2002 YAMAHA YZF600 wheel

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
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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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
10*WheelsCheck runout and for damage.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chainCheck 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 bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 SidestandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
22*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


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
_

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.


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
U4TVE6.book Page 22 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
_

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.


Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.


Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
_
CE-10E
CE-14E
1. Tire air valve
2. Tire valve core
3. Tire valve cap with seal
FRONT
Manufacturer Size Model
Dunlop
120/60 ZR17 (55W)
D204F
120/60 ZR17 M/C (55W)
Metzeler
120/60 ZR17 (55W)
MEZ1 FRONT
120/60 ZR17 M/C (55W)
Bridgestone
120/60 ZR17 (55W)
BT57F
120/60 ZR17 M/C (55W)
Michelin
120/60 ZR17 (55W)
MACADAM 90X
120/60 ZR17 M/C (55W)
REAR
Manufacturer Size Model
Dunlop
160/60 ZR17 (69W)
D204
160/60 ZR17 M/C (69W)
Metzeler
160/60 ZR17 (69W)
MEZ1
160/60 ZR17 M/C (69W)
Bridgestone
160/60 ZR17 (69W)
BT57
160/60 ZR17 M/C (69W)
Michelin
160/60 ZR17 (69W)
MACADAM 90X
160/60 ZR17 M/C (69W)FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
U4TVE6.book Page 23 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU00684
WARNING
_ This motorcycle is fitted with su-
per-high-speed tires. Note the fol-
lowing points in order to make the
most efficient use of these tires.

Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.


Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any
high-speed riding to ride con-
servatively for approximately
100 km after installing a new
tire.


The tires must be warmed up
before a high-speed run.


Always adjust the tire air pres-
sure according to the operating
conditions.
_
EAU03773
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
U4TVE6.book Page 24 Saturday, August 4, 2001 12:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU00744
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it. _
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain
slack as shown.
4. If the drive chain slack is incorrect,
adjust it as follows.
EAU03752
To adjust the drive chain slack
1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction
b, and then
push the rear wheel forward.
a. Drive chain slack
Drive chain slack:
20–30 mm
1. Axle nut
2. Alignment marks
3. Drive chain slack adjusting nut
4. Locknut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po-
sition 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:
117 Nm (11.7 m·kgf)
U4TVE6.book Page 30 Saturday, August 4, 2001 12:14 PM