2002 YAMAHA YZF600 brake

DESCRIPTION
2-2
2
Right view11. Luggage strap holders (page 3-18)
12. Rear brake fluid level check window (page 6-28)
13. Coolant reservoir (page 6-13)
14. Front fork spring preload adjusting bolt (page 3-13)
15. Front fork rebound damping force adjusting screw (page 3-14)
16. Radiator cap (page 6-15)
17. Front fork compression damping force adjusting screw (page 3-14)
18. Engine oil level check window (page 6-10)
19. Brake pedal (page 3-8)
20. Engine oil filler cap (page 6-10)
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM

DESCRIPTION
2-3
2
Controls and instruments1. Clutch lever (page 3-7)
2. Left handlebar switches (page 3-5)
3. Starter (choke) lever (page 3-11)
4. Speedometer unit (page 3-3)
5. Tachometer (page 3-4)
6. Coolant temperature gauge (page 3-5)
7. Right handlebar switches (page 3-6)
8. Brake lever (page 3-7)
9. Throttle grip (page 6-20)
10. Main switch/steering lock (page 3-1)
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM

3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................ 3-2
Speedometer unit ................................................ 3-3
Tachometer .......................................................... 3-4
Self-diagnosis device ........................................... 3-4
Coolant temperature gauge ................................. 3-5
Anti-theft alarm (optional) .................................... 3-5
Handlebar switches ............................................. 3-5
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-7
Brake lever ........................................................... 3-7
Brake pedal .......................................................... 3-8
Fuel tank cap ....................................................... 3-8Fuel ..................................................................... 3-9
Fuel tank breather hose (for Germany only) ..... 3-10
Starter (choke) lever .......................................... 3-11
Seat ................................................................... 3-11
Helmet holder .................................................... 3-12
Storage compartment ....................................... 3-12
Adjusting the front fork ...................................... 3-13
Adjusting the shock absorber assembly ............ 3-15
Matching the front and rear suspension
settings ............................................................ 3-17
Luggage strap holders ...................................... 3-18
Sidestand .......................................................... 3-18
Ignition circuit cut-off system ............................. 3-19
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-7
3
EAU00152
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition
circuit cut-off system. (See page 3-19
for an explanation of the ignition circuit
cut-off system.)
EAU00157
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU00161
Brake lever The brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
The brake lever is equipped with a po-
sition adjusting dial. To adjust the dis-
tance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure that
the appropriate setting on the adjusting
dial is aligned with the arrow mark on
the brake lever.
1. Clutch lever
1. Shift pedal
1. Arrow mark
2. Brake lever position adjusting dial
3. Brake lever
a. Distance between brake lever and handlebar
grip
U4TVE6.book Page 7 Saturday, August 4, 2001 12:14 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
EAU00162
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU02935
Fuel tank cap To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock. 2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
NOTE:_ The fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked. _
EWA00025
WARNING
_ Make sure that the fuel tank cap is
properly closed before riding. _
1. Brake pedal
1. Fuel tank cap lock cover
2. Unlock.
U4TVE6.book Page 8 Saturday, August 4, 2001 12:14 PM

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13–6-14
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-27–6-28
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-25–6-28
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-25
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM

PRE-OPERATION CHECKS
4-2
4
Throttle gripMake sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.6-20
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-31
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-29, 6-30
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-21–6-24
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-31
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-32
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-32
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-18
Air intake ductCheck that the screen is not clogged.
Clean if necessary.6-19 ITEM CHECKS PAGE
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM

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 ............................................................. 6-31
Checking and lubricating the brake and clutch
levers ............................................................... 6-32
Checking and lubricating the sidestand ............ 6-32
Lubricating the rear suspension ........................ 6-32
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-33
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
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM