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OWNER’S MANUAL

YZF-R6
5EB-28199-E2
E_5eb_Intro0.fm Page 1 Thursday, November 18, 1999 4:00 PM

EAU00001
INTRODUCTION

Welcome to the Yamaha world of motorcycling!

As the owner of a YZF-R6, you are benefiting from Yamaha’s vast experience in and
newest technology for the design and the manufacture of high-quality products,
which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your YZF-R6’s
advantages. The owner’s manual does not only instruct you in how to operate,
inspect and maintain your motorcycle, but also in how to safeguard yourself and oth-
ers from trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in
the best possible condition. If you have any further questions, do not hesitate to con-
tact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put
safety first!
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IMPORTANT MANUAL INFORMATION EAU00005

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

NOTE:
@

● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If there is any
question concerning this manual, please consult your Yamaha dealer.
@
E_5eb_Info0.fm Page 2 Thursday, November 18, 1999 4:01 PM

IMPORTANT MANUAL INFORMATION


EW000002

@
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
@
E_5eb_Info0.fm Page 3 Thursday, November 18, 1999 4:01 PM

IMPORTANT MANUAL INFORMATION

EAU00008

YZF-R6
OWNER’S MANUAL
© 1999 by Yamaha Motor Co., Ltd.
1st Edition, November 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
E_5eb_Toc0.fm Page 1 Thursday, November 18, 1999 4:01 PM

EAU00009
TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY 1

2 DESCRIPTION 2

3 INSTRUMENT AND CONTROL FUNCTIONS 3

4 PRE-OPERATION CHECKS 4

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

8 SPECIFICATIONS 8

9 CONSUMER INFORMATION 9

INDEX
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E_5eb_LabelTOC.fm Page 1 Thursday, November 18, 1999 4:01 PM

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY................................................. 1-1

1
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GIVE SAFETY THE RIGHT OF WAY


1-
EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving your motorcycle’s value and operating
condition. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders - more than car drivers - must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Though full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively - avoiding all dangers, including those caused by others.

Enjoy your ride!

1-1
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DESCRIPTION

Left view ............................................................................................. 2-1


Right view........................................................................................... 2-2
Controls/Instruments .......................................................................... 2-3

2
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DESCRIPTION
2-
EAU00026

Left view

1. Front fork compression damping force 6. Rear shock absorber spring preload
adjusting screw (page 3-19) adjusting ring (page 3-20)
2. Front fork rebound damping force 7. Rear shock absorber rebound damping
adjusting screw (page 3-18) force adjusting knob (page 3-20)
3. Front fork spring preload adjusting bolt (page 3-18) 8. Shift pedal (page 3-11)
4. Air filter (page 6-17) 9. Coolant reservoir tank (page 6-13)
5. Rear shock absorber compression 10. Engine oil filter (page 6-11)
damping force adjusting screw (page 3-20)

2-1
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DESCRIPTION
Right view

11. Luggage strap holders (page 3-23)


12. Tool kit (page 6-1)
13. Fuses (page 6-34)
14. Rear brake fluid reservoir
15. Radiator cap (page 6-14)
16. Front brake fluid reservoir
17. Rear brake pedal (page 3-12)

2-2
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DESCRIPTION
Controls/Instruments

1. Clutch lever (page 3-11) 6. Tachometer (page 3-8)


2. Left handlebar switches (page 3-9) 7. Right handlebar switches (page 3-10)
3. Starter (choke) “ ” (page 3-15) 8. Throttle grip (page 6-21)
4. Digital speedometer (page 3-7) 9. Front brake lever (page 3-11)
5. Main switch (page 3-1)

2-3
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INSTRUMENT AND CONTROL FUNCTIONS

Main switch/Steering lock .....................................3-1 Fuel tank cap ..................................................... 3-13


Indicator lights ......................................................3-2 Fuel .................................................................... 3-13
Oil level / coolant temperature indicator light Fuel tank breather hose ..................................... 3-14
circuit check ........................................................3-5 Starter (choke) “ ” .......................................... 3-15
Fuel indicator light circuit check............................3-6 Seats.................................................................. 3-15
Digital speedometer..............................................3-7 Helmet holder..................................................... 3-17
Tachometer ...........................................................3-8 3
Storage compartment ........................................ 3-17
Diagnosis device...................................................3-9 Front fork adjustment ......................................... 3-17
Handlebar switches ..............................................3-9 Rear shock absorber adjustment ....................... 3-19
Clutch lever .........................................................3-11 Recommended combinations of the front fork
Shift pedal...........................................................3-11 and the rear shock absorber settings............... 3-22
Front brake lever .................................................3-11 Luggage strap holders ....................................... 3-23
Rear brake pedal ................................................3-12 Sidestand ........................................................... 3-23
Antitheft alarm (optional) ....................................3-12 Sidestand/clutch switch operation check............ 3-24
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INSTRUMENT AND CONTROL FUNCTIONS


3-
EAU00027

3
1. Push
EAU00029 EAU00040 2. Turn
Main switch/Steering lock LOCK EW000016

The main switch controls the ignition The steering is locked in this position WARNING
@

and lighting systems. Its operation is and all electrical circuits are switched Never turn the key to “OFF” or
described below. off. The key can be removed in this po- “LOCK” when the motorcycle is
sition. To lock the steering, turn the moving. The electrical circuits will
EAU00036 handlebars all the way to the left. While be switched off which may result in
ON pushing the key into the main switch, loss of control or an accident. Be
Electrical circuits are switched on. The turn it from “OFF” to “LOCK” and re- sure the motorcycle is stopped be-
engine can be started. The key cannot move it. To release the lock, turn the fore turning the key to “OFF” or
be removed in this position. key to “OFF” while pushing. “LOCK”.
@

EAU00038

OFF
All electrical circuits are switched off.
The key can be removed in this posi-
tion.

3-1
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INSTRUMENT AND CONTROL FUNCTIONS


EAU01237 EAU00057

(Parking) Turn indicator light “ ”


The steering is locked in this position, This indicator flashes when the turn
and the taillights and auxiliary lights switch is moved to the left or right.
come on, but all other circuits are off.
The key can be removed in this posi- EAU01154

Fuel indicator light “ ”


tion.
When the fuel level drops below ap-
To use the parking position, first lock
proximately 3.5 L, this light will come 3
the steering, then turn the key to “ ”.
on. When this light comes on, fill the
Do not use this position for an extend- 1. Neutral indicator light “ ”
2. High beam indicator light “ ” tank at the first opportunity. This light
ed length of time as the battery may
3. Turn indicator light “ ” circuit can be checked by the proce-
discharge. 4. Fuel indicator light “ ” dure on page 3-6.
EAU00056

Indicator lights
EAU00061

Neutral indicator light “ ”


This indicator comes on when the
transmission is in neutral.

EAU00063

High beam indicator light “ ”


This indicator comes on when the
headlight high beam is used.

3-2
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INSTRUMENT AND CONTROL FUNCTIONS


The light will come on and symbol

“ ” will flash if the coolant tem-
perature is too high. The following
chart shows the conditions of the
indicator light, symbol and tem-
perature display in accordance to
coolant temperature.
3 The light circuit can be checked by the
procedure on page 3-5.
1. Oil level symbol “ ” EC000118
2. Oil level/coolant temperature
indicator light “ ”
CAUTION:
@

3. Coolant temperature symbol “ ” ● Do not run the motorcycle until


EAU01564
you know it has sufficient en-
Oil level/coolant temperature indica-
gine oil.
tor light “ ”
● Do not run the motorcycle if the
This indicator light has two functions.
engine is overheated.
● The light will come on and symbol @

“ ” will flash if the engine oil lev- NOTE:


@

el is low. If this symbol flashes, Even if the oil is fislled to the specified
stop the engine immediately and level, the indicator light may flicker
fill it with oil to the specified level. when riding on a slope or during sud-
den acceleration or deceleration, but
this is normal.
@

3-3
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INSTRUMENT AND CONTROL FUNCTIONS


CB-77E
Coolant
Display Conditions What to do
temperature

˚C Symbol and “LO” are dis-


0 °C ~ 40 °C OK. Go ahead with riding.
played.

