l
Make sure the air filter is prop-
erly seated in the air filter case.
l
The engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@8. Reverse the removal procedures
for installation.
EW000131
WA R N I N G
@ Make sure that the fuel hoses and
vacuum hose are properly connect-
ed, in place and not pinched. If a
hose is damaged, be sure to replace
it. @
1. Air filter element
2. Air filter guide
Recommended oil:
SAE 10W30 type SE motor oil
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SPECIFICATIONS
8-2
8
Cooling system capacity
(total amount)
1.95 L
Air filter
Wet type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 19 L
Carburetor
Ty p e ´ quantity CVKD36 ´ 4
Manufacturer KEIHIN
Spark plug
Manufacturer/Type NGK / CR9E or
DENSO / U27ESR-N
Gap 0.7 ~ 0.8 mm
Clutch type
Wet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.708
Secondary reduction system Chain drive
Secondary reduction ratio 3.133
Transmission type Constant mesh 6-speed
Operation Left foot operationGear ratio
1st 2.846
2nd 1.947
3rd 1.545
4th 1.333
5th 1.190
6th 1.074
Chassis
Frame type Diamond
Caster angle 25°
Tr a i l 9 7 m m
Tire
Fro nt
Ty p e Tu b e l e s s
Size 120/60 ZR17 (55 W)
Manufacturer/model Bridgestone / BT57F
Dunlop / D204F
Metzeler / MEZ1 ‘Front’
Michelin / MACADAM 90X
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