2004 YAMAHA YZF-R6 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU23110
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.
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
5SLE1.book Page 29 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU23200
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
5SLE1.book Page 30 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU23271
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
WARNING
EWA10750
Securely support the vehicle so thatthere 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 vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
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.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
5SLE1.book Page 31 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6


Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of awattage higher than specified.
6. Connect the headlight coupler.
7. Install the headlight bulb cover by
turning it clockwise.
8. Install the panel.
9. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24180
Tail/brake light This model 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.
EAU24201
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 counter-
clockwise.
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.CAUTION:
ECA11190
Do not overtighten the screw, other-wise the lens may break.
1. Do not touch the glass part of the bulb.
1. Screw
5SLE1.book Page 36 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6 a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU24360
Front wheel
EAU24510
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle bolt, the wheel
axle pinch bolts, and then the
brake caliper bolts.
2. Lift the front wheel off the ground
according to the procedure on
page 6-38.3. Remove the brake hose holder on
each side by removing the bolt.
4. Remove the brake caliper on each
side by removing the bolts.
5. Remove the axle bolt, pull the
wheel axle out, and then remove
the wheel.
1. Front wheel axle pinch bolt
1. Brake hose holder
2. Brake caliper
3. Axle bolt
4. Bolt
5SLE1.book Page 39 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
EAU25031
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts, and then tightening
them to the specified torque.
NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brakediscs.
5. Install the brake hose holders by
installing the bolts.
6. Secure the wheel axle by installing
the axle bolt, and then tightening
the wheel axle to the specified
torque.NOTE:While tightening the wheel axle, holdthe axle bolt to keep it from turning.
7. Tighten wheel axle pinch bolt B,
and then tighten pinch bolt A to the
specified torque.8. Retighten pinch bolt B to the spec-
ified torque.
9. Tap the outer side of the left fork
leg with a rubber mallet to align it
with the end of the wheel axle.
10. Tighten wheel axle pinch bolt D,
and then tighten pinch bolt C to the
specified torque.
11. Retighten pinch bolt D to the spec-
ified torque.
1. Wheel axle
Tightening torque:
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
Tightening torque:
Wheel axle:
91 Nm (9.1 m·kgf, 66 ft·lbf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Tightening torque:
Wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
5SLE1.book Page 40 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6 12. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.
EAU25080
Rear wheel
EAU25310
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.2. Lift the rear wheel off the ground
according to the procedure on
page 6-38.
3. Remove the axle nut.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction (a).
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:The drive chain does not need to be
disassembled in order to remove andinstall the rear wheel.
7. While supporting the brake caliper
bracket, pull the wheel axle out,
and then remove the wheel.
1. Front wheel axle pinch bolt A
2. Front wheel axle pinch bolt B
3. Front wheel axle pinch bolt C
4. Front wheel axle pinch bolt D
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
5. Brake caliper bracket
5SLE1.book Page 41 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU25660
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.NOTE:

Be sure to insert the retainer on the
brake caliper bracket into the slot
in the swingarm.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-26.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
EAU25870
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Wheel axle
1. Retainer
2. SlotTightening torque:
Axle nut:
110 Nm (11.0 m·kgf, 80 ft·lbf)
5SLE1.book Page 42 Friday, August 1, 2003 4:09 PM