˚C Symbol and temperature


41 °C ~ 117 °C OK. Go ahead with riding
are displayed.

Stop the motorcycle and allow it


to idle until coolant temperature
˚C
goes down.
Symbol and temperature
If the temperature does not go
118 °C ~ 140 °C flash.
down, stop the engine. See
Indicator light comes on.
“Engine overheating” in the trou-
bleshooting chart on page 6-42
for instructions.

Stop the engine and allow it to


˚C Symbol and “HI” flash. cool. See “Engine overheating”
141 °C ~
Indicator light comes on. in the troubleshooting chart on
page 6-42 for instructions.

3-4
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INSTRUMENT AND CONTROL FUNCTIONS


EAU02987

Oil level / coolant temperature indicator light circuit check


CB-75E

Turn the main switch to “ON”.

Indicator comes on. After a few seconds: Indicator does not come on.

3
Indicator goes off. Indicator does not go off. Have a Yamaha dealer inspect
the electrical circuit.

Symbol “ ” or No symbol is on.


“ ” is displayed.

Have a Yamaha OK. Go ahead If symbol “ ” is If symbol “ ” is displayed, check the


dealer inspect the with riding. displayed, inspect engine temperature. (See page 3-4.)
electrical circuit. the oil level.

Oil level is OK. Oil level is low. If the engine is hot, If the engine
allow it to cool and see temperature is
Supply “Engine overheating” normal, have a
Have a Yamaha dealer
recommended in the troubleshooting Yamaha dealer
inspect the electrical
engine oil. chart on page 6-42 for inspect the
circuit.
instructions. electrical circuit.

3-5
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INSTRUMENT AND CONTROL FUNCTIONS


EAU01295

Fuel indicator light circuit check


CB-69E

Turn the main switch to “ON”.

Indicator comes on. Indicator does not come


After a few seconds: on.
3

Indicator goes off. Indicator does not go off. Have a Yamaha dealer
Inspect the fuel level. inspect the electric
circuit.

OK. Go ahead with Fuel level is OK. Fuel level is low.


riding. Have a Yamaha Supply recommended
dealer inspect the fuel.
electric circuit.

3-6
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INSTRUMENT AND CONTROL FUNCTIONS


Odometer and trip meter modes Resetting a meter
Use the trip meters to estimate how far To reset a trip odometer to 0.0, select it
you can ride on a tank of fuel. by pushing the “SELECT” button and
Use the fuel reserve trip meter to see push the “RESET” button for at least
the distance traveled from when the one second. To reset the fuel reserve
fuel level dropped to the reserve level. trip meter, select it by pushing the
“SELECT” button and push the
3 Selecting a mode “RESET” button for at least one sec-
Push the “SELECT” button to change ond. The display will return to “TRIP 1”.
1. Speedometer
2. Clock, odometer between the odometer mode “ODO” If you do not reset the fuel reserve trip
3. “SELECT” button and the trip odometer modes “TRIP 1” meter manually, it will automatically re-
4. “RESET” button and “TRIP 2” in the following order: set and return to “TRIP 1” after refuel-
EAU01601
“ODO” → “TRIP 1” → “TRIP 2” → ing and the motorcycle has traveled
Digital speedometer
“ODO” both 5 km and for approximately 3 min-
This speedometer is equipped with:
utes.
● an odometer
If the fuel level indicator light comes on
● two trip odometers NOTE:
(see page 3-2), the odometer display @

● a fuel reserve trip meter After the fuel reserve trip meter is reset,
will automatically change to the fuel re-
● a clock the display always returns to the
serve trip meter mode “TRIP F” and
“TRIP 1” mode. If “TRIP 2” was being
NOTE: start counting the distance traveled
@
used before the fuel reserve trip meter
For UK and USA models only: from that point. Push the “SELECT”
is reset, be sure to push the “SELECT”
To change the speedometer display button to change between the fuel
button to change back to the “TRIP 2”
from kilometers to miles, press the odometer, trip odometer and odometer
mode.
“SELECT” button for at least two sec- modes in the following order: @

onds. “TRIP F” → “TRIP 1” → “TRIP 2” →


“ODO” → “TRIP F”
@

3-7
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INSTRUMENT AND CONTROL FUNCTIONS


Clock mode NOTE:
@

To change the display to the clock After setting the clock, be sure to push
mode, push both the “SELECT” and the “SELECT” button before turning the
“RESET” buttons. main switch to “OFF”, otherwise the
To change the display back to the clock will not be set.
@

odometer mode, push the “RESET”


button.
3
To set the clock
1. Tachometer
1. Push both the “SELECT” and 2. Red zone
“RESET” buttons for at least two EAU00101

seconds. Tachometer
2. When the hour digits start flashing, This model is equipped with an electric
push the “RESET” button to set tachometer so the rider can monitor the
the hours. engine speed and keep it within the
3. Push the “SELECT” button to ideal power range.
EC000003
change the minutes.
4. When the minute digits start flash- CAUTION:
@

ing, push the “RESET” button to Do not operate in the red zone.
set the minutes. Red zone: 15,500 r/min and above
@

5. Push the “SELECT” button to start


the clock.

3-8
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INSTRUMENT AND CONTROL FUNCTIONS


EAU00105
Use this chart to identify what circuit is
Diagnosis device faulty according to the specified r/min
This model is equipped with a self diag- displayed.
nosis for the following circuits: CB-60E

● Throttle Position Sensor (T.P.S.) Specified r/min Faulty circuit


circuit Throttle Position Sensor
3,000 r/min
(T.P.S.)
● Fuel indicator light circuit
8,000 r/min Fuel indicator light
If some trouble should occur in any of
3
these circuits, the tachometer will re- If the tachometer displays as described
peatedly display as follows: above, take note of the specified r/min 1. Pass switch “PASS”
2. Dimmer switch
CB-53E and then take your motorcycle to a
3. Turn signal switch
0 r/min Specified r/min for Current Yamaha dealer for repair. 4. Horn switch “ ”
for 3 the faulty circuit engine EC000004 EAU00118
seconds for 2.5 seconds r/min for 3
(see chart below) seconds @
CAUTION: Handlebar switches
EAU00120
To prevent engine damage, be sure
Pass switch “PASS”
to consult a Yamaha dealer as soon
Press the switch to operate the passing
as possible if the tachometer dis-
light.
plays a repeated change in r/min.
@

EAU00121

Dimmer switch
Turn the switch to “ ” for the high
beam and to “ ” for the low beam.

3-9
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INSTRUMENT AND CONTROL FUNCTIONS


EAU00127 EAU01238

Turn signal switch Light switch


To signal a right-hand turn, push the Turning the light switch to “ ”,
switch to “ ”. To signal a left-hand turns on the auxiliary lights, meter
turn, push the switch to “ ”. Once the lights and taillights. Turning the light
switch is released it will return to the switch to “ ” turns the headlight on
center position. To cancel the signal, also.
push the switch in after it has returned
3
to the center position. EAU00143

Start switch “ ”
1. Engine stop switch
EAU00129 2. Lights switch The starter motor cranks the engine
Horn switch “ ” 3. Start switch “ ” when pushing the start switch.
EAU00138
Press the switch to sound the horn. EC000005
Engine stop switch
CAUTION:
The engine stop switch is a safety de- @

See starting instructions prior to


vice for use in an emergency such as
starting the engine.
when the motorcycle overturns or if @

trouble occurs in the throttle system.


Turn the switch to “ ” to start the en-
gine. In case of emergency, turn the
switch to “ ” to stop the engine.

3-10
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Shift pedal
EAU00152 EAU00157 EAU00161

Clutch lever Shift pedal Front brake lever


The clutch lever is located on the left This motorcycle is equipped with a con- The front brake lever is located on the
handlebar, and the ignition circuit cut- stant-mesh 6-speed transmission. right handlebar and is equipped with a
off system is incorporated in the clutch The shift pedal is located on the left brake lever adjusting dial. To activate
lever holder. Pull the clutch lever to the side of the engine and is used in com- the front brake, pull the lever toward
handlebar to disengage the clutch, and bination with the clutch when shifting. the handlebar.
release the lever to engage the clutch.
The lever should be pulled rapidly and
released slowly for smooth clutch oper-
ation. (Refer to the engine starting pro-
cedures for a description of the ignition
circuit cut-off system.)

