2004 YAMAHA YZF-R6 suspension

SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
193 kg (425 lb). When loading within
this weight limit, keep the following in
mind:

Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessoriesare added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
5SLE1.book Page 3 Friday, August 1, 2003 4:09 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-20
3


When storing items in the storage
compartment, be sure to wrap
them in a plastic bag to preventlosing them.
EAU14761
Adjusting the front fork This front fork is equipped with spring
preload adjusting bolts, rebound damp-
ing force adjusting screws and com-
pression damping force adjusting
screws.
WARNING
EWA10180
Always adjust both fork legs equal-
ly, otherwise poor handling and lossof stability may result.
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in di-
rection (a). To decrease the spring pre-load and thereby soften the
suspension, turn the adjusting bolt on
each fork leg in direction (b).
NOTE:Align the appropriate groove on the ad-
justing mechanism with the top of thefront fork cap bolt.
1. Spring preload adjusting bolt
1. Current setting
2. Front fork cap boltSpring preload setting:
Minimum (soft):
8
Standard:
7
Maximum (hard):
1
5SLE1.book Page 20 Friday, August 1, 2003 4:09 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-22
3
EAU15051
Adjusting the shock absorber
assembly This shock absorber assembly is
equipped with a spring preload adjust-
ing ring and rebound and compression
damping force adjusting screws.CAUTION:
ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum orminimum settings.
Spring preloadTo increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To de-
crease the spring preload and thereby
soften the suspension, turn the adjust-
ing ring in direction (b).
Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damp-
ing, turn the adjusting screw in direction(a). To decrease the rebound damping
force and thereby soften the rebound
damping, turn the adjusting screw in di-
rection (b).
Compression damping force
To increase the compression damping
force and thereby harden the compres-
sion damping, turn the adjusting screw1. Spring preload adjusting ring
2. Special wrench
3. Position indicator
Spring preload setting:
Minimum (soft):
1
Standard:
4
Maximum (hard):
91. Rebound damping force adjusting screw
Rebound damping setting:
Minimum (soft):
20 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
5 click(s) in direction (b)*
* With the adjusting screw fully turned
in direction (a)1. Compression damping force adjusting screw
5SLE1.book Page 22 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout and for damage.√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
14*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
15 SidestandCheck operation.
Lubricate.√√√√ √
16*Sidestand switchCheck operation.√√√√√ √
17*Front forkCheck operation and for oil leakage.√√√√
18*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
19*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
20*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
22Engine oil filter car-
tridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
5SLE1.book Page 3 Friday, August 1, 2003 4:09 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
WARNING
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.


NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the suspension and tire
air pressure with regard to the
load.


Check the tire condition and airpressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
90–193 kg (198–425 lb):
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Maximum load*:
193 kg (425 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
5SLE1.book Page 20 Friday, August 1, 2003 4:09 PM

SPECIFICATIONS
8-2
8
Gear ratio:
1st:
37/13 (2.846)
2nd:
37/19 (1.947)
3rd:
28/18 (1.556)
4th:
32/24 (1.333)
5th:
25/21 (1.190)
6th:
26/24 (1.083)Chassis:Frame type:
Diamond
Caster angle:
24.0 °
Trail:
86.0 mm (3.39 in)Front tire:Type:
Tubeless
Size:
120/60 ZR17M/C (55W)
Manufacturer/model:
MICHELIN/Pilot SPORT N
Manufacturer/model:
DUNLOP/D208F JRear tire:Type:
Tubeless
Size:
180/55 ZR17M/C (73W)Manufacturer/model:
MICHELIN/Pilot SPORT B
Manufacturer/model:
DUNLOP/D208 AJ
Loading:Maximum load:
193 kg (425 lb)
(Total weight of rider, passenger, cargo and
accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0–198 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Loading condition:
90–193 kg (198–425 lb)
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Front:
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)Front wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT3.50
Rear wheel:Wheel type:
Cast wheel
Rim size:
17M/C x MT5.50Front brake:Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
120.0 mm (4.72 in)Rear suspension:Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
120.0 mm (4.72 in)
5SLE1.book Page 2 Friday, August 1, 2003 4:09 PM