2015 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
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 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 ................................... 3-24
Luggage strap holders ................. 3-27 EXUP system ................................ 3-27
Sidestand ...................................... 3-28
Ignition circuit cut-off system ....... 3-28
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 ............................................ 6-20
Valve clearance............................. 6-20
Tires .............................................. 6-20
Cast wheels .................................. 6-23
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 .............. 6-27
Drive chain slack........................... 6-27
Cleaning and lubricating the drive chain.......................................... 6-29
Checking and lubricating the cables ........................................ 6-29
Checking and lubricating the
throttle grip and cable ............... 6-30
Checking and lubricating the brake and shift pedals............... 6-30
Checking and lubricating the brake and clutch levers ............. 6-31
Checking and lubricating the
sidestand................................... 6-31
Lubricating the swingarm pivots......................................... 6-32
Checking the front fork ................. 6-32
Checking the steering................... 6-33U2CXE1E0.book Page 1 Friday, July 25, 2014 11:05 AM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15598
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
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an acci dent or equipment damag e.
Do not operate the vehicle if you fin d any pro blem. If a pro blem cannot be corrected b y the proce dures provi ded in
this manual, have the vehicle inspecte d b y a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel • Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose and overflow hose for obstructions, cracks or
damage, and check hose connections. 3-17, 3-19
En gine oil • Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage. 6-13
Coolant • Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage. 6-16
Front brake • Check 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 specified brake fluid to specified level.
• Check hydraulic system for leakage. 6-25, 6-25
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake • Check 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 specified brake fluid to specified level.
• Check hydraulic system for leakage. 6-25, 6-25
Clutch • Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
6-23
Throttle g rip • Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing. 6-20, 6-30
Control ca bles • Make sure that operation is smooth.
• Lubricate if necessary. 6-29
Drive chain • Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.
6-27, 6-29
Wheels an d tires •Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
6-20, 6-23
Brake an d shift pe dals • Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary. 6-30
Brake an d clutch levers • Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-31
Si destan d • Make sure that operation is smooth.
• Lubricate pivot if necessary.
6-31
ITEM
CHECKS PAGE
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770K
General maintenance and lu brication chartNO. ITEM CHECK OR MAINTENANCE JOB ODOMETER 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 element •Replace. √
2Clutch • Check operation.
•Adjust.
√√√√√
3 *Front brake • Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
• Replace brake pads. Whenever worn to the limit
4 *Rear brake • Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
• Replace brake pads. Whenever worn to the limit
5 *Brake hoses • Check for cracks or damage.
• Check for correct routing and
clamping. √√√√√
• Replace. Every 4 years
6 *Brake flui d • Replace. Every 2 years
7 *Wheels • Check runout and for damage. √√√√
8 *Tires • Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√√√√
9 *Wheel bearin gs • Check bearings for looseness or
damage. √√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6
EAU22393
Checking the front an d rear
b rake pa dsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU36891
Front brake pa ds
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 to
the point that a wear indicator almost touches the brake disc, have a
Yamaha dealer replace the brake pads as a set.
EAU46292
Rear brake pad s
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.
EAU22582
Checkin g the brake flui d levelBefore riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
1. Brake pad wear indicator
1. Brake pad wear indicator groove
1
1
1. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6
Rear
brake
WARNING
EWA15991
Improper maintenance can result in
loss of b raking a bility. O bserve
these precautions:  Insufficient brake flui d may al-
low air to enter the brake sys-
tem, re ducin g brakin g
performance.
 Clean the filler cap before re-
movin g. Use only DOT 4 brake
flui d from a seale d container. 
Use only the specified b rake flu-
i d ; otherwise, the ru bber seals
may deteriorate, causin g leak-
a g e.
 Refill with the same type of
brake flui d. A dding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
 Be careful that water d oes not
enter the brake flui d reservoir
when refillin g. Water will si gnifi-
cantly lower the boilin g point of
the flui d an d may result in vapor
lock.
NOTICE
ECA17641
Brake flui d may d amage painte d
surfaces or plastic parts. Always
clean up spilled fluid imme diately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
1. Minimum level markSpecifie
d b rake flui d:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-41
6have
been removed , otherwise
the brake pa ds will be forced
shut.
[ECA11052]
To install the front wheel 1. Lift the wheel up between the fork legs.
2. Insert the wheel axle.
3. Install the axle bolt, lower the front wheel so that it is on the ground,
and then put the sidestand down.
4. Install the brake caliper on each side by installing the bolts.
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 holder oneach side by installing the bolt and
nut.
6. Tighten the brake caliper bolts and the brake hose holder bolts to the
specified torques.
7. 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.
8. Tighten wheel axle pinch bolt B,then pinch bolt A to the specified
torque.
9. Retighten pinch bolt B to the specified torque.
10. Tap the outer side of the right fork leg with a rubber mallet to align it
with the end of the wheel axle.
11. Tighten wheel axle pinch bolt D, then pinch bolt C to the specified
torque.
1. Wheel axle
Tightenin g torques:
Brake caliper bolt: 35 Nm (3.5 m·kgf, 25 ft·lbf)
Brake hose holder bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ti ghtenin g 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 DTightenin g torque:
Wheel axle pinch bolt: 21 Nm (2.1 m·kgf, 15 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-43
6
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 b rake
after the wheel an d b rake disc
have been removed , otherwise
the brake pa ds will be forced
shut.
[ECA11073]
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
before installing the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Install the axle nut, and then lower the rear wheel so that it is on the
ground, and then put the side-
stand down.
4. Adjust the drive chain slack. (See page 6-27.)
5. Tighten the axle nut to the speci- fied torque.
6. Tighten the drive chain slack ad- justing bolts in direction (b) to their
specified torque.
1. Wheel axle
1. Retainer
2. SlotTightenin g torque:
Axle nut: 110 Nm (11 m·kgf, 80 ft·lbf)
U2CXE1E0.book Page 43 Friday, July 25, 2014 11:05 AM