3-11
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INSTRUMENT AND CONTROL FUNCTIONS


EAU00109

Antitheft alarm (optional)


An antitheft alarm can be equipped to
this motorcycle. Consult your Yamaha
dealer to obtain and install the alarm.

3
1. Lever position adjusting dial 1. Rear brake pedal
2. Arrow mark EAU00162

a. Lever distance Rear brake pedal


To adjust the front brake lever position, The rear brake pedal is on the right
turn the brake lever adjusting dial while side of the motorcycle. Press down on
pulling the lever forward. Make sure the the brake pedal to apply the rear brake.
setting on the brake lever adjusting dial
is aligned with the arrow mark.

3-12
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INSTRUMENT AND CONTROL FUNCTIONS


NOTE:
@

This tank cap cannot be closed unless


the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
@

EW000023

@
WARNING
3 Be sure the cap is properly installed
1. Lock cover and locked in place before riding the 1. Filler tube
2. Open motorcycle. 2. Fuel level
EAU02935 @
EAU01183

Fuel tank cap Fuel


To open Make sure there is sufficient fuel in the
Open the lock cover. Insert the key and tank. Fill the fuel tank to the bottom of
turn it 1/4 turn clockwise. The lock will the filler tube as shown in the illustra-
be released and the cap can be tion.
opened. EW000130

@
WARNING
To close Do not overfill the fuel tank. Avoid
Push the tank cap into position with the spilling fuel on the hot engine. Do
key inserted. To remove the key, turn it not fill the fuel tank above the bot-
counterclockwise to the original posi- tom of the filler tube or it may over-
tion. Then, close the lock cover. flow when the fuel heats up later and
expands.
@

3-13
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INSTRUMENT AND CONTROL FUNCTIONS


EAU00185

CAUTION:
@

Always wipe off spilled fuel immedi-


ately with a dry and clean soft cloth.
Fuel may deteriorate painted surfac-
es or plastic parts.
@

EAU00191 3
Recommended fuel: 1. Fuel tank breather hose
EAU02955*
Regular unleaded gasoline with a
Fuel tank breather hose
research octane number of 91 or
This model is equipped with a fuel tank
higher.
breather hose.
Fuel tank capacity:
Before using this motorcycle:
Total:
● Check the fuel tank breather hose
17 L
connection.
Reserve:
● Check the fuel tank breather hose
3.5 L
for cracks or damage and replace
NOTE: it if damaged.
@

If knocking or pinging occurs, use a dif- ● Make sure the end of the fuel tank

ferent brand of gasoline or higher oc- breather hose is not blocked and
tane grade. clean it if necessary.
@

3-14
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INSTRUMENT AND CONTROL FUNCTIONS


ECA00038

CAUTION:
@

Do not use the starter (choke) for


more than 3 minutes as the exhaust
pipe may discolor from excessive
heat. Also, longer use of the starter
(choke) will cause afterburning. If af-
3 terburning occurs, turn off the
starter (choke).
1. Starter (choke) “ ” @ 1. Bolt (× 2)
EAU02973 EAU01890

Starter (choke) “ ” Seats


Starting a cold engine requires a richer Rider seat
air-fuel mixture. A separate starter cir- To remove
cuit supplies this mixture. Lift up the rear corners of the seat as
Move in direction a to turn on the shown and remove the bolts.
starter (choke).
Move in direction b to turn off the
starter (choke).

3-15
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Projection 1. Passenger seat lock 1. Projection
2. Seat holder 2. Open 2. Seat holder
To install Passenger seat To install
Insert the projection on the front of the To remove Insert the projection on the rear of the
seat into the seat holder and install the Insert the key into the seat lock and seat into the seat holder and push
bolts. turn it counterclockwise. While holding down on the front of the seat.
the key in that position, lift up the front
of the seat and pull it forward. NOTE:
@

Make sure that the seats are securely


fitted.
@

3-16
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INSTRUMENT AND CONTROL FUNCTIONS


EAU01862*

Front fork adjustment


This front fork is equipped with spring
preload and damping force adjusters.
EW000037

@
WARNING
Each fork leg must be set to the
same pressure. Uneven setting can
3
cause poor handling and loss of sta-
1. Helmet holder 1. Storage compartment bility.
EAU00265 EAU01242 @

Helmet holder Storage compartment


Remove the passenger seat and hook The storage compartment is located
the helmet into the helmet holder. Then under the passenger seat. (Refer to
install the passenger seat. page 3-15 for details on how to open
EW000030
the seat.)
@
WARNING EW000033

Never ride with a helmet in the hel- @


WARNING
met holder. The helmet may hit ob- Do not exceed maximum load. Maxi-
jects, causing loss of control and mum load: 3 kg
possibly an accident. @

3-17
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Spring preload adjusting bolt 1. Setting position 1. Rebound damping force adjusting screw
Adjusting spring preload 2. Front fork cap bolt Adjusting rebound damping force
Turn the adjusting bolt in direction a to in- Standard Turn adjusting screw in direction a to
CI-18E
crease spring preload and in direction b Hard Soft increase rebound damping force and in
to decrease spring preload. Align the Adjusting direction b to decrease rebound
1 2 3 4 5 6 7 8
preferred setting with the top of the position damping force.
front fork cap bolt. CI-33E
Minimum (soft) 9 clicks out*
EC000013
Standard 6 clicks out*
CAUTION:
@ Maximum (hard) 1 click out*
The grooves are provided to show * From the fully turned-in position
the adjustment level. Always keep
the adjustment level equal on both
fork legs.
@

3-18
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INSTRUMENT AND CONTROL FUNCTIONS


EAU01863
NOTE:
@

Although the number of clicks between Rear shock absorber


the minimum and maximum settings adjustment
may vary with each individual shock This shock absorber is equipped with
absorber and may not exactly match spring preload and damping force ad-
these specifications, it is always the full justers.
EC000015
damping force range that extends over
the actual number of clicks. CAUTION:
3 @

@
Never attempt to turn an adjuster
1. Compression damping force adjusting screw beyond the maximum or minimum
Adjusting compression damping setting.
force
Turn the adjusting screw in direction a
to increase compression damping
force and in direction b to decrease
compression damping force.
CI-33E
Minimum (soft) 10 clicks out*
Standard 6 clicks out*
Maximum (hard) 1 click out*
* From the fully turned-in position
EC000015

CAUTION:
@

Never attempt to turn an adjuster


beyond the maximum or minimum
setting.
@

3-19
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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Spring preload adjusting ring 1. Rebound damping force adjusting knob 1. Compression damping force adjusting screw
2. Special wrench Adjusting rebound damping force Adjusting compression damping
3. Position indicator
Turn the adjusting knob in direction a force
Adjusting spring preload
to increase rebound damping force and Turn the adjusting screw in direction a
Turn the adjusting ring in direction a to in-
in direction b to decrease rebound to increase compression damping
crease spring preload and in direction b
damping force. force and in direction b to decrease
to decrease spring preload. CI-34E
compression damping force.
Make sure that the appropriate notch in Minimum (soft) 25 clicks out*
CI-34E

the adjusting ring is aligned with the po- Standard 9 clicks out* Minimum (soft) 13 clicks out*

sition indicator on the rear shock ab- Maximum (hard) 1 click out* Standard 7 clicks out*
* From the fully turned-in position Maximum (hard) 1 click out*
sorber.
CI-18E * From the fully turned-in position
Stan-
Hard Soft
dard
Adjusting
9 8 7 6 5 4 3 2 1
position

3-20
E_5eb_Functions.fm Page 21 Thursday, November 18, 1999 4:03 PM

INSTRUMENT AND CONTROL FUNCTIONS


EAU00315
NOTE:
@

Although the number of clicks between @


WARNING
the minimum and maximum settings This shock absorber contains high-
may vary with each individual shock ly pressurized nitrogen gas. Read
absorber and may not exactly match and understand the following infor-
these specifications, it is always the full mation before handling the shock
damping force range that extends over absorber. The manufacturer cannot
3 the actual number of clicks. be held responsible for property
damage or personal injury that may
@

result from improper handling.


