2003 YAMAHA YZF-R6 brake

DESCRIPTION
2-2
2
Right view13. Luggage strap holder (page 3-27)
14. Helmet holder (page 3-21)
15. Fuse box 1 (page 6-40)
16. Main fuse (page 6-40)
17. Battery (page 6-38)
18. Throttle stop screw (page 6-23)
19. Air filter element (page 6-19)20. Front brake fluid reservoir (page 6-31)
21. Radiator cap (page 6-16)
22. Coolant drain bolt (page 6-16)
23. Engine oil filler cap (page 6-10)
24. Brake pedal (page 3-16)
25. Engine oil dipstick (page 6-10)
26. Rear brake fluid reservoir (page 6-31)
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM

DESCRIPTION
2-3
2
Controls and instruments1. Clutch lever (page 3-15)
2. Left handlebar switches (page 3-13)
3. Multi-function display (page 3-8)
4. Main switch/steering lock (page 3-2)
5. Tachometer (page 3-13)6. Right handlebar switches (page 3-14)
7. Throttle grip (page 6-23)
8. Brake lever (page 3-16)
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3
INSTRUMENT AND CONTROL FUNCTIONS
Immobilizer system .............................................. 3-1
Main switch/steering lock ..................................... 3-2
Indicator and warning lights ................................ 3-4
Multi-function display ........................................... 3-8
Tachometer ........................................................ 3-13
Anti-theft alarm (optional) .................................. 3-13
Handlebar switches ........................................... 3-13
Clutch lever ........................................................ 3-15
Shift pedal .......................................................... 3-15
Brake lever ......................................................... 3-16
Brake pedal ........................................................ 3-16
Fuel tank cap ..................................................... 3-17Fuel ................................................................... 3-17
Fuel tank breather hose .................................... 3-18
Catalytic converter ............................................ 3-19
Seats ................................................................. 3-19
Helmet holders .................................................. 3-21
Storage compartment ....................................... 3-21
Adjusting the front fork ...................................... 3-23
Adjusting the shock absorber assembly ............ 3-25
Luggage strap holders ...................................... 3-27
Sidestand .......................................................... 3-27
Ignition circuit cut-off system ............................. 3-28
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
EAU00161
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar 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.
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.
1. Brake lever
1. Brake lever position adjusting dial
2. Arrow mark
a. Distance between brake lever and handlebar
grip
1. Brake pedal
U5SLE0.book Page 16 Wednesday, September 11, 2002 11:46 AM

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.3-17–3-18
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9–6-10
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-13–6-15
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.6-30–6-32
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.6-29–6-32
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-27–6-28
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM

PRE-OPERATION CHECKS
4-2
4
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-23, 6-34
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-34
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-32–6-34
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-24–6-27
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-35–6-36
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-35
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-36
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.3-29
Air intake ductCheck that the screen is not clogged.
Clean if necessary.6-22 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 and panels ..... 6-5
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-19
Air intake duct .................................................... 6-22
Adjusting the engine idling speed ...................... 6-23
Adjusting the throttle cable free play .................. 6-23
Adjusting the valve clearance ............................ 6-24
Tires ................................................................... 6-24
Cast wheels ....................................................... 6-27
Adjusting the clutch lever free play .................... 6-27
Adjusting the brake pedal position ..................... 6-29
Adjusting the rear brake light switch .................. 6-29
Checking the front and rear brake pads ............. 6-30
Checking the brake fluid level ............................ 6-31
Changing the brake fluid .................................... 6-32
Drive chain slack ................................................ 6-32
Lubricating the drive chain ................................. 6-33
Checking and lubricating the cables .................. 6-34Checking and lubricating the throttle grip and
cable ............................................................... 6-34
Checking and lubricating the brake and
clutch levers .................................................... 6-35
Checking and lubricating the brake and
shift pedals ...................................................... 6-35
Checking and lubricating the sidestand ............ 6-36
Checking the front fork ...................................... 6-37
Checking the steering ....................................... 6-37
Checking the wheel bearings ............................ 6-38
Battery ............................................................... 6-38
Replacing the fuses .......................................... 6-40
Replacing a headlight bulb ................................ 6-41
Replacing an auxiliary light bulb ....................... 6-43
Tail/brake light ................................................... 6-44
Replacing a turn signal light bulb ...................... 6-44
Replacing the license plate light bulb ................ 6-45
Supporting the motorcycle ................................ 6-45
Front wheel ....................................................... 6-46
Rear wheel ........................................................ 6-49
Troubleshooting ................................................. 6-51
Troubleshooting charts ...................................... 6-52
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
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 lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4*Air filter elementClean.√√
Replace.√√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
9*WheelsCheck runout and for damage.√√√√
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM