2003 YAMAHA YZF-R6 coolant

2-1
2
EAU00026
2-DESCRIPTION Left view1. Front fork rebound damping force
adjusting screw (page 3-24)
2. Front fork spring preload adjusting bolt (page 3-23)
3. Fuse box 2 (page 6-40)
4. Coolant reservoir (page 6-14)
5. Shock absorber assembly spring
preload adjusting ring (page 3-25)
6. Shock absorber assembly compression
damping force adjusting screw (page 3-26)7. Owner’s tool kit (page 6-1)
8. Shock absorber assembly rebound
damping force adjusting screw (page 3-26)
9. Shift pedal (page 3-15)
10. Engine oil drain bolt (page 6-11)
11. Engine oil filter cartridge (page 6-11)
12. Front fork compression damping force
adjusting screw (page 3-24)
U5SLE0.book Page 1 Wednesday, September 11, 2002 11:46 AM

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

INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU04972*
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and
30 seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After
24 hours have passed, the indicator
light will stop flashing, however the im-
mobilizer system is still enabled.NOTE:_ This model is also equipped with a self-
diagnosis device for the immobilizer
system. If the immobilizer system is de-
fective, the indicator will start flashing
and the multi-function meter will display
an error code. (See “Self-diagnosis de-
vice” on page 3-9 for details.) _
EAU04975
Shift timing indicator light
This indicator light can be set to come
on and go off at the desired engine
speeds and is used to inform the rider
when it is time to shift to the next higher
gear.
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit. (See pages 3-10–3-12 for a de-
tailed explanation of the function of this
indicator light and on how to set it.)
EAU04923
Coolant temperature warning light
“”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
EC000002
CAUTION:_ Do not operate the engine if it is
overheated. _
1. Shift timing indicator light
2. Coolant temperature warning light “”
3. Coolant temperature display
U5SLE0.book Page 6 Wednesday, September 11, 2002 11:46 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-7
3
CB-25E
Coolant
temperatureDisplay Conditions What to do0–39 °CMessage “LO” is
displayed.OK. Go ahead with riding.
40–116 °CTemperature is
displayed.OK. Go ahead with riding.
117–139 °CTemperature flashes.
Warning light comes on.Stop the motorcycle and allow it to
idle until the coolant temperature
goes down.
If the temperature does not go
down, stop the engine. (See the
“Engine overheating” section on
page 6-53 for further instructions.)
Above 140 °CMessage “HI” flashes.
Warning light comes on.Stop the engine and allow it to cool.
(See the “Engine overheating” sec-
tion on page 6-53 for further in-
structions.)
U5SLE0.book Page 7 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
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5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate
ventilation.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU04953
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
_

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-29.


Never ride with the sidestand
down.
_1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA00147
CAUTION:_ The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light


Fuel level warning light


Coolant temperature warning
light


Shift timing indicator light


Engine trouble warning light


Immobilizer system indicator
light
If a warning or indicator light does
not go off, see pages 3-4–3-7 for the
corresponding warning and indica-
tor light circuit check.
_2. Shift the transmission into the neu-
tral position.NOTE:_ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit. _
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
6-4
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