● Do not tamper with or attempt to
open the cylinder assembly.
● Do not subject the shock ab-
sorber to an open flame or other
high heat source. This may
cause the unit to explode due to
excessive gas pressure.
● Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
● Take your shock absorber to a
Yamaha dealer for any service.
@

3-21
E_5eb_Functions.fm Page 22 Thursday, November 18, 1999 4:03 PM

INSTRUMENT AND CONTROL FUNCTIONS


EAU01580

Recommended combinations of the front fork and the rear shock absorber settings
Use this table as a guide for specific settings according to motorcycle load conditions.
CI-31E

Loading condition Front fork adjustment Rear shock absorber adjustment

Compression Rebound Compression Rebound


Spring preload Spring preload
damping force damping force damping force damping force

Solo rider 1~8 1 ~ 10 1~9 1~7 4 ~ 13 3 ~ 25


3
With passenger 1~8 1 ~ 10 1~9 4~9 1~8 1~7

EC000016

CAUTION:
@

Never attempt to turn the adjuster beyond the maximum or minimum setting.
@

3-22
E_5eb_Functions.fm Page 23 Thursday, November 18, 1999 4:03 PM

INSTRUMENT AND CONTROL FUNCTIONS


EAU00330 EW000044

Sidestand WARNING
@

This model is equipped with an ignition This motorcycle must not be operat-
circuit cut-off system. The motorcycle ed with the sidestand in the down
must not be ridden when the sidestand position. If the stand is not properly
is down. The sidestand is located on retracted, it could contact the
the left side of the frame. (Refer to ground and distract the operator, re-
page 5-1 for an explanation of this sys- sulting in a possible loss of control.
3
tem.) Yamaha has designed into this
1. Luggage strap holder (× 2)
EAU01600
motorcycle a lockout system to as-
Luggage strap holders sist the operator in fulfilling the re-
There are two luggage strap holders sponsibility of retracting the
below the rear of the passenger seat. sidestand. Please check carefully
the operating instructions listed be-
low and if there is any indication of a
malfunction, return the motorcycle
to a Yamaha dealer immediately for
repair.
@

3-23
E_5eb_Functions.fm Page 24 Thursday, November 18, 1999 4:03 PM

INSTRUMENT AND CONTROL FUNCTIONS


EAU00331

Sidestand/clutch switch ENGINE WILL STALL.


operation check
Check the operation of the sidestand
SIDESTAND SWITCH IS OK.
switch and clutch switch against the in-
formation below. EW000045
CD-11E
@
WARNING
TURN THE MAIN SWITCH TO “ON” If improper operation is noted, con- 3
AND THE ENGINE STOP SWITCH TO
sult a Yamaha dealer immediately.
“ ”. @

TRANSMISSION IS IN GEAR AND


SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND


PUSH THE START SWITCH.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

SIDESTAND IS DOWN.

3-24
E_5eb_Functions.fm Page 25 Thursday, November 18, 1999 4:03 PM
E_5eb_PreopTOC.fm Page 1 Thursday, November 18, 1999 4:04 PM

PRE-OPERATION CHECKS

Pre-operation check list...................................................................... 4-1

4
E_5eb_Preop.fm Page 1 Thursday, November 18, 1999 4:05 PM

PRE-OPERATION CHECKS
4-
EAU01114

Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340

PRE-OPERATION CHECK LIST


ITEM CHECKS PAGE
Front brake • Check operation, free play, fluid level and fluid leakage. 6-25 ~ 6-28
Rear brake • Fill with DOT 4 brake fluid if necessary. 6-25 ~ 6-28
4 • Check operation condition and free play.
Clutch 6-25
• Adjust if necessary.
• Check for smooth operation.
Throttle grip and housing 6-21, 6-30
• Lubricate if necessary.
• Check oil level.
Engine oil 6-10 ~ 6-13
• Fill with oil if necessary.
• Check coolant level.
Coolant reservoir tank 6-13 ~ 6-16
• Fill with coolant if necessary.
• Check chain slack and condition.
Drive chain 6-28 ~ 6-29
• Adjust if necessary.
6-21 ~ 6-24
Wheels and tires • Check tire pressure, wear and damage.
6-37 ~ 6-40
• Check for smooth operation.
Control cable 6-30
• Lubricate if necessary.
• Check for smooth operation.
Brake pedal shaft 6-30
• Lubricate if necessary.
Brake and clutch lever • Check for smooth operation.
6-31
pivots • Lubricate if necessary.

4-1
E_5eb_Preop.fm Page 2 Thursday, November 18, 1999 4:05 PM

PRE-OPERATION CHECKS
ITEM CHECKS PAGE
• Check for smooth operation.
Sidestand pivot 6-31
• Lubricate if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
• Check fuel level.
Fuel tank 3-13 ~ 3-14
• Fill with fuel if necessary.
Lights, signals and
• Check for proper operation. 6-35 ~ 6-36
switches

NOTE: 4
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom-
plished in a very short time; and the added safety it assures is more than worth the time involved.

WARNING
If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating
the motorcycle.

4-2
E_5eb_Preop.fm Page 3 Thursday, November 18, 1999 4:05 PM
E_5eb_OperationTOC.fm Page 1 Thursday, November 18, 1999 4:05 PM

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine............................................................................. 5-1


Starting a warm engine ...................................................................... 5-3
Shifting ............................................................................................... 5-4
Tips for reducing fuel consumption .................................................... 5-4
Engine break-in .................................................................................. 5-5
Parking ............................................................................................... 5-5

5
E_5eb_Operation.fm Page 1 Thursday, November 18, 1999 4:05 PM

OPERATION AND IMPORTANT RIDING POINTS


5-
EAU00372

EAU00373 EAU01382*

WARNING Starting the engine


@

● Before riding this motorcycle,


NOTE:
become thoroughly familiar
@

This motorcycle is equipped with an ig-


with all operating controls and nition circuit cut-off system. The engine
their functions. Consult a can be started only under one of the
Yamaha dealer regarding any following conditions:
control or function that you do ● The transmission is in neutral.
not thoroughly understand. ● The sidestand is up, the transmis-
● Never start your engine or let it sion is in gear and the clutch is dis-
run for any length of time in a engaged.
closed area. The exhaust fumes The motorcycle must not be ridden
5
are poisonous and can cause when the sidestand is down.
loss of consciousness and @

EW000054
death within a short time. Al-
WARNING
ways operate your motorcycle @

in an area with adequate ventila- Before going through the following


tion. steps, check the function of the
sidestand switch and clutch switch.
● Before starting out, always be
(Refer to page 3-24.)
sure the sidestand is up. Failure @

to retract the sidestand com-


pletely can result in a serious
accident when you try to turn a
corner.
@

5-1
E_5eb_Operation.fm Page 2 Thursday, November 18, 1999 4:05 PM

OPERATION AND IMPORTANT RIDING POINTS


CF-28E

TURN THE MAIN SWITCH TO “ON” AND THE


ENGINE STOP SWITCH TO “ ”.

IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND


SIDESTAND IS DOWN, SIDESTAND IS UP,

PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH START
ENGINE WILL START. THE SWITCH. ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT 5


TRANSMISSION IN GEAR.

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.

5-2
E_5eb_Operation.fm Page 3 Thursday, November 18, 1999 4:05 PM

OPERATION AND IMPORTANT RIDING POINTS


1. Turn the main switch to “ON” and NOTE: EAU01258

the engine stop switch to “ ”.


@

If the engine fails to start, release the Starting a warm engine


ECA00005 start switch, wait a few seconds, then The starter (choke) is not required
CAUTION: try again. Each attempt should be as when the engine is warm.
@
EC000046
The oil level/coolant temperature in- short as possible to preserve the bat-
tery. Do not crank the engine more CAUTION:
dicator light and fuel indicator light @

should come on for a few seconds than 10 seconds on any one attempt. See the “Engine break-in” section
and then go off. If an indicator light
@
prior to operating the motorcycle for
5. After starting the engine, move the the first time.
does not go off, refer to the corre- starter (choke) to the halfway posi- @

sponding indicator light circuit tion.


check in the “INSTRUMENT AND
CONTROL FUNCTIONS” section. NOTE:
5 @
@

For maximum engine life, never accel-


2. Shift the transmission into neutral.
erate hard with a cold engine!
@

NOTE:
@ 6. After the engine is warm, turn off
When the transmission is in neutral, the the starter (choke) completely.
neutral indicator light should be on. If
the light does not come on, ask a NOTE:
@

Yamaha dealer to inspect it. The engine is warm when it responds


@
normally to the throttle with the starter
3. Turn on the starter (choke) and
(choke) turned off.
completely close the throttle grip. @

4. Start the engine by pushing the


start switch.

