2003 YAMAHA YZF-R6 brake fluid

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

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

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
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_24
*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
25*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Air induction systemCheck the air cut-off valve, reed valve, and hose for
damage.
Replace any damaged parts if necessary.√√√√ √
29*Muffler and exhaust pipeCheck the screw clamp for looseness.√√√√√
30*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5SLE0.book Page 4 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU04856
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level markFront
1. Minimum level mark
Recommended brake fluid: DOT 4Rear
U5SLE0.book Page 31 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake hoses: Replace every four
years.
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.
a. Drive chain slackDrive chain slack:
35–45 mm
U5SLE0.book Page 32 Wednesday, September 11, 2002 11:46 AM

SPECIFICATIONS
8-3
8
Maximum load* 193 kg
Tire air pressure (measured on
cold tires)
Up to 90 kg*
Front 250 kPa (2.50 kgf/cm
2, 2.50 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 290 kPa (2.90 kgf/cm2, 2.90 bar)
High-speed riding*
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 17 M/C × MT 3.50
Rear
Type Cast wheel
Size 17 M/C × MT 5.50Brakes
Fr o n t
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (link suspension)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 120 mm
Rear 120 mm
Electrical system
Ignition system DC-C.D.I.
Charging system
Model A.C. magneto
Standard output 14 V, 300 W@ 5,000 r/min
U5SLE0.book Page 3 Wednesday, September 11, 2002 11:46 AM