2004 YAMAHA YZF-R6 service

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SAFETY INFORMATION
EAU10280
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE USE
AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE EX-
PERTISE OF THE OPERATOR. EV-
ERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTOR-
CYCLE.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.


OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.


OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.


OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUALAND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding


Always make pre-operation
checks. Careful checks may help
prevent an accident.


This motorcycle is designed to car-
ry the operator and a passenger.


The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.


Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
Make sure that you are qualified
and that you only lend your
motorcycle to other qualified op-
erators.
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.


Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
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INSTRUMENT AND CONTROL FUNCTIONS
3-23
3 in direction (a). To decrease the com-
pression damping force and thereby
soften the compression damping, turn
the adjusting screw in direction (b).
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above spec-
ifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the num-
ber of clicks of each damping force ad-
justing mechanism and to modify thespecifications as necessary.
WARNING
EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to
open the gas cylinder.


Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.


Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.


Always have a Yamaha dealerservice the shock absorber.
EAU15181
Luggage strap holders There are four luggage strap holders on
the bottom of the passenger seat. To
use the strap holders, remove the pas-
senger seat, unhook the straps from
the hooks, and then install the seat with
the straps hanging out from under the
passenger seat. (See page 3-17.)
Compression damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)
1. Luggage strap holder
2. Hook
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17490
Owner’s tool kit The owner’s tool kit is located inside the
storage compartment under the pas-
senger seat. (See page 3-17.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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EAU18670
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.
23*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
24 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate. Every 800 km and after washing the motorcycle or
riding in the rain
25*Front and rear brake
switchesCheck operation.√√√√√ √
26Moving parts and ca-
blesLubricate.√√√√ √
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 dam-
age.
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 (× 1000 km)
ANNUAL
CHECK
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU23020
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.CAUTION:
ECA10580
The drive chain must be lubricated
after washing the motorcycle orriding in the rain.
1. Clean the drive chain with kero-
sene and a small soft brush.CAUTION:
ECA11120
To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers orinappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
CAUTION:
ECA11110
Do not use engine oil or any other lu-
bricants for the drive chain, as they
may contain substances that coulddamage the O-rings.
EAU23100
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
63. Remove the defective bulb by pull-
ing it out.
4. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by pushing it in.
6. Install the auxiliary light bulb cover
by installing the quick fastener.
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 untilit is flush with the fastener head.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
1. Auxiliary light bulb
2. Auxiliary light bulb socket
1. Quick fastener
2. Pin
12
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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
6-41
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