5-3
E_5eb_Operation.fm Page 4 Thursday, November 18, 1999 4:05 PM

OPERATION AND IMPORTANT RIDING POINTS


EC000048 EAU00424

CAUTION: Tips for reducing fuel


consumption
@

● Do not coast for long periods


with the engine off, and do not Your motorcycle’s fuel consumption
tow the motorcycle a long dis- depends to a large extent on your
tance. Even with gears in neu- riding style. The following tips can help
tral, the transmission is only reduce fuel consumption:
properly lubricated when the ● Warm up the engine before riding.
engine is running. Inadequate ● Turn off the starter (choke) as
1. Shift pedal
lubrication may damage the soon as possible.
N. Neutral
EAU00423 transmission. ● Shift up swiftly and avoid high en-
Shifting ● Always use the clutch when gine speeds during acceleration.
● Do not double-clutch or rev the en-
5
The transmission lets you control the changing gears. The engine,
amount of power you have available at transmission, and driveline are gine while shifting down and avoid
a given speed for starting, accelerating, not designed to withstand the high engine speeds with no load
climbing hills, etc. The use of the shift shock of forced shifting and can on the engine.
pedal is shown in the illustration. be damaged by shifting without ● Turn off the engine instead of let-
To shift into neutral, depress the shift using the clutch. ting it idle for an extended length
pedal repeatedly until it reaches the @
of time, i.e. in traffic jams, at traffic
end of its travel, then raise the pedal lights or railroad crossings.
slightly.

5-4
E_5eb_Operation.fm Page 5 Thursday, November 18, 1999 4:05 PM

OPERATION AND IMPORTANT RIDING POINTS


EAU01128 EAU01329 EAU00460

Engine break-in 0 ~ 1,000 km Parking


There is never a more important period Avoid operation above 5,000 r/min. When parking the motorcycle, stop the
in the life of your motorcycle than the engine and remove the ignition key.
period between zero and 1,600 km. For 1,000 ~ 1,600 km EW000058

this reason we ask that you carefully Avoid cruising speeds in excess of @
WARNING
read the following material. Because 6,000 r/min. The exhaust system is hot. Park the
EC000052
the engine is brand new, you must not motorcycle in a place where pedes-
put an excessive load on it for the first CAUTION: trians or children are not likely to
@

1,600 km. The various parts in the en- After 1,000 km of operation, be sure touch the motorcycle. Do not park
gine wear and polish themselves to the to replace the engine oil and oil fil- the motorcycle on a slope or soft
correct operating clearances. During ter. ground; the motorcycle may over-
5 this period, prolonged full throttle oper-
@

turn.
@

ation, or any condition which might re- 1,600 km and beyond


sult in excessive heating of the engine, Proceed with normal riding.
must be avoided. EC000053

CAUTION:
@

● Never let engine speeds enter


the red zone.
● If any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
@

5-5
E_5eb_PeriodicTOC.fm Page 1 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit...................................................................6-1 Drive chain slack adjustment ............................. 6-29


Periodic maintenance and lubrication...................6-3 Drive chain lubrication........................................ 6-29
Cowling and panel removal and installation..........6-6 Cable inspection and lubrication ........................ 6-30
Cowlings A and B .................................................6-6 Throttle cable and grip lubrication ...................... 6-30
Panel C .................................................................6-8 Brake pedal lubrication....................................... 6-30
Spark plug inspection ...........................................6-9 Brake and clutch lever lubrication ...................... 6-31
Engine oil ............................................................6-10 Sidestand lubrication.......................................... 6-31
Cooling system ...................................................6-13 Rear suspension lubrication............................... 6-31
Changing the coolant..........................................6-14 Front fork inspection........................................... 6-32
Air filter ...............................................................6-17 Steering inspection ............................................ 6-32
Air intake duct .....................................................6-19 Wheel bearings .................................................. 6-33
Carburetor adjustment ........................................6-20 Battery................................................................ 6-33
6
Idle speed adjustment ........................................6-20 Fuse replacement .............................................. 6-34
Throttle cable free play inspection ......................6-21 Headlight bulb replacement ............................... 6-35
Valve clearance adjustment ................................6-21 Tail/brake light bulb replacement........................ 6-36
Tires....................................................................6-21 Turn signal light bulb replacement...................... 6-36
Wheels................................................................6-24 Supporting the motorcycle ................................. 6-37
Clutch lever free play adjustment........................6-25 Front wheel removal........................................... 6-37
Brake light switch adjustment .............................6-25 Front wheel installation ...................................... 6-38
Checking the front and rear brake pads..............6-26 Rear wheel removal ........................................... 6-39
Inspecting the brake fluid level............................6-27 Rear wheel installation ....................................... 6-40
Brake fluid replacement ......................................6-28 Troubleshooting.................................................. 6-40
Drive chain slack check ......................................6-28 Troubleshooting chart......................................... 6-41
E_5eb_Periodic.fm Page 1 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


6-
EAU00462

EAU00464 EAU01296

Periodic inspection, adjustment and lu- CAUTION:


brication will keep your motorcycle in @

Do not test this motorcycle on a dy-


the safest and most efficient condition
namometer for an extended period
possible. Safety is an obligation of the
of time as discoloration to the fiber
motorcycle owner. The maintenance
constructed muffler may occur from
and lubrication schedule chart should
the heat.
be considered strictly as a guide to @

general maintenance and lubrication


intervals. YOU MUST TAKE INTO 1. Tool kit
EAU01129
CONSIDERATION THAT WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
Tool kit
TIONS, AND A VARIETY OF INDIVID- The tool kit is located inside the storage
UAL USES ALL TEND TO DEMAND compartment. (See page 3-17 for com-
partment opening procedures.) The
6 THAT EACH OWNER ALTER THIS
TIME SCHEDULE TO SHORTER IN- tools provided in the owner’s tool kit are
TERVALS TO MATCH THE ENVI- to assist you in the performance of pe-
riodic maintenance. However, some
RONMENT. The most important points
of motorcycle inspection, adjustment, other tools such as a torque wrench are
and lubrication are explained in the fol- also necessary to perform the mainte-
nance correctly.
lowing pages.
EW000060 The service information included in this
WARNING manual is intended to provide you, the
owner, with the necessary information
@

If you are not familiar with motor-


cycle service, this work should be for completing some of your own pre-
done by a Yamaha dealer. ventive maintenance and minor re-
@ pairs.

6-1
E_5eb_Periodic.fm Page 2 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


NOTE:
@

If you do not have necessary tools re-


quired during a service operation, take
your motorcycle to a Yamaha dealer for
service.
@

EW000062

@
WARNING
Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, excessive
emissions, and render it unsafe for
use. Consult a Yamaha dealer be-
fore attempting any changes.
@

6-2
E_5eb_Periodic.fm Page 3 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00473

PERIODIC MAINTENANCE AND LUBRICATION


CP-01E
EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check fuel hoses for cracks or damage.
1 * Fuel line √ √
• Replace if necessary.
• Check condition.
2 * Fuel filter √
• Replace if necessary.
• Check condition.
3 Spark plugs √ √ √
• Clean, regap or replace if necessary.
• Check valve clearance. Every 42,000 km or 42 months
4 * Valves • Adjust if necessary. (whichever comes first)
5 Air filter • Replace if necessary. √ √
6
• Check operation.
6 Clutch √ √ √
• Adjust or replace cable.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
7 * Front brake √ √ √
• Correct accordingly.
• Replace brake pads if necessary.
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
8 * Rear brake √ √ √
• Correct accordingly.
• Replace brake pads if necessary.
• Check balance, runout and for damage.
9 * Wheels √ √
• Rebalance or replace if necessary.

