2001 YAMAHA YZF-R6 brake pads

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-3
Removing and installing cowlings and panels ..... 6-6
Cowlings A and B ................................................. 6-6
Checking the spark plugs .................................... 6-9
Engine oil and oil filter cartridge ........................ 6-10
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-17
Air intake duct .................................................... 6-20
Adjusting the carburetors ................................... 6-20
Adjusting the engine idling speed ...................... 6-21
Adjusting the throttle cable free play .................. 6-21
Adjusting the valve clearance ............................ 6-22
Tires ................................................................... 6-22
Wheels ............................................................... 6-25
Adjusting the clutch lever free play .................... 6-25
Adjusting the brake pedal position ..................... 6-27
Adjusting the rear brake light switch .................. 6-27
Checking the front and rear brake pads ............. 6-28
Checking the brake fluid level ............................ 6-29
Changing the brake fluid .................................... 6-30
Drive chain slack ................................................ 6-31Lubricating the drive chain ................................ 6-32
Checking and lubricating the cables ................. 6-33
Checking and lubricating the throttle
grip and cable ................................................. 6-33
Lubricating the brake pedal ............................... 6-34
Checking and lubricating the brake and
clutch levers .................................................... 6-34
Checking and lubricating the sidestand ............ 6-34
Lubricating the rear suspension ........................ 6-35
Checking the front fork ...................................... 6-35
Checking the steering ....................................... 6-36
Checking the wheel bearings ............................ 6-36
Battery ............................................................... 6-37
Replacing the fuses .......................................... 6-38
Replacing the headlight bulb ............................. 6-39
Tail/brake light ................................................... 6-40
Replacing a turn signal light bulb ...................... 6-40
Supporting the motorcycle ................................ 6-41
Front wheel ....................................................... 6-41
Rear wheel ........................................................ 6-43
Troubleshooting ................................................. 6-44
Troubleshooting charts ...................................... 6-45
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
•Replace.ÖÖ
4*Valves• Check valve clearance.
• Adjust.Every 40,000 km
5 Air filter element• Clean.ÖÖ
•Replace.ÖÖ
6Clutch• Check operation.
• Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU01641
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
Check the brake pad wear as follows.
1. Remove the rear brake caliper by
removing the bolt, and then tilt the
caliper forward to inspect the wear
indicator groove. If a brake pad
has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer re-
place the brake pads as a set.
1. Front brake pad wear indicator grooveFront
1. Bolt
2. Rear brake caliperRear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
62. Install the brake caliper by install-
ing the bolt, then tightening it to the
specified torque.
EAU03776
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:
l
When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
1. Rear brake pad wear indicator grooveTightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kg)Rear
1. Front brake fluid reservoir
2. Minimum level markFront
1. Rear brake fluid reservoir
2. Minimum level mark
Recommended brake fluid: DOT 4Rear
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
l
Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03238
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6 3. Lift the front wheel off the ground
according to the procedure on
page 6-41.
4. Remove the brake hose holders
by removing the bolts.
5. Remove the brake calipers by re-
moving the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
ECA00046
CAUTION:@ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. @
EAU01638
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Push down hard on the handlebar
several times to check for proper
fork operation.
5. Install the brake calipers by install-
ing the bolts.NOTE:@ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. @6. Install the brake hose holders by
installing the bolts.
7. Install the front wheel axle pinch
bolt, and then tighten the wheel
axle, pinch bolt and brake caliper
bolts to the specified torques.
1. Bolt (´ 3)
2. Brake hose holder
3. Front brake caliper
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kg)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
6
EAU03537
Rear wheel To remove the rear wheel
EW000122
WARNING
_ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the axle nut and the brake
caliper bolts.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-41.3. Remove the axle nut, and then re-
move the brake caliper by remov-
ing the bolts.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain adjusting
bolts fully in direction
a.6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _7. Pull the wheel axle out, and then
remove the wheel.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
1. Bolt (´ 2)
2. Rear brake caliper
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6
EAU03538
To install the rear wheel
1. Install the wheel by inserting the
wheel axle from the left hand side.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-31 for
drive chain slack adjustment pro-
cedures.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Install the brake caliper by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brake
disc. _5. Tighten the axle nut and the brake
caliper bolts to the specified
torques.
EAU03087
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. Tightening torques:
Axle nut:
150 Nm (15.0 m·kg)
Brake caliper bolt:
40 Nm (4.0 m·kg)
E_5mt.book Page 44 Monday, September 18, 2000 9:08 AM