2012 YAMAHA YZF-R6 valve

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 hose and
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 ..................3-22
Adjusting the shock absorber assembly ...................................3-25 Luggage 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 ........................... 6-19 Checking 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 ........................................... 6-23
Brake light switches ..................... 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 .......................... 6-27
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 ........................................ 6-31U1JSE0E0.book Page 1 Wednesday, July 27, 2011 10:34 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
EAU13221
Fuel Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.1. Before refueling, turn off the en-gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank. 3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.
[ECA10071]
4. Be sure to securely close the fuel tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi- ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU13391
NOTICE
ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.Your Yamaha engine has been de-
signed to use premium unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different
1. Fuel tank filler tube
2. Maximum fuel level
2
1
Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity: 17.3 L (4.57 US gal, 3.81 Imp.gal)
Fuel reserve amount (when the fuel
level warning light comes on): 3.5 L (0.92 US gal, 0.77 Imp.gal)
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INSTRUMENT AND CONTROL FUNCTIONS
3-28
3
EAU41941
EXUP system This model is equipped with Yamaha’s
EXUP (EXhaust Ultimate Power valve)
system. This system boosts engine
power by means of a valve that regu-
lates the inner diameter of the exhaust
pipe. The EXUP system valve is con-
stantly adjusted in accordance with the
engine speed by a computer-controlled
servomotor.NOTICE
ECA15610
The EXUP system has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU15305
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.TIPThe built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See the following section for an expla-
nation of the ignition circuit cut-off sys-
tem.)
WARNING
EWA10241
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, checkthis system regularly and have a
Yamaha dealer repair it if it does not
function properly.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU46861
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 technical
skills.
EAU46910
Periodic maintenance chart for the emission control system 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 line Check fuel hoses for cracks or
damage. √√√√√
2 *Spark plugs Check condition.
Clean and regap.
√√
Replace. √√
3 *Valves Check valve clearance.
Adjust.
Every 40000 km (24000 mi)
4 *Fuel injection sys-
tem Adjust synchronization.
√√√√√
5 *Muffler and exhaust
pipe Check the screw clamp(s) for
looseness. √√√√√
6 *Air induction sys-
tem Check the air cut-off valve, reed
valve, and hose for damage.
Replace any damaged parts if necessary. √√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU21775
Tires To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10503
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.●
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
●
The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
WARNING
EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.Tire air pressure (measured on cold
tires):0–90 kg (0–198 lb):Front:
250 kPa (2.50 kgf/cm², 36 psi)
Rear: 290 kPa (2.90 kgf/cm², 42 psi)
90–186 kg (198–410 lb): Front:250 kPa (2.50 kgf/cm², 36 psi)
Rear: 290 kPa (2.90 kgf/cm², 42 psi)
High-speed riding:
Front:250 kPa (2.50 kgf/cm², 36 psi)
Rear:
290 kPa (2.90 kgf/cm², 42 psi)
Maximum load*: 186 kg (410 lb)
* Total weight of rider, passenger, car- go and accessories
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
TIPThe tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
WARNING
EWA10471
●
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.
●
The replacement of all wheel
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the necessary professional knowl-
edge and experience to do so.
●
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
Tire information
This motorcycle is equipped with tube-
less tires, tire air valves and cast
wheels.
WARNING
EWA10481
●
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle may be different, which
could lead to an accident.
●
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear): 1.6 mm (0.06 in)
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
U1JSE0E0.book Page 21 Wednesday, July 27, 2011 10:34 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6
●
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA10600
This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.●
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
●
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
(60 mi) after installing a new tire.
●
The tires must be warmed up
before a high-speed run.
●
Always adjust the tire air pres-
sure according to the operating
conditions.
EAU21962
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, warpage or oth-
er damage before each ride. If any
damage is found, have a Yamaha
dealer replace 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.
Front tire:Size:120/70 ZR17M/C (58W)
Manufacturer/model: BRIDGESTONE/BT016F F
DUNLOP/Qualifier PT M
Rear tire: Size:180/55 ZR17M/C (73W)
Manufacturer/model: BRIDGESTONE/BT016R F
DUNLOP/Qualifier PT M
FRONT and REAR: Tire air valve:TR412
Va l ve c o r e : #9100 (original)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-33
6
EAU23291
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU50210
Battery The battery is located under the rider
seat. (See page 3-20.)
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electro-
lyte or to add distilled water. However,
the battery lead connections need to be
checked and, if necessary, tightened.
WARNING
EWA10760
●
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact withskin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty of water.
INTERNAL: Drink large quan- tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15 minutes and seek prompt
medical attention.
●
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
●
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that the
1. Battery
2. Negative battery lead (black)
3. Positive battery lead (red)
1
2
3
U1JSE0E0.book Page 33 Wednesday, July 27, 2011 10:34 AM