6-3
E_5eb_Periodic.fm Page 4 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or damage.
11 * Wheel bearings √ √
• Replace if necessary.
• Check swingarm pivoting point for play.
• Correct if necessary.
12 * Swingarm √ √
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is properly Every 1,000 km and after washing the
13 Drive chain
aligned. motorcycle or riding in the rain 6
• Clean and lubricate.
• Check bearing play and steering for roughness.
• Correct accordingly.
14 * Steering bearings √ √
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).
• Make sure that all nuts, bolts and screws are properly tightened.
15 * Chassis fasteners √ √
• Tighten if necessary.
• Check operation.
16 Sidestand √ √
• Lubricate and repair if necessary.
• Check operation.
17 * Sidestand switch √ √ √
• Replace if necessary.
• Check operation and for oil leakage.
18 * Front fork √ √
• Correct accordingly.
Rear shock absorber • Check operation and shock absorber for oil leakage.
19 * assembly √ √
• Replace shock absorber assembly if necessary.

6-4
E_5eb_Periodic.fm Page 5 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
Rear suspension relay
• Check operation.
20 * arm and connecting arm • Correct if necessary. √ √
pivoting points
• Check engine idling speed, synchronization and starter operation.
21 * Carburetors √ √ √
• Adjust if necessary.
• Check oil level and vehicle for oil leakage.
22 Engine oil • Correct if necessary. √ √ √
• Change. (Warm engine before draining.)
23 Engine oil filter cartridge • Replace. √ √
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
24 * Cooling system √ √
• Change coolant every 24,000 km or 24 months (whichever comes
6 first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970*

NOTE:
@

● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@

6-5
E_5eb_Periodic.fm Page 6 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Cowling A (right side) 1. Screw (× 5) 1. Screw (× 6)


Cowling B (left side) EAU01602

2. Panel C Cowlings A and B


EAU01139
To remove
Cowling and panel removal
1. Remove the screws.
and installation
The cowlings and panels illustrated 6
need to be removed to perform some
of the maintenance described in this
chapter. Refer to this section each time
a cowling or panel has to be removed
or reinstalled.

6-6
E_5eb_Periodic.fm Page 7 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Cowling A 1. Slot (× 2) 1. Tab (× 2)


2. Cowling B 2. Projection (× 2) 2. Place the cowling in its original po-
2. Disengage the cowling by sliding it To install sition. Make sure that the tabs at
forward (for A) or backward (for B), 1. Fit the slots and projections at the the front of the cowlings fit side by
then pulling it outward. rear bottom of the cowlings togeth- side as shown and that all slots
er and slide the cowling into place. and projections fit together.
6
3. Install the screws.

6-7
E_5eb_Periodic.fm Page 8 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2) 1. Projection
EAU01315 2. Slot
Panel C To install
To remove Place the panel in the original position
Remove the screws. and install the screws.
6

6-8
E_5eb_Periodic.fm Page 9 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


Do not attempt to diagnose such prob- When installing a spark plug, the gas-
lems yourself. Instead, take the motor- ket surface should always be cleaned
cycle to a Yamaha dealer. The spark and a new gasket used. Any grime
plugs should be periodically removed should be wiped off from the threads
and inspected because heat and de- and the spark plug tightened to the
posits will cause any spark plug to specified torque.
slowly break down and erode. If elec-
trode erosion becomes excessive, or if Tightening torque:
carbon and other deposits are exces- Spark plug:
a. Spark plug gap
EAU01639
sive, the spark plug should be replaced 12.5 Nm (1.25 m·kg)
Spark plug inspection with the specified plug.
The spark plug is an important engine NOTE:
@

Specified spark plug: If a torque wrench is not available when


component and should be inspected
periodically, preferably by a Yamaha CR10EK (NGK) installing a spark plug, a good estimate
6 of the correct torque is 1/4 to 1/2 turn
dealer. The condition of the spark plug
Before installing any spark plug, mea- past finger tight. The spark plug should
can indicate the condition of the en-
sure the electrode gap with a wire be tightened to the specified torque as
gine.
thickness gauge and adjust it to specifi- soon as possible.
Normally, all spark plugs from the
cation. @

same engine should have the same


color on the white insulator around the
Spark plug gap:
center electrode. The ideal color at this
0.6 ~ 0.7 mm
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-
ly. If one spark plug shows a distinctly
different color, there could be some-
thing wrong with the engine.

6-9
E_5eb_Periodic.fm Page 10 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


ECA00021

CAUTION:
@

Do not use any type of tools to re-


move or install the cap as the igni-
tion coil coupler may get damaged.
The spark plug cap may be difficult
to remove because a rubber seal on
the end of the cap is tightly fit into
the cylinder bore. To remove the
1. Dipstick 1. Maximum level mark
cap, simply twist it back and forth EAU01610* 2. Minimum level mark
while pulling it upward; when install- Engine oil 2. Stop the engine and remove the
ing the cap, twist it back and forth Oil level inspection dipstick.
while pushing it downward. 1. Place the motorcycle on a level
@

place and hold it in an upright posi- NOTE:


@

Wait a few minutes until the oil level 6


tion. Warm up the engine for sev-
settles before checking.
eral minutes. @

3. The oil level should be between


NOTE:
@
maximum and minimum marks on
Be sure the motorcycle is positioned
the dipstick. If the level is low, fill
straight up when checking the oil level.
the engine with sufficient oil to
A slight tilt toward the side can result in
reach the specified level.
false readings.
@

6-10
E_5eb_Periodic.fm Page 11 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oil filler cap 1. Engine oil drain bolt 1. Oil filter wrench
Engine oil and oil filter cartridge re- 4. Remove the drain bolt and drain 2. Oil filter cartridge
placement the oil. NOTE:
@

1. Remove cowling B. (See page 6-6 5. Remove the oil filter by using an oil An oil filter wrench is available at a
for removal and installation proce- filter wrench. nearby Yamaha dealer.
@

6 dures.) 6. Reinstall the drain bolt and tighten


2. Warm up the engine for several it to the specified torque.
minutes.
3. Stop the engine. Place an oil pan Tightening torque:
under the engine and remove the Drain bolt:
engine oil filler cap. 43 Nm (4.3 m·kg)

6-11
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PERIODIC MAINTENANCE AND MINOR REPAIR


9. Fill the engine with sufficient oil to
reach the specified level. Install
the engine oil filler cap and tighten
it.

Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
1. O-ring 1. Torque wrench
3.5 L
7. Apply a light coat of engine oil to 8. Install the oil filter and tighten it to
Periodic oil change:
the O-ring of the new oil filter. the specified torque with an oil fil-
2.5 L
ter wrench.
NOTE:
@
With oil filter replacement:
Make sure the O-ring is seated proper- 2.7 L
Tightening torque: 6
ly.
@
Oil filter: EC000066

17 Nm (1.7 m·kg) CAUTION:


@

● Do not put in any chemical addi-


tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
● Be sure no foreign material en-
ters the crankcase.
@

6-12
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PERIODIC MAINTENANCE AND MINOR REPAIR


10. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
11. After the engine is started, the oil
level indicator light should go off if
the oil is at the specified level.
EC000067
1. Maximum level mark 1. Bolt (× 2)
2. Minimum level mark 2. If the level is low, remove the res-
CAUTION: EAU01611
@
ervoir tank cover by removing the
If the indicator light flickers or re- Cooling system
bolts.
mains on, immediately stop the en- 1. Check the coolant level in the res-
3. Add coolant or distilled water to
gine and consult with a Yamaha ervoir tank when the engine is cold
6 raise it to the specified level.
dealer. as the coolant level will vary with
4. Install the reservoir tank cover and
@

engine temperature. The coolant


12. Install the cowling. bolts.
level should be between the maxi-
mum and minimum marks.
Reservoir tank capacity:
0.44 L

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PERIODIC MAINTENANCE AND MINOR REPAIR


EC000080

CAUTION:
@

Hard water or salt water is harmful


to the engine. You may use distilled
water if you can’t get soft water.
@

NOTE:
@

If water is added, have a Yamaha deal-


er check the antifreeze content of the
coolant as soon as possible. 1. Radiator cap 1. Water pump drain bolt
EAU01612 2. Clamp bolt
The radiator fan operation is complete- Changing the coolant 4. Remove the water pump drain bolt
ly automatic. It is switched on or off ac-
1. Remove panel C, cowling A and and drain the coolant from the wa-
cording to the coolant temperature in
cowling B. (See page 6-6 for re- ter pump housing.
the radiator.
moval and installation proce- 5. Disconnect the radiator hose by
@

6
5. If your motorcycle overheats, see dures.) loosening the clamp and drain the
page 6-42 for details. 2. Place a container under the en- coolant completely.
gine. 6. Thoroughly flush the cooling sys-
3. Remove the radiator cap. tem with clean tap water.

