2001 YAMAHA YZF-R6 torque

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic main-
tenance and lubrication chart should be
simply considered as a general guide
under normal riding conditions. Howev-
er, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TION, AND INDIVIDUAL USE, THE
MAINTENANCE INTERVALS MAY
NEED TO BE SHORTENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01296
CAUTION:@ Do not test this motorcycle on a dy-
namometer stand for an extended
period of time, otherwise heat-in-
duced discoloration of the fiber-con-
structed muffler may occur. @
EAU01129
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment. (See
page 3-15 for storage compartment
opening procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU01639
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
a. Spark plug gap
Specified spark plug:
CR10EK (NGK)
Spark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 5. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:@ An oil filter wrench is available at a
Yamaha dealer. @
6. Apply a thin coat of engine oil to
the O-ring of the new oil filter
cartridge.NOTE:@ Make sure that the O-ring is properly
seated. @
7. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
1. Oil filter wrench
2. Oil filter cartridgeLeft side
1. O-ring
1. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kg)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)Left side
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU01612
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove panel C, and cowlings A
and B. (See pages 6-6–6-8 for
panel and cowling removal and in-
stallation procedures.)
3. Place a container under the en-
gine to collect the used coolant.
4. Remove the radiator cap.
EW000067
WARNING
@ Never attempt to remove the radia-
tor cap when the engine is hot. @
5. Remove the water pump drain bolt
to drain the water pump housing.
6. Loosen the clamp screw, and then
disconnect the radiator hose to
drain the radiator.
7. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
8. Connect the radiator hose, and
then tighten the clamp screw.
9. Install the coolant drain bolt, and
then tighten it to the specified
torque.
NOTE:@ Check the washer for damage and re-
place it if necessary. @
1. Radiator capRight side
1. Water pump drain bolt
2. Clamp screwRight side
Tightening torque:
Coolant drain bolt:
12 Nm (1.2 m·kg)
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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
6-32
6
NOTE:@ Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment. @
EC000096
CAUTION:@ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. @3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:@ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. @1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:@ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. @2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:@ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. @
Tightening torque:
Axle nut:
150 Nm (15.0 m·kg)
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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
6-44
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