2009 YAMAHA YZF-R6 torque

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, 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, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer performservice.
WARNING
EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.

A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.


Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-ide.
EAU17542
Owner’s tool kit The owner’s tool kit is located under the
passenger seat. (See page 3-20.)
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.TIPIf you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.1. Owner’s tool kit
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
EAU19652
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.NOTICE
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twistit back and forth while pushing it in.
Specified spark plug:
NGK/CR10EK
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6 5. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
TIPSkip steps 6–12 if the oil filter cartridgeis not being replaced.
6. Remove the shift arm by removing
the bolt and pulling it off the shift
shaft.
7. Remove the fuel tank breath-
er/overflow hoses from the guides.8. Remove the oil filter cartridge with
an oil filter wrench.
TIPAn oil filter wrench is available at aYamaha dealer.
9. Apply a thin coat of clean engine
oil to the O-ring of the new oil filter
cartridge.TIPMake sure that the O-ring is properlyseated.
10. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
1. Engine oil drain bolt
1. Bolt
2. Shift arm
3. Engine oil filter cartridge
4. Guide
5. Fuel tank breather/overflow hose
1. Oil filter wrench
1. O-ring
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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)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6 6. Move the hose clamp in the direc-
tion shown, and then disconnect
the radiator hose to drain the radi-
ator.
7. Remove the coolant reservoir by
removing the bolts.
8. Remove the coolant reservoir cap,
and then turn the coolant reservoir
upside down to empty it.9. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
10. Install the coolant reservoir by in-
stalling the bolts.
11. Connect the radiator hose, and
then move the hose clamp back to
its original position.
12. Install the coolant drain bolt, and
then tighten it to the specified
torque.
TIPCheck the washer for damage and re-place it if necessary.13. Pour the recommended coolant
into the reservoir to the maximum
level mark, and then install the
coolant reservoir cap.
14. Pour the recommended coolant
into the radiator until it is full.
15. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
1. Coolant drain bolt
2. Hose clamp
3. Radiator hose
1. Coolant reservoir cap
2. Coolant reservoir
3. Bolt
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol anti-
freeze containing corrosion inhibitors
for aluminum engines
Coolant quantity:
Radiator capacity (including all
routes):
2.30 L (2.43 US qt, 2.02 Imp.qt)
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
64. If the drive chain slack is incorrect,
adjust it as follows.
EAU39054
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.2. To tighten the drive chain, turn the
drive chain slack adjusting bolt on
each side of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt on each side
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10571]
TIPUsing the alignment marks on each
chain puller, make sure that both chain
pullers are in the same position for
proper wheel alignment. Use the end of
the swingarm as the reference point forthe alignment marks.
3. Tighten the axle nut to the speci-
fied torque.
4. Tighten the adjusting bolts in direc-
tion (a) to their specified torque.
5. Tighten the locknuts to their speci-
fied torque.
1. Drive chain slack
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
Tightening torque:
Axle nut:
110 Nm (11.0 m·kgf, 80 ft·lbf)
Tightening torque:
Drive chain slack adjusting bolt:
2 Nm (0.2 m·kgf, 1.4 ft·lbf)
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
EAU24360
Front wheel
EAU33923
To remove the front wheel
WARNING
EWA10821
To avoid injury, securely support the
vehicle so there is no danger of itfalling over.
1. Loosen the front wheel axle pinch
bolts, the axle bolt, and then the
brake caliper bolts.
2. Lift the front wheel off the ground
according to the procedure on
page 6-37.3. Remove the brake hose holder on
each side by removing the bolt and
nut.
4. Remove the brake caliper on each
side by removing the bolts.
5. Remove the axle bolt, push the
wheel axle out from the left side,
and then remove the wheel.
NOTICE: Do not apply the brake
after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11051]EAU33933
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Install the axle bolt, and then lower
the front wheel so that it is on the
ground.
4. Install the brake calipers by install-
ing the bolts, and then tightening
them to the specified torque.TIPMake sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brakediscs.
1. Front wheel axle pinch bolt
1. Brake hose holder
2. Bolt and nut
3. Brake caliper bolt
4. Brake caliper
5. Axle bolt
1. Wheel axle
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
6 5. Install the brake hose holders by
installing the bolts and nuts.
6. Tighten the axle bolt to the speci-
fied torque.
TIPWhile tightening the axle bolt, hold the
wheel axle with a 19-mm hexagonwrench to keep it from turning.
7. Tighten wheel axle pinch bolt B,
then pinch bolt A to the specified
torque.8. Retighten pinch bolt B to the spec-
ified torque.
9. Tap the outer side of the right fork
leg with a rubber mallet to align it
with the end of the wheel axle.
10. Tighten wheel axle pinch bolt D,
then pinch bolt C to the specified
torque.
11. Retighten pinch bolt D to the spec-
ified torque.12. While applying the front brake,
push down hard on the handlebar
several times to check for proper
fork operation.Tightening torque:
Brake caliper bolt:
35 Nm (3.5 m·kgf, 25 ft·lbf)
Tightening torque:
Axle bolt:
91 Nm (9.1 m·kgf, 66 ft·lbf)
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
Tightening torque:
Wheel axle pinch bolt:
21 Nm (2.1 m·kgf, 15 ft·lbf)
Tightening torque:
Wheel axle pinch bolt:
21 Nm (2.1 m·kgf, 15 ft·lbf)
U13SE1E0.book Page 39 Monday, July 7, 2008 1:43 PM