2003 YAMAHA YZF-R6 check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
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. @
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
Recommended lubricant:
Engine oil
U5SLE0.book Page 34 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
U5SLE0.book Page 37 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-45
6
EAU04574
Replacing the license plate
light bulb 1. Remove the license plate light unit
by removing the screws.2. Remove the socket (together with
the bulb) by pulling it out.
3. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with
the bulb) by pushing it in.
6. Install the license plate light unit by
installing the screws.
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
1. Screw (× 2)
1. License plate light bulb
2. License plate light unit
U5SLE0.book Page 45 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-52
6
EAU02990
Troubleshooting charts Starting problems or poor engine performance
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U5SLE0.book Page 52 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-53
6Engine overheating
EW000070
WARNING
@

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.


After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
@aNOTE:@ If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible. @
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
U5SLE0.book Page 53 Wednesday, September 11, 2002 11:46 AM

MOTORCYCLE CARE AND STORAGE
7-4
7
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:_

Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
_
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
U5SLE0.book Page 4 Wednesday, September 11, 2002 11:46 AM

10-INDEXAAir filter element, checking ..................... 6-19
Air intake duct ........................................ 6-22
Anti-theft alarm ...................................... 3-13
Auxiliary light bulb, replacing .................. 6-43BBattery ................................................... 6-38
Brake and clutch levers, checking and
lubricating ............................................ 6-35
Brake and shift pedals, checking and
lubricating ............................................ 6-35
Brake fluid, changing ............................. 6-32
Brake fluid level, checking...................... 6-31
Brake lever............................................. 3-16
Brake light switch (rear), adjusting ......... 6-29
Brake pads, checking............................. 6-30
Brake pedal............................................ 3-16
Brake pedal position, adjusting .............. 6-29CCables, checking and lubricating............ 6-34
Care.........................................................7-1
Catalytic converter ................................. 3-19
Clutch lever ............................................ 3-15
Clutch lever free play, adjusting ............. 6-27
Conversion table ......................................8-5
Coolant .................................................. 6-13
Changing .......................................... 6-15
Checking .......................................... 6-13
Coolant temperature warning light............3-6
Cowlings and panels, removing and
installing ................................................6-5
DDimmer switch ....................................... 3-13
Drive chain, lubricating .......................... 6-33
Drive chain slack ................................... 6-32
Adjusting .......................................... 6-33
Checking .......................................... 6-32EEngine break-in ....................................... 5-3
Engine idling speed ............................... 6-23
Engine oil and oil filter cartridge ............... 6-9
Engine stop switch................................. 3-14
Engine trouble warning light .................... 3-5FFront fork, adjusting ............................... 3-23
Front fork, checking ............................... 6-37
Fuel ....................................................... 3-17
Fuel consumption, tips for reducing ......... 5-3
Fuel level warning light ............................ 3-4
Fuel tank breather hose ......................... 3-18
Fuel tank cap ......................................... 3-17
Fuses, replacing .................................... 6-40HHandlebar switches ............................... 3-13
Hazard switch ........................................ 3-14
Headlight bulb, replacing ....................... 6-41
Helmet holders ...................................... 3-21
High beam indicator light ......................... 3-5
Horn switch ........................................... 3-14
IIdentification numbers ..............................9-1
Ignition circuit cut-off system ..................3-28
Immobilizer system..................................3-1
Immobilizer system indicator light.............3-6
Indicator and warning lights......................3-4KKey identification number .........................9-1LLicense plate light bulb, replacing...........6-45
Luggage strap holders ...........................3-27MMain switch/steering lock .........................3-2
Model label ..............................................9-2
Multi-function display................................3-8NNeutral indicator light ...............................3-5OOil level warning light ...............................3-5PParking.....................................................5-4
Part locations ...........................................2-1
Pass switch ............................................3-13
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM

INDEX
SSafety information.................................... 1-1
Seats ..................................................... 3-19
Passenger seat ................................ 3-20
Rider seat ........................................ 3-19
Shifting .................................................... 5-2
Shift pedal ............................................. 3-15
Shift points (for Switzerland only)............. 5-3
Shift timing indicator light ......................... 3-6
Shock absorber assembly, adjusting ..... 3-25
Sidestand .............................................. 3-27
Sidestand, checking and lubricating....... 6-36
Spark plugs, checking ............................. 6-8
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch ............................................ 3-15
Steering, checking ................................. 6-37
Storage.................................................... 7-4
Storage compartment ............................ 3-21
Supporting the motorcycle ..................... 6-45TTachometer ........................................... 3-13
Tail/brake light ....................................... 6-44
Throttle cable free play, adjusting .......... 6-23
Throttle grip and cable, checking and
lubricating............................................ 6-34
Tires ...................................................... 6-24
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-51
Troubleshooting charts .......................... 6-52
Turn signal indicator lights ....................... 3-4
Turn signal light bulb, replacing ............. 6-44
Turn signal switch ................................. 3-14VValve clearance, adjusting .................... 6-24
Vehicle identification number................... 9-1WWheel bearings, checking ..................... 6-38
Wheel (front) ......................................... 6-46
Installing .......................................... 6-47
Removing ........................................ 6-46
Wheel (rear) .......................................... 6-49
Installing .......................................... 6-50
Removing ........................................ 6-49
Wheels .................................................. 6-27
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM