2008 YAMAHA YZF-R6 brake fluid

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 ............3-4
Multi-function meter unit .................3-7
Anti-theft alarm (optional) .............3-13
Handlebar switches ......................3-14
Clutch lever ...................................3-15
Shift pedal .....................................3-15
Brake lever ...................................3-16
Brake pedal ..................................3-16
Fuel tank cap ................................3-17
Fuel ...............................................3-17
Fuel tank breather/overflow
hose ..........................................3-18
Catalytic converters ......................3-19
Seats ............................................3-19
Helmet holding cable ....................3-20
Adjusting the front fork ..................3-21
Adjusting the shock absorber
assembly ...................................3-23
Luggage strap holders ..................3-26
EXUP system ...............................3-26Sidestand ..................................... 3-27
Ignition circuit cut-off system ........ 3-27
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 .................................. 6-7
Checking the spark plugs ............. 6-11
Engine oil and oil filter cartridge ... 6-12
Coolant ......................................... 6-15
Air filter element ........................... 6-19
Checking the engine idling
speed ........................................ 6-19
Checking the throttle cable free
play ........................................... 6-19
Valve clearance ............................ 6-20Tires ............................................. 6-20
Cast wheels ................................. 6-23
Adjusting the clutch lever free
play ........................................... 6-23
Adjusting the rear brake light
switch ....................................... 6-24
Checking the front and rear brake
pads .......................................... 6-24
Checking the brake fluid level ...... 6-25
Changing the brake fluid .............. 6-26
Drive chain slack .......................... 6-26
Cleaning and lubricating the drive
chain ......................................... 6-27
Checking and lubricating
the cables ................................. 6-28
Checking and lubricating
the throttle grip and cable ......... 6-28
Checking and lubricating
the brake and shift pedals ........ 6-29
Checking and lubricating
the brake and clutch levers ...... 6-29
Checking and lubricating
the sidestand ............................ 6-30
Lubricating the swingarm
pivots ........................................ 6-30
Checking the front fork ................. 6-31
Checking the steering .................. 6-31
Checking the wheel bearings ....... 6-32
Battery ......................................... 6-32
Replacing the fuses ..................... 6-34
Replacing a headlight bulb .......... 6-35U13SE0E0.book Page 1 Monday, August 27, 2007 4:53 PM

DESCRIPTION
2-2
2
EAU10420
Right view1. Luggage strap holder (page 3-26)
2. Helmet holder (page 3-20)
3. Fuse box 1 (page 6-34)
4. Main fuse (page 6-34)
5. Fuel injection system fuse (page 6-34)
6. Battery (page 6-32)
7. Air filter element (page 6-19)
8. Front brake fluid reservoir (page 6-25)9. Radiator cap (page 6-15)
10.Coolant reservoir (page 6-15)
11.Engine oil filler cap (page 6-12)
12.Coolant drain bolt (page 6-16)
13.Dipstick (page 6-12)
14.Brake pedal (page 3-16)
15.Rear brake light switch (page 6-24)
16.Rear brake fluid reservoir (page 6-25)
U13SE0E0.book Page 2 Monday, August 27, 2007 4:53 PM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-17
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-12
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-15
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-24, 6-25
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-24, 6-25
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-23
U13SE0E0.book Page 2 Monday, August 27, 2007 4:53 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU1770A
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.


From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*Fuel lineCheck fuel hoses for cracks or
damage.√√√√√
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km (24000 mi)
4*Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
U13SE0E0.book Page 2 Monday, August 27, 2007 4:53 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18680
NOTE:

Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
29*Front and rear brake
switchesCheck operation.√√√√√√
30Moving parts and
cablesLubricate.√√√√√
31*Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.√√√√√
32*Air induction sys-
temCheck the air cut-off valve, reed
valve, and hose for damage.
Replace any damaged parts if
necessary.√√√√√
33*Muffler and exhaust
pipeCheck the screw clamp for loose-
ness.√√√√√
34*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)U13SE0E0.book Page 5 Monday, August 27, 2007 4:53 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 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.
U13SE0E0.book Page 6 Monday, August 27, 2007 4:53 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU22580
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
U13SE0E0.book Page 25 Monday, August 27, 2007 4:53 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU22730
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake hoses: Replace every four
years.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU39052
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
Drive chain slack:
30.0–45.0 mm (1.18–1.77 in)
1. Drive chain slack
U13SE0E0.book Page 26 Monday, August 27, 2007 4:53 PM