2002 YAMAHA YZF-R6 air filter

2-1
2
EAU00026
2-DESCRIPTION Left view1. Front fork compression damping force
adjusting screw (page 3-18)
2. Front fork rebound damping force
adjusting screw (page 3-18)
3. Front fork spring preload adjusting bolt (page 3-17)
4. Air filter element (page 6-17)
5. Shock absorber assembly compression
damping force adjusting screw (page 3-20)6. Shock absorber assembly spring preload
adjusting ring (page 3-19)
7. Shock absorber assembly rebound
damping force adjusting knob (page 3-20)
8. Shift pedal (page 3-9)
9. Coolant reservoir (page 6-13)
10. Engine oil filter cartridge (page 6-9)
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-3
Removing and installing the cowlings and
panel .................................................................. 6-6
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-17
Air intake duct .................................................... 6-19
Adjusting the carburetors ................................... 6-20
Adjusting the engine idling speed ...................... 6-20
Adjusting the throttle cable free play .................. 6-21
Adjusting the valve clearance ............................ 6-21
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-25
Adjusting the brake pedal position ..................... 6-26
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-27
Checking the brake fluid level ............................ 6-28
Changing the brake fluid .................................... 6-29
Drive chain slack ................................................ 6-29Lubricating the drive chain ................................ 6-31
Checking and lubricating the cables ................. 6-31
Checking and lubricating the throttle grip and
cable ............................................................... 6-32
Checking and lubricating the brake and
clutch levers .................................................... 6-32
Lubricating the brake pedal ............................... 6-32
Checking and lubricating the sidestand ............ 6-33
Lubricating the rear suspension ........................ 6-33
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-34
Checking the wheel bearings ............................ 6-35
Battery ............................................................... 6-35
Replacing the fuses .......................................... 6-37
Replacing a headlight bulb ................................ 6-38
Tail/brake light ................................................... 6-39
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
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


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.√√√√ √
2*Fuel filter•Check condition.√√
3 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
4*Valves•Check valve clearance.
•Adjust.Every 40,000 km
5*Air filter element•Clean.√√
•Replace.√√
6Clutch•Check operation.
•Adjust.√√√√√
7*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√ √ √ √ √
•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.)√√ √ √ √ √
•Replace brake pads. Whenever worn to the limit
9*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.) Every 4 years
U5MTE1.book Page 3 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
10
*Wheels•Check runout and for damage.√√√√
11*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
12*Wheel bearings•Check bearing for looseness or damage.√√√√
13*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based 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.√√√√√
•Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 Sidestand•Check operation.
•Lubricate.√√√√ √
18*Sidestand switch•Check operation.√√√√√ √
19*Front fork•Check operation and for oil leakage.√√√√
20*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√
22*Carburetors•Check starter (choke) operation.
•Adjust engine idling speed and synchronization.√√√√√ √
23 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridge•Replace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5MTE1.book Page 4 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
•Replace the brake hoses every four years and if cracked or damaged.
_25
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change. Every 3 years
26*Front and rear brake
switches•Check operation.√√√√√ √
27 Moving parts and cables•Lubricate.√√√√ √
28*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5MTE1.book Page 5 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6Before 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. @
ECA00021
CAUTION:@ Do not use any tools to remove or
install the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in. @
EAU04224
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _
a. Spark plug gapSpark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
U5MTE1.book Page 9 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowlings A and B. (See
page 6-6 for cowling removal and
installation procedures.)
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
1. Engine oil filler capRight side
1. Maximum level mark
2. Minimum level mark
U5MTE1.book Page 10 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
64. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:_ Skip steps 5–7 if the oil filter cartridge is
not being replaced. _
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 car-
tridge.NOTE:_ Make sure that the O-ring is properly
seated. _
1. Engine oil drain boltLeft side
1. Oil filter wrench
2. Oil filter cartridgeLeft side
1. O-ring
U5MTE1.book Page 11 Monday, August 6, 2001 6:10 PM