2009 YAMAHA YZF-R6 clutch

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
NOTICE
ECA11831
If a warning or indicator light does
not go off, see page 3-4 for the corre-
sponding warning and indicatorlight circuit check.
2. Shift the transmission into the neu-
tral position. (See page 5-2.) The
neutral indicator light should come
on. If not, ask a Yamaha dealer to
check the electrical circuit.
3. Start the engine by pushing the
start switch. NOTICE: For maxi-
mum engine life, never acceler-
ate hard when the engine is
cold!
[ECA11041]
If the engine fails to start, release
the start switch, wait a few sec-
onds, and then try again. Each
starting attempt should be as short
as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one at-
tempt.
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel, and then slightly raise it.
NOTICE
ECA10260


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand theshock of forced shifting.
1. Shift pedal
2. Neutral position
U13SE1E0.book Page 2 Monday, July 7, 2008 1:43 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU1770A
Periodic maintenance and lubrication chart TIP

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
U13SE1E0.book Page 2 Monday, July 7, 2008 1:43 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
17Brake pedal pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
18Clutch lever pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
19Shift pedal pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
20 SidestandCheck operation.
Lubricate.√√√√√
21*Sidestand switchCheck operation.√√√√√√
22*Front forkCheck operation and for oil leak-
age.√√√√
23*Shock absorber as-
semblyCheck operation and shock ab-
sorber for oil leakage.√√√√
24*Rear suspension re-
lay arm and con-
necting arm
pivoting pointsCheck operation.√√√√
25*Fuel injection sys-
temAdjust synchronization.√√√√√
26 Engine oilChange.
Check oil level and vehicle for oil
leakage.√√√√√√
27Engine oil filter car-
tridgeReplace.√√√
28*Cooling systemCheck coolant level and vehicle
for coolant leakage.√√√√√
Change. Every 3 years 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)U13SE1E0.book Page 4 Monday, July 7, 2008 1:43 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
611. Install the fuel tank breather/over-
flow hoses into the guides, then
place them in their original posi-
tion.
12. Install the shift arm by aligning the
match mark on the shift arm with
the match mark on the shift shaft
and installing the bolt, then tighten-
ing it to the specified torque.
NOTICE: Be sure to align the
match marks to ensure proper
shifting. If the match marks are
not aligned, the shift arm willnot move correctly and you may
not be able to shift up or down.
[ECA15342]
13. Install the engine oil drain bolt, and
then tighten it to the specified
torque.TIPCheck the washer for damage and re-place it if necessary.14. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-tem have cooled down.NOTICE
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
1. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
1. Bolt
2. Shift shaft
3. Match marks
4. Shift armTightening torque:
Shift arm bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.40 L (2.54 US qt, 2.11 Imp.qt)
With oil filter cartridge replacement:
2.60 L (2.75 US qt, 2.29 Imp.qt)
U13SE1E0.book Page 14 Monday, July 7, 2008 1:43 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6
EAU21960
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU33891
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
To increase the clutch lever free play,
turn the clutch lever free play adjusting
bolt at the clutch lever in direction (a).
To decrease the clutch lever free play,
turn the adjusting bolt in direction (b).
TIPIf the specified clutch lever free play
cannot be obtained as describedabove, proceed as follows.
1. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
2. Loosen the locknut at the crank-
case.
3. To increase the clutch lever free
play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free play,
turn the adjusting nut in direction
(b).
1. Clutch lever free play adjusting bolt
2. Clutch lever free play
1. Locknut
2. Clutch lever free play adjusting nut (crank-
case)
U13SE1E0.book Page 22 Monday, July 7, 2008 1:43 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
6
EAU23142
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.
EAU23202
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
EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-sulting in a possible loss of control.
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
U13SE1E0.book Page 29 Monday, July 7, 2008 1:43 PM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
2040 mm (80.3 in)
Overall width:
705 mm (27.8 in)
Overall height:
1100 mm (43.3 in)
Seat height:
850 mm (33.5 in)
Wheelbase:
1380 mm (54.3 in)
Ground clearance:
130 mm (5.12 in)
Minimum turning radius:
3600 mm (141.7 in)Weight:With oil and fuel:
185.0 kg (408 lb)Engine:Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 4-cylinder
Displacement:
599.0 cm³
Bore × stroke:
67.0 × 42.5 mm (2.64 × 1.67 in)
Compression ratio:
13.10 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE 10W-40, SAE 10W-50, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Without oil filter cartridge replacement:
2.40 L (2.54 US qt, 2.11 Imp.qt)
With oil filter cartridge replacement:
2.60 L (2.75 US qt, 2.29 Imp.qt)Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator capacity (including all routes):
2.30 L (2.43 US qt, 2.02 Imp.qt)Air filter:Air filter element:
Oil-coated paper elementFuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
17.3 L (4.57 US gal, 3.81 Imp.gal)
Fuel reserve amount:
3.5 L (0.92 US gal, 0.77 Imp.gal)Fuel injection:Throttle body:
Manufacturer:
MIKUNI
Type/quantity:
41EIDW/1
Spark plug (s):Manufacturer/model:
NGK/CR10EK
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
85/41 (2.073)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
45/16 (2.813)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
Gear ratio:
1st:
31/12 (2.583)
2nd:
32/16 (2.000)
3rd:
30/18 (1.667)
4th:
26/18 (1.444)
5th:
27/21 (1.286)
6th:
23/20 (1.150)
U13SE1E0.book Page 1 Monday, July 7, 2008 1:43 PM

