2000 YAMAHA YZF600 cooling

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
6-4
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
6-12
6
EAU03024
Cooling system1. Remove the seat. (See page 3-14
for seat removal and installation
procedures.)
2. Check the coolant level in the res-
ervoir tank when the engine is cold
as the coolant level will vary with
engine temperature. The coolant
level should be between the maxi-
mum and minimum marks.
3. If the level is low, add coolant or
distilled water to raise it to the
specified level.
4. Install the seat.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @NOTE:@ l
If water is added, have a Yamaha
dealer check the antifreeze con-
tent of the coolant as soon as pos-
sible.
l
The radiator fan operation is com-
pletely automatic. It is switched on
or off according to the coolant tem-
perature in the radiator.
@5. If your motorcycle overheats, see
page 6-41 for details.
1. Maximum level mark
2. Minimum level mark
Coolant reservoir capacity:
0.55 L
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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.
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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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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
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