2005 YAMAHA YZF-R6 engine

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Tachometer ....................................3-8
Multi-function display ......................3-8
Anti-theft alarm (optional) .............3-12
Handlebar switches ......................3-12
Clutch lever ...................................3-14
Shift pedal .....................................3-14
Brake lever ...................................3-14
Brake pedal ..................................3-15
Fuel tank cap ................................3-15
Fuel ...............................................3-16
Fuel tank breather/overflow
hose ..........................................3-17
Catalytic converter ........................3-17
Seats ............................................3-18
Helmet holders .............................3-19
Storage compartment ...................3-19
Adjusting the front fork ..................3-20
Adjusting the shock absorber
assembly ...................................3-22Luggage strap holders ................. 3-24
Sidestand ..................................... 3-24
Ignition circuit cut-off system ........ 3-25
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing cowlings
and panels .................................. 6-6
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge ..... 6-9
Coolant ......................................... 6-12
Checking the air filter element ...... 6-16
Air intake duct .............................. 6-17
Adjusting the engine idling
speed ........................................ 6-18Checking the throttle cable free
play ........................................... 6-18
Valve clearance ........................... 6-19
Tires ............................................. 6-19
Cast wheels ................................. 6-22
Adjusting the clutch lever free
play ........................................... 6-22
Adjusting the rear brake light
switch ....................................... 6-23
Checking the front and rear
brake pads ................................ 6-23
Checking the brake fluid level ...... 6-24
Changing the brake fluid .............. 6-25
Drive chain slack .......................... 6-25
Lubricating the drive chain ........... 6-27
Checking and lubricating the
cables ....................................... 6-27
Checking and lubricating the
throttle grip and cable ............... 6-28
Checking and lubricating the
brake and shift pedals .............. 6-28
Checking and lubricating the
brake and clutch levers ............ 6-29
Checking and lubricating the
sidestand .................................. 6-29
Lubricating the swingarm
pivots ........................................ 6-30
Checking the front fork ................. 6-30
Checking the steering .................. 6-31
Checking the wheel bearings ....... 6-31
Battery ......................................... 6-32U5SLE2E0.book Page 1 Friday, August 6, 2004 9:48 AM

SAFETY INFORMATION
1-2
1 due to EXCESSIVE SPEED or un-
dercornering (insufficient lean an-
gle for the speed).
Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.


The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.


Never ride under the influence of
alcohol or other drugs.


This motorcycle is designed for on-
road use only. It is not suitable for
off-road use.
Protective apparel
The majority of fatalities from motor-
cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre-
vention or reduction of head injuries.


Always wear an approved helmet.


Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.


The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.


Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.


Never touch the engine or exhaust
system during or after operation.
They become very hot and cancause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.


A passenger should also observe
the above precautions.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
U5SLE2E0.book Page 2 Friday, August 6, 2004 9:48 AM

SAFETY INFORMATION
1-4
1 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.
Gasoline and exhaust gas


GASOLINE IS HIGHLY FLAMMA-
BLE:
Always turn the engine off when
refueling.
Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
Never refuel while smoking or in
the vicinity of an open flame.


Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.


Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motor-
cycle, note the following:
The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.
Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
Do not park the motorcycle near
a flammable source, (e.g., a ker-
osene heater, or near an open
flame), otherwise it could catch
fire.


When transporting the motorcycle
in another vehicle, make sure that
it is kept upright. If the motorcycle
should lean over, gasoline may
leak out of the fuel tank.


If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skinor clothing, immediately wash the
affected area with soap and water
and change your clothes.
U5SLE2E0.book Page 4 Friday, August 6, 2004 9:48 AM

DESCRIPTION
2-1
2
EAU10410
Left view1. Front fork rebound damping force adjusting screw (page 3-20)
2. Front fork spring preload adjusting bolt (page 3-20)
3. Fuse box 2 (page 6-33)
4. Coolant reservoir (page 6-12)
5. Shock absorber assembly spring preload adjusting ring (page 3-22)
6. Shock absorber assembly compression damping force adjusting screw
(page 3-22)
7. Owner’s tool kit (page 6-1)
8. Shock absorber assembly rebound damping force adjusting screw
(page 3-22)
9. Shift pedal (page 3-14)10.Engine oil drain bolt (page 6-9)
11.Engine oil filter cartridge (page 6-9)
12.Front fork compression damping force adjusting screw (page 3-20)U5SLE2E0.book Page 1 Friday, August 6, 2004 9:48 AM

DESCRIPTION
2-2
2
EAU10420
Right view1. Luggage strap holder (page 3-24)
2. Helmet holder (page 3-19)
3. Fuse box 1 (page 6-33)
4. Main fuse (page 6-33)
5. Battery (page 6-32)
6. Idle adjusting screw (page 6-18)
7. Air filter element (page 6-16)
8. Front brake fluid reservoir (page 6-24)
9. Radiator cap (page 6-12)
10.Coolant drain bolt (page 6-13)
11.Engine oil filler cap (page 6-9)12.Brake pedal (page 3-15)
13.Dipstick (page 6-9)
14.Rear brake fluid reservoir (page 6-24)
U5SLE2E0.book Page 2 Friday, August 6, 2004 9:48 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU10471
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.NOTE:Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-registering.
EAU10550
ON
All electrical circuits are supplied with
power, the meter lighting, taillight, li-
cense plate light and auxiliary lights
come on, and the engine can be start-
ed. The key cannot be removed.NOTE:The headlights come on automatically
when the engine is started and stay on
until the key is turned to “OFF”, even ifthe engine stalls.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.1. Push.
2. Turn.
U5SLE2E0.book Page 2 Friday, August 6, 2004 9:48 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3 To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
WARNING
EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or“LOCK”.
EAU10940
(Parking)
The steering is locked, and the taillight,
license plate light and auxiliary lights
are on. The hazard light and turn signal
lights can be turned on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “”.
CAUTION:
ECA11020
Do not use the parking position for
an extended length of time, other-wise the battery may discharge.
EAU11002
Indicator and warning lights
1. Push.
2. Turn.
1. Right turn signal indicator light “”
2. Fuel level warning light “”
3. Oil level warning light “”
4. Neutral indicator light “”
5. Engine trouble warning light “”
6. High beam indicator light “”
7. Immobilizer system indicator light “”
8. Left turn signal indicator light “”
U5SLE2E0.book Page 3 Friday, August 6, 2004 9:48 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU11030
Turn signal indicator lights “” and
“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11250
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
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.NOTE:

Even if the oil level is sufficient, the
warning light may flicker when
riding on a slope or during sudden
acceleration or deceleration, but
this is not a malfunction.


This model is also equipped with a
self-diagnosis device for the oil
level detection circuit. If the oil lev-
el detection circuit is defective, the
following cycle will be repeated un-
til the malfunction is corrected: The
oil level warning light will flash ten
times, then go off for 2.5 seconds.
If this occurs, have a Yamahadealer check the vehicle.
EAU11360
Fuel level warning light “”
This warning light comes on when the
fuel level drops below approximately
3.5 L (0.92 US gal) (0.77 Imp.gal).
When this occurs, refuel as soon as
possible.
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.NOTE:This model is also equipped with a self-
diagnosis device for the fuel level de-
tection circuit. If the fuel level detection
circuit is defective, the following cycle
will be repeated until the malfunction is
corrected: The fuel level warning light
will flash eight times, then go off for 2.5
seconds. If this occurs, have a Yamahadealer check the vehicle.
1. Shift timing indicator light
2. Coolant temperature warning light “”
3. Coolant temperature displayU5SLE2E0.book Page 4 Friday, August 6, 2004 9:48 AM