2002 YAMAHA YZF600 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01065
Removing and installing
cowlings The cowlings shown above need to be
removed to perform some of the main-
tenance jobs described in this chapter.Refer to this section each time a cowl-
ing needs to be removed and installed.
EAU04277
Cowlings A and C
To remove one of the cowlings1. Remove the bolts.
1. Cowling A
2. Cowling B
1. Cowling C
2. Cowling D
1. Bolt (× 3 on each side)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 2. Disconnect the turn signal connec-
tors (and, for the left-side cowling,
also the auxiliary light coupler),
and then take the cowling off.
To install the cowling
1. Connect the turn signal connec-
tors (and, for the left-side cowling,
also the auxiliary light coupler).
2. Place the cowling in the original
position, and then install the bolts.
Bolt (× 6) Bolt (× 7)Left side
Right side
1. Bolt (× 5 on each side)
1. Auxiliary light coupler
2. Turn signal connector (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU03595
Cowling B
To remove the cowling1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove the screws, and then pull
the cowling off as shown.NOTE:_ Pull the cowling up, then back to re-
move it. _To install the cowling1. Place the cowling in the original
position, and then install the
screws.
2. Install the seat.
EAU04278
Cowling D
To remove the cowling1. Remove the seat and cowling B.
(See pages 3-11 and 6-7 for seat
and cowling removal and installa-
tion procedures.)
2. Remove the grab bar by removing
the bolts.
3. Remove the screw, and then pull
the cowling off as shown.To install the cowling
1. Place the cowling in the original
position, and then install the
screw.
2. Install the grab bar by installing the
bolts.
3. Install the cowling and the seat.
1. Screw (× 2)
1. Bolt (× 2)
2. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU03329
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs 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.
To remove a spark plug
1. Remove the spark plug cap.2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medi-
um-to-light tan (the ideal color
when the motorcycle is ridden nor-
mally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:_ 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. _
1. Spark plug cap (× 2 on each side)
1. Spark plug wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
63. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
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. _4. Install the spark plug cap. Specified spark plug:
CR9E (NGK) or
U27ESR-N (DENSO)
a. Spark plug gap
Spark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EAU04279
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. _
2. Start the engine, warm it up for sev-
eral minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.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.To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion 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 level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
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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. _7. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
1. Engine oil drain boltLeft side
1. Oil filter cartridge
2. Oil filter wrench
1. O-ring
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
9. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00105
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowling. Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.6 L
With oil filter cartridge
replacement:
2.9 L
Total amount (dry engine):
3.5 L
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