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PERIODIC MAINTENANCE AND MINOR REPAIR


7. Connect the radiator hose and
tighten the clamp.
8. Retighten the drain bolt to the
specified torque. If the gasket is
damaged, replace it.

Tightening torque:
Drain bolt:
12 Nm (1.2 m·kg)
1. Bolt (× 2) 1. Bolt (× 2)
9. Remove the reservoir tank cover 10. Remove the reservoir tank by re-
by removing the bolts. moving the bolts.
11. Remove the reservoir tank cap
and turn the tank upside down to
6 empty it.
12. Install the reservoir tank.
13. Fill the reservoir tank with coolant
up to the maximum level, then in-
stall the cap and cover.
14. Pour the recommended coolant
into the radiator until it is full.

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PERIODIC MAINTENANCE AND MINOR REPAIR


17. Check for coolant leakage.
Recommended anti-freeze:
High quality ethylene glycol NOTE:
@

anti-freeze containing corrosion If you find any leaks, ask a Yamaha


inhibitors for aluminum engines. dealer to inspect.
Antifreeze and water mix ratio:
@

18. Install the panel and the cowling.


1:1
Total amount:
2.15 L
Reservoir tank capacity:
0.44 L
EC000080

CAUTION:
@

Hard water or salt water is harmful


6
to the engine. You may use distilled
water if you can’t get soft water.
@

15. Install the radiator cap.


16. Run the engine several minutes to
recheck the coolant level in the ra-
diator. If it is low, fill with more
coolant until it reaches the top of
the radiator.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt (× 2) 1. Fuel cock


EAU01821* 2. Hose (× 2) 7. Tilt the front of the fuel tank back
Air filter 3. Fuel sender lead coupler
away from the air filter case. Be
The air filter element’s condition should 4. Set the fuel cock to “OFF”.
sure to support it as shown.
be checked at the specified intervals. It 5. Disconnect the fuel sender lead
should be checked more frequently if coupler.
6 6. Disconnect the hoses.
you are riding in unusually wet or dusty
areas.
NOTE:
1. Remove the rider seat. (See page @

Before removing the hoses, mark them


3-15 for seat removal and installa-
to ensure that they will be reinstalled in
tion procedures.)
their correct positions.
2. Remove the bolts holding the fuel @

tank.
3. Lift the fuel tank upward.

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PERIODIC MAINTENANCE AND MINOR REPAIR


10. Check the air filter element’s con-
dition. If it is damaged or exces-
sively dusty, it should be replaced.

1. Screw (× 6) 1. Air filter element


8. Remove the screws holding the air 9. Remove the air filter element.
filter case cover.

6-18
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PERIODIC MAINTENANCE AND MINOR REPAIR


EC000082* EW000131

CAUTION: @
WARNING
@

● Make sure the air filter element Make sure that the fuel hoses and
is properly seated in the air filter vacuum hose are properly connect-
case. ed, in place and not pinched. If a
● The engine should never be run hose is damaged, be sure to replace
without the air filter installed. it.
Excessive piston and/or cylin-
@

der wear may result.


@ 1. Air intake duct
11. Reverse the removal procedure EAU01335

for installation. Air intake duct


Check that the screen of the intake
duct is not blocked. Clean the screen if
necessary.
6

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00630

Carburetor adjustment Standard idle speed:


The carburetors are important parts of 1,250 ~ 1,350 r/min
the engine and require very sophisti-
cated adjustment. Most adjustments NOTE:
@

should be left to a Yamaha dealer who If the specified idle speed cannot be
obtained by performing the above ad-
has the professional knowledge and
experience to do so. However, the idle justment, consult a Yamaha dealer.
@

speed may be adjusted by the owner


as part of routine maintenance. 1. Throttle stop screw
EAU00632
EC000095

CAUTION:
Idle speed adjustment
@
1. Start the engine and warm it up for
The carburetors were set at the
a few minutes at approximately
Yamaha factory after many tests. If
1,000 to 2,000 r/min. Occasionally
they are changed, poor engine per- 6
rev the engine to 4,000 to
formance and damage may result.
@
5,000 r/min. The engine is warm
when it quickly responds to the
throttle.
2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rection a to increase engine
speed and in direction b to de-
crease engine speed.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00637 EAU00658

Valve clearance adjustment Tires


The correct valve clearance changes To ensure maximum performance,
with use, resulting in improper fuel/air long service and safe operation, note
supply or engine noise. To prevent this, the following:
the valve clearance must be adjusted
regularly. This adjustment however, Tire air pressure
should be left to a professional Always check and adjust the tire pres-
Yamaha service technician. sure before operating the motorcycle.
a. Free play EW000082

EAU00635
WARNING
Throttle cable free play @

Tire inflation pressure should be


inspection checked and adjusted when the
There should be a free play of 6 ~ temperature of the tire equals the
6 8 mm at the throttle grip. If the free play ambient air temperature. Tire infla-
is incorrect, ask a Yamaha dealer to tion pressure must be adjusted ac-
make this adjustment. cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR


CE-33E EW000083
Maximum load* 187 kg
Cold tire pressure Front Rear @
WARNING
250 kPa 250 kPa Proper loading of your motorcycle
Up to 90 kg load* (2.50 kg/cm2, (2.50 kg/cm2,
is important for several characteris-
2.50 bar) 2.50 bar)
250 kPa 290 kPa
tics of your motorcycle, such as
90 kg Maximum load* (2.50 kg/cm2, (2.90 kg/cm2, handling, braking, performance and
2.50 bar) 2.90 bar)
safety. Do not carry loosely packed
250 kPa 250 kPa
High speed riding (2.50 kg/cm2, (2.50 kg/cm2,
items that can shift. Securely pack
2.50 bar) 2.50 bar) your heaviest items close to the
1. Tread depth
* Load is the total weight of cargo, rider, passenger center of the motorcycle, and dis- 2. Side wall
and accessories.
tribute the weight evenly from side Tire inspection
to side. Properly adjust the suspen- Always check the tires before operating
sion for your load, and check the the motorcycle. If center tread depth
condition and pressure of your tires. reaches the limit as shown, if the tire
NEVER OVERLOAD YOUR MOTOR- 6
has a nail or glass fragments in it, or if
CYCLE. Make sure the total weight the side wall is cracked, contact a
of the cargo, rider, passenger, and Yamaha dealer immediately and have
accessories (fairing, saddlebags, the tire replaced.
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury.
@

6-22
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PERIODIC MAINTENANCE AND MINOR REPAIR


EW000095 EW000080

@
WARNING @
WARNING
Operating the motorcycle with ex- ● After extensive tests, the tires
cessively worn tires decrease riding mentioned below have been ap-
stability and can lead to loss of con- proved by Yamaha Motor Co.,
trol. Have excessively worn tires re- Ltd. for this model. No guaran-
placed by a Yamaha dealer tee for handling characteristics
immediately. Brakes, tires, and relat- can be given if tire combina-
ed wheel parts replacement should tions other than what is ap-
1. Tire valve
be left to a Yamaha Service Techni- proved are used on this 2. Valve core
cian. motorcycle. The front and rear 3. Valve cap with seal
@