INDEXAAir filter element .................................... 6-18
Anti-theft alarm (optional)...................... 3-13
Auxiliary light ......................................... 6-37BBattery................................................... 6-31
Brake and clutch levers,
checking and lubricating ..................... 6-29
Brake and shift pedals,
checking and lubricating ..................... 6-28
Brake fluid, changing ............................ 6-25
Brake fluid level, checking .................... 6-24
Brake lever ............................................ 3-16
Brake pedal ........................................... 3-16CCables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converters .............................. 3-19
Clutch lever ........................................... 3-15
Clutch lever free play, adjusting ............ 6-22
Coolant.................................................. 6-15
Coolant temperature warning light .......... 3-5
Cowlings and panels,
removing and installing ......................... 6-7DDimmer switch ...................................... 3-14
Drive chain, cleaning and lubricating .... 6-27
Drive chain slack ................................... 6-25EEngine break-in ....................................... 5-3
Engine idling speed, checking .............. 6-18
Engine oil and oil filter cartridge ............ 6-12
Engine stop switch ................................ 3-14
Engine trouble warning light.................... 3-7EXUP system ....................................... 3-27
FFront and rear brake pads, checking .... 6-23
Front fork, adjusting .............................. 3-22
Front fork, checking .............................. 6-30
Fuel....................................................... 3-17
Fuel consumption, tips for reducing........ 5-3
Fuel level warning light ........................... 3-4
Fuel tank breather/overflow hose ......... 3-19
Fuel tank cap ........................................ 3-17
Fuses, replacing ................................... 6-33HHandlebar switches .............................. 3-14
Hazard switch ....................................... 3-15
Headlight bulb, replacing ...................... 6-34
Helmet holding cable ............................ 3-21
High beam indicator light ........................ 3-4
Horn switch ........................................... 3-14IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-28
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-7
Indicator and warning lights .................... 3-4KKey identification number ....................... 9-1LLicense plate light bulb, replacing ........ 6-36
Luggage strap holders .......................... 3-27MMain switch/steering lock........................ 3-2
Matte color, caution ................................ 7-1
Model label ............................................. 9-2
Multi-function meter unit ......................... 3-7
NNeutral indicator light .............................. 3-4OOil level warning light .............................. 3-4PParking .................................................... 5-4
Part locations .......................................... 2-1
Pass switch ........................................... 3-14
Periodic maintenance and lubrication
chart ...................................................... 6-2
Pre-operation check list........................... 4-2RRear brake light switch, adjusting ......... 6-23SSafety information ................................... 1-1
Seats ..................................................... 3-20
Shifting .................................................... 5-2
Shift pedal ............................................. 3-15
Shift timing indicator light ........................ 3-7
Shock absorber assembly, adjusting .... 3-24
Sidestand .............................................. 3-28
Sidestand, checking and lubricating...... 6-29
Spark plugs, checking ........................... 6-11
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch............................................ 3-14
Steering, checking................................. 6-31
Storage.................................................... 7-4
Supporting the motorcycle .................... 6-37
Swingarm pivots, lubricating ................. 6-30TTail/brake light ....................................... 6-35
Throttle cable free play, checking ......... 6-19
U13SE1E0.book Page 1 Monday, July 7, 2008 1:43 PM