2003 YAMAHA YZF-R6 brake light

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
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
U5SLE0.book Page 2 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
6-4
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
6-29
6
EAU01357
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 7–11 mm be-
low the bottom of the footrest bracket
as shown. Periodically check the brake
pedal position and, if necessary, have
a Yamaha dealer adjust it.
EW000109
WARNING
_ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
a. Distance between brake pedal and footrest
bracket
1. Rear brake light switch
2. Rear brake light switch adjusting nut
U5SLE0.book Page 29 Wednesday, September 11, 2002 11:46 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6
NOTE:_ To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the auxiliary light bulb cover,
and then push the protruding pin in until
it is flush with the fastener head. _
EAU03730
Tail/brake light This motorcycle is equipped with an
LED type of tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it
counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
CAUTION:@ Do not overtighten the screw, other-
wise the lens may break. @
1. Quick fastener
2. Pin
After removal
Before installation
1. Screw
U5SLE0.book Page 44 Wednesday, September 11, 2002 11:46 AM

MOTORCYCLE CARE AND STORAGE
7-2
7


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic mayleave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
_After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning. Use the
special sponge, which is included in the
plastic bag containing the owner’s
manual, to clean the muffler and to re-
move any discoloration from it.After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:_ Salt sprayed on roads in the winter may
remain well into spring. _1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:_ Do not use warm water since it in-
creases the corrosive action of the
salt. _2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM

SPECIFICATIONS
8-4
8
Battery
Model GT9B-4
Voltage, capacity 12 V, 8 Ah
Headlight typeHalogen bulb
Bulb voltage, wattage × quantity
Headlight 12 V, 55 W × 2
Tail/brake light LED
Turn signal light 12 V, 10 W × 4
Auxiliary light 12 V, 5 W × 2
License plate light 12 V, 5 W × 1
Meter lighting LED
Neutral indicator light LED
High beam indicator light LED
Turn signal indicator light LED
Fuel level warning light LED
Oil level warning light LED
Coolant temperature warning
light LED
Engine trouble warning light LED
Shift timing indicator light LED
Immobilizer system
indicator light LEDFuses
Main fuse 40 A
Headlight fuse 20 A
Signaling system fuse 15 A
Radiator fan fuse 15 A
Ignition fuse 15 A
Electronic fuel injection fuse 15 A
Turn signal light, taillight,
license plate light, auxiliary
light and hazard fuse 10 A
Odometer, clock and
immobilizer system fuse
(backup fuse) 10 A
U5SLE0.book Page 4 Wednesday, September 11, 2002 11:46 AM