2001 YAMAHA YZF600 air suspension

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings ........................ 6-5
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge ........................ 6-10
Coolant .............................................................. 6-13
Cleaning the air filter element ............................ 6-17
Checking the air vent hose ................................ 6-18
Air intake duct .................................................... 6-19
Adjusting the carburetors ................................... 6-19
Adjusting the engine idling speed ...................... 6-19
Adjusting the throttle cable free play .................. 6-20
Adjusting the valve clearance ............................ 6-20
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-25
Adjusting the brake pedal position ..................... 6-25
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-27
Checking the brake fluid level ............................ 6-27
Changing the brake fluid .................................... 6-28
Drive chain slack ................................................ 6-29
Lubricating the drive chain ................................. 6-30Checking and lubricating the cables ................. 6-31
Checking and lubricating the throttle grip and
cable ............................................................... 6-31
Checking and lubricating the brake and
shift pedals ...................................................... 6-32
Checking and lubricating the brake and
clutch levers .................................................... 6-32
Checking and lubricating the sidestand ............ 6-32
Lubricating the rear suspension ........................ 6-33
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-34
Checking the wheel bearings ............................ 6-34
Battery ............................................................... 6-35
Replacing the fuses .......................................... 6-36
Replacing the headlight bulb ............................. 6-37
Replacing the tail/brake light bulb ..................... 6-38
Replacing a turn signal light bulb ...................... 6-39
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-40
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-43
Troubleshooting charts ...................................... 6-44
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
10*Wheels• Check runout and for damage.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14 Drive chain• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain.
15*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
18*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
19*Front fork• Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
21*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease.ÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
l
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
l
Adjust the suspension and tire
air pressure with regard to the
load.
l
Check the tire condition and air
pressure before each ride.
_
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.CE-08ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
EW000079
WARNING
_ l
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
l
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
E_4tv.book Page 22 Wednesday, October 4, 2000 2:15 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU00790
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:_ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. _
Recommended lubricant:
Molybdenum disulfide grease
E_4tv.book Page 33 Wednesday, October 4, 2000 2:15 PM

SPECIFICATIONS
8-3
8
Rear
Type Tubeless tire
Size 160/60 ZR17 (69W)
Manufacturer/model Bridgestone / BT57
Dunlop / D204
Metzeler / MEZ1
Michelin / MACADAM 90X
Maximum load* 180 kg (except for A, CH, S)
178 kg (for A, CH, S)
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 225 kPa (2.25 kg/cm
2, 2.25 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
High-speed riding
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 290 kPa (2.90 kg/cm2, 2.90 bar)
* Total weight of rider, passenger, cargo and accessoriesWheels
Fr o n t
Type Cast wheel
Size 17 ´ MT 3.50
Rear
Type Cast wheel
Size 17 ´ MT 5.00
Brakes
Fr o n t
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (link suspention)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
E_4tv.book Page 3 Wednesday, October 4, 2000 2:15 PM

INDEXAAir filter element, cleaning ...................... 6-17
Air intake duct ........................................ 6-19
Air vent hose, checking .......................... 6-18
Anti-theft alarm ........................................3-5BBattery ................................................... 6-35
Brake and clutch levers, checking and
lubricating ............................................ 6-32
Brake and shift pedals, checking and
lubricating ............................................ 6-32
Brake fluid, changing ............................. 6-28
Brake fluid level, checking...................... 6-27
Brake lever...............................................3-7
Brake light switch (rear), adjusting ......... 6-26
Brake pads, checking............................. 6-27
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-25CCables, checking and lubricating............ 6-31
Carburetors, adjusting............................ 6-19
Care.........................................................7-1
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-25
Conversion table ......................................8-5
Coolant .................................................. 6-13
Changing .......................................... 6-14
Checking .......................................... 6-13
Coolant temperature gauge .....................3-5
Cowlings, removing and installing ............6-5
DDimmer switch ......................................... 3-5
Drive chain, lubricating .......................... 6-30
Drive chain slack ................................... 6-29
Checking .......................................... 6-29
Adjusting .......................................... 6-29EEngine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............. 6-10
Engine stop switch................................... 3-6FFront and rear suspension settings ........ 3-17
Front fork, adjusting ............................... 3-12
Front fork, checking ............................... 6-33
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel level warning light ............................ 3-3
Fuel tank breather hose
(Germany only) ..................................... 3-9
Fuel tank cap ........................................... 3-8
Fuses, replacing .................................... 6-36HHandlebar switches ................................. 3-5
Headlight bulb, replacing ....................... 6-37
Helmet holder ........................................ 3-11
High beam indicator light ......................... 3-3
Horn switch ............................................. 3-6
IIdentification numbers ..............................9-1
Idling speed, adjusting ...........................6-19
Ignition circuit cut-off system ..................3-19
Indicator and warning lights......................3-2KKey identification number .........................9-1LLight switch ..............................................3-6
Luggage strap holders ...........................3-18MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level warning light ...............................3-2PParking.....................................................5-6
Part locations ...........................................2-1
Pass switch ..............................................3-5
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1
E_4tv.book Page 1 Wednesday, October 4, 2000 2:15 PM