2003 YAMAHA YZF-R6 cooling

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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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 4. Loosen the clamp screw, and then
disconnect the air intake duct.5. Remove the radiator cap.
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
6. Remove the coolant drain bolt to
drain the cooling system.
7. Loosen the clamp screw, and then
disconnect the radiator hose to
drain the radiator.
1. Clamp screw
2. Air intake duct
1. Radiator cap
1. Coolant drain bolt
2. Clamp screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
622. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
23. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap.
24. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
25. Connect the air intake duct, and
then tighten the clamp screw.
26. Install the panel and the cowling.
EAU04946*
Checking the air filter element The air filter element should be
checked at the intervals specified in the
periodic maintenance and lubrication
chart. Check the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the rider seat. (See page
3-19 for rider seat removal and in-
stallation procedures.)
2. Remove the fuel tank bolts and
slightly lift the fuel tank.
1. Bolt (× 2)
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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

SPECIFICATIONS
8-2
8
Cooling system capacity
(total amount)
2.15 L
Air filterWet element
Fuel
Type PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity 17 L
Amount remaining when the
fuel level warning light comes
on 3.5 L
Electric fuel injection
ModelINP-250/4
Manufacturer NIPPON INJECTOR
Spark plug
Manufacturer/type NGK / CR9EK, CR10EK
Gap 0.6–0.7 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.955
Secondary reduction system Chain drive
Secondary reduction ratio 3.000
Number of drive chain
sprocket teeth (front/rear) 16/48
Transmission type Constant-mesh 6-speed
Operation Left footGear ratio
1st 2.846
2nd 1.947
3rd 1.556
4th 1.333
5th 1.190
6th 1.083
Chassis
Frame type Diamond
Caster angle 24°
Trail 86 mm
Tires
Front
Type Tubeless tire
Size 120/60 ZR17 M/C (55 W)
Manufacturer/model Michelin / Pilot SPORT N
Dunlop / D208F L
Rear
Type Tubeless tire
Size 180/55 ZR17 M/C (73 W)
Manufacturer/model Michelin / Pilot SPORT B
Dunlop / D208 L
U5SLE0.book Page 2 Wednesday, September 11, 2002 11:46 AM