2011 YAMAHA YZF-R6 brake pads

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 lights and warning
lights ............................................3-4
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-14
Handlebar switches ......................3-14
Clutch lever ...................................3-15
Shift pedal .....................................3-16
Brake lever ...................................3-16
Brake pedal ..................................3-17
Fuel tank cap ................................3-17
Fuel ...............................................3-18
Fuel tank breather/overflow
hose ..........................................3-19
Catalytic converters ......................3-19
Seats ............................................3-20
Helmet holding cable ....................3-21
Rear view mirrors .........................3-22
Adjusting the front fork ..................3-23
Adjusting the shock absorber
assembly ...................................3-25Luggage strap holders ................. 3-27
EXUP system ............................... 3-28
Sidestand ..................................... 3-28
Ignition circuit cut-off system ........ 3-29
FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 4-1
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
ADJUSTMENT................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the
emission control system ............. 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing cowlings
and panels .................................. 6-8
Checking the spark plugs ............. 6-12
Engine oil and oil filter cartridge ... 6-13
Coolant ......................................... 6-16
Air filter element ........................... 6-19Checking the engine idling
speed ........................................ 6-19
Checking the throttle grip free
play ........................................... 6-19
Valve clearance ........................... 6-20
Tires ............................................. 6-20
Cast wheels ................................. 6-22
Adjusting the clutch lever free
play ........................................... 6-23
Checking the brake lever free
play ........................................... 6-24
Brake light switches ..................... 6-24
Checking the front and rear brake
pads .......................................... 6-25
Checking the brake fluid level ...... 6-25
Changing the brake fluid .............. 6-26
Drive chain slack .......................... 6-27
Cleaning and lubricating the drive
chain ......................................... 6-28
Checking and lubricating the
cables ....................................... 6-29
Checking and lubricating the
throttle grip and cable ............... 6-29
Checking and lubricating the
brake and shift pedals .............. 6-30
Checking and lubricating the
brake and clutch levers ............ 6-30
Checking and lubricating the
sidestand .................................. 6-31
Lubricating the swingarm
pivots ........................................ 6-31U13SE3E0.book Page 1 Tuesday, June 8, 2010 4:39 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather/overflow hose for obstructions, cracks or damage, and
check hose connection.3-18, 3-19
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-13
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-16
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.6-25, 6-25
U13SE3E0.book Page 1 Tuesday, June 8, 2010 4:39 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
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.6-25, 6-25
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-23
Throttle gripMake sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable
and grip housing.6-19, 6-29
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-29
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-27, 6-28
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-20, 6-22
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-30
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-30
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-31 ITEM CHECKS PAGE
U13SE3E0.book Page 2 Tuesday, June 8, 2010 4:39 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart 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*Air filter elementReplace.√
2ClutchCheck operation.
Adjust.√√√√√
3*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
4*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
5*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
6*WheelsCheck runout and for damage.√√√√
7*TiresCheck tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
8*Wheel bearingsCheck bearing for looseness or
damage.√√√√
9*SwingarmCheck operation and for exces-
sive play.√√√√
Lubricate with lithium-soap-based
grease.Every 50000 km (30000 mi)
U13SE3E0.book Page 4 Tuesday, June 8, 2010 4:39 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6
EAU22392
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36890
Front brake pads
Each front brake pad is provided with
wear indicators, which allows you to
check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
of the wear indicators while applying
the brake. If a brake pad has worn tothe point that a wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU46291
Rear brake pads
Each rear brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that a wear
indicator groove almost appears, have
a Yamaha dealer replace the brake
pads as a set.
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.
1. Brake pad wear indicator
1. Brake pad wear indicator groove
1
1
1. Minimum level mark
1. Minimum level mark
U13SE3E0.book Page 25 Tuesday, June 8, 2010 4:39 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6Before 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.
EAU22731
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.

Oil seals: Replace every two
years.


Brake hoses: Replace every four
years.
Recommended brake fluid:
DOT 4
U13SE3E0.book Page 26 Tuesday, June 8, 2010 4:39 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-40
63. 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]EAU33934
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, and then put the sidestand
down.
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 brake
discs.
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 hexagon
wrench to keep it from turning.7. Tighten wheel axle pinch bolt B,
then pinch bolt A to the specified
torque.
1. Brake hose holder
2. Bolt and nut
3. Brake caliper bolt
4. Brake caliper
5. Axle bolt
1. Wheel axle
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)
U13SE3E0.book Page 40 Tuesday, June 8, 2010 4:39 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-42
64. Fully loosen the locknut on each
side of the swingarm.
5. Turn the drive chain slack adjust-
ing bolts in direction (a) to loosen
the drive chain enough so it can be
removed from the rear sprocket,
and then push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
TIP

If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.


The drive chain cannot be disas-
sembled.
7. While supporting the brake caliper
bracket, pull the wheel axle out,
and then remove the wheel.
NOTICE: Do not apply the brake
after the wheel has been re-
moved together with the brake
disc, otherwise the brake pads
will be forced shut.
[ECA11071]EAU39172
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.TIP

Be sure to insert the retainer on the
brake caliper bracket into the slot
in the swingarm.


Make sure that there is enough
space between the brake pads be-
fore installing the wheel.
1. Drive chain slack adjusting bolt
2. Locknut
(a)
12
1. Wheel axle
U13SE3E0.book Page 42 Tuesday, June 8, 2010 4:39 PM