CE-26E tires should be of the same CE-10E


FRONT
Minimum tire tread depth
1.6 mm manufacture and design.
(front and rear) Manufacturer Size Type
● The use of tire valves and valve
Bridgestone 120/60 ZR17 (55W) BT56FE
6 cores other than listed below
NOTE:
@
Dunlop 120/60 ZR17 (55W) D207FJ
These limits may be different by regula- could cause tire deflation dur-
REAR
tion from country to country. If so, con- ing extreme high speed riding.
Manufacturer Size Type
form to the limits specified by the Always use genuine parts or
Bridgestone 180/55 ZR17 (73W) BT56RE
regulations of your own country. their equivalent for replace- Dunlop 180/55 ZR17 (73W) D207N
@
ment. CE-12E
● Be sure to install the valve caps Type
Tire information
securely, as these are important Tire valve TR412
This motorcycle is equipped with tube-
to prevent air pressure leakage Valve core #9000A (original)
less tires, tire valves and cast wheels.
during extreme high speed
riding.
@

6-23
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00684 EAU00687

WARNING Wheels
@

This motorcycle is fitted with super To ensure maximum performance,


high-speed running tires. The fol- long service, and safe operation, note
lowing points must be observed in the following:
order for you to make fully effective ● Always inspect the wheels before

use of these tires. a ride. Check for cracks, bends, or


● Never fail to use the specified warpage of the wheels. If any ab-
tires in tire replacement. Other normal condition exists in a wheel,
tires may have a danger of consult a Yamaha dealer. Do not
bursting at super high-speeds. attempt even small repairs to the
● New tires have a relatively low wheel. If a wheel is deformed or
grip on the road surface until cracked, it must be replaced.
they have been slightly worn. ● Tires and wheels should be bal-

Therefore, approximately anced whenever either one is 6


100 km should be traveled at changed or replaced. Failure to
normal speed before any high- have a wheel balanced can result
speed riding is done. in poor performance, adverse han-
● Before any high-speed runs, the dling characteristics, and short-
tires should be warmed-up suf- ened tire life.
ficiently. ● Ride at moderate speeds after

● Always inflate to the correct tire changing a tire since the tire sur-
pressure according to the oper- face must first be broken in for it to
ating conditions. develop its optimal characteristics.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Adjusting bolt 1. Locknut 1. Brake light switch


2. Free play 2. Adjusting nut 2. Adjusting nut
EAU01356
3. Remove cowling A. (See page 6-6 EAU00713

Clutch lever free play for removal and installation proce- Brake light switch adjustment
adjustment dures.) The rear brake light switch is activated
The clutch lever free play should be ad- 4. Loosen the locknut at the crank- by the brake pedal and is properly ad-
6 justed when the brake light comes on
justed to 10 ~ 15 mm. case side.
1. Turn the adjusting bolt at the 5. Turn the adjusting nut at the just before braking takes effect. To ad-
clutch lever in direction a to in- crankcase in direction a to in- just the rear brake light switch, hold the
crease free play or in direction b crease free play or in direction b switch body so it does not rotate while
to decrease free play. If the speci- to decrease free play. Then tight- turning the adjusting nut.
fied free play cannot be obtained, en the locknut. Turn the adjusting nut in direction a to
proceed with the following steps. 6. Install the cowling. make the brake light come on earlier.
2. Turn the adjusting bolt at the Turn the adjusting nut in direction b to
clutch lever in direction a to loos- make the brake light come on later.
en the cable.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Wear indicator groove 1. Caliper bolt 1. Wear indicator groove


EAU00721 EAU01641
Inspect the groove. If the groove has
Checking the front and rear Rear brake
almost disappeared, ask a Yamaha
brake pads A wear indicator groove is provided on
dealer to replace the pads. Install the
EAU00725 each brake pad. This indicator allows
caliper and caliper bolt, then tighten the
Front brake checking of brake pad wear without
bolt to the specified torque. 6
A wear indicator groove is provided on disassembling the brake. Remove the
each brake pad. This indicator allows rear caliper bolt and tilt the caliper for-
Tightening torque:
checking of brake pad wear without ward.
disassembling the brake. Inspect the Caliper bolt:
groove. If the groove has almost disap- 40 Nm (4.0 m·kg)
peared, ask a Yamaha dealer to re-
place the pads.

6-26
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PERIODIC MAINTENANCE AND MINOR REPAIR


● Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
● Have a Yamaha dealer check the
cause if the brake fluid level goes
down.

1. Minimum level mark 1. Minimum level mark


EAU00731
● Use only the designated quality
Inspecting the brake fluid brake fluid. Otherwise, the rubber
level seals may deteriorate, causing
Insufficient brake fluid may let air enter leakage and poor brake perfor-
6 the brake system, possibly causing the mance.
brakes to become ineffective.
Before riding, check that the brake fluid Recommended brake fluid: DOT 4
is above the minimum level and replen-
ish when necessary. ● Refill with the same type of brake
Observe these precautions: fluid. Mixing fluids may result in a
● When checking the fluid level, harmful chemical reaction and
make sure the top of the master lead to poor brake performance.
cylinder is level by turning the han- ● Be careful that water does not en-
dlebars. ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00742

Brake fluid replacement


The brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:
● oil seals (every two years)
● brake hoses (every four years) a. Chain slack
EAU00744

Drive chain slack check


NOTE:
@

Spin the wheel several times and find


the tightest position of the chain. Check 6
and/or adjust the chain slack while it’s
in this tightest position.
@

To check the chain slack the motor-


cycle must be held straight up with both
wheels on the ground and without rider.
Check the slack at the position shown
in the illustration. Normal slack is ap-
proximately 40 ~ 50 mm. If the slack
exceeds 50 mm, adjust.

6-28
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PERIODIC MAINTENANCE AND MINOR REPAIR


EC000096 EAU03006

CAUTION: Drive chain lubrication


@

Too little chain slack will overload The chain consists of many parts which
the engine and other vital parts. work with each other. If the chain is not
Keep the slack within the specified maintained properly, it will wear out
limits. quickly. Therefore, the chain must be
@
serviced regularly. This service is es-
3. After adjusting, tighten the lock- pecially necessary when riding in dusty
nuts. Then tighten the axle nut to areas. This motorcycle is equipped
1. Axle nut the specified torque. with a sealed type chain. Steam clean-
2. Adjusting bolt
3. Locknut
ing, high-pressure washers, and sol-
Tightening torque: vents can damage the drive chain, so
4. Alignment marks
EAU01251 Axle nut: do not use these for cleaning it. Use
Drive chain slack adjustment 150 Nm (15.0 m·kg) only kerosene to clean the drive chain.
6 1. Loosen the axle nut. Wipe it dry, and thoroughly lubricate it
2. Loosen the locknuts on each side. with SAE 30 ~ 50W motor oil. Do not
To tighten the chain, turn the chain use any other lubricants on the drive
adjusting bolts in direction a. To chain. They may contain solvents that
loosen the chain, turn the adjust- could damage the sealed chain.
ing bolts in direction b and push EC000097

the wheel forward. Turn each ad- CAUTION:


@

justing bolt exactly the same Be sure to oil the chain after wash-
amount to maintain correct axle ing the motorcycle or riding in the
alignment. There are marks on rain.
each side of the swingarm. Use @

these marks to align the rear


wheel.
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU02962 EAU00773

Cable inspection and Throttle cable and grip


lubrication lubrication
EW000112
The throttle twist grip assembly should
@
WARNING be greased at the time that the cable is
Damage to the outer housing of ca- lubricated, since the grip must be re-
bles may lead to internal rusting and moved to get at the end of the throttle
interfere with the cable movement. cable. After removing the screws, hold
Replace damaged cables as soon as the end of the cable up in the air and
possible to prevent unsafe condi- put in several drops of lubricant. With EAU01290*
tions. the throttle grip disassembled, coat the Brake pedal lubrication
@

Lubricate the cables and cable ends. If metal surface of the grip assembly with Lubricate the pivoting parts.
a cable does not operate smoothly, ask a suitable all-purpose grease.
a Yamaha dealer to replace it. Recommended lubricant:
6
Engine oil
Recommended lubricant:
Engine oil

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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00791

Rear suspension lubrication


Lubricate the pivoting parts.

Recommended lubricant:
Lithium soap base grease

EAU02985 EAU02986

Brake and clutch lever Sidestand lubrication


lubrication Lubricate the sidestand pivoting point
Lubricate the pivoting parts. and metal-to-metal contact surfaces.
Check that the sidestand moves up
6
Recommended lubricant: and down smoothly.
Engine oil
Recommended lubricant:
Engine oil
EW000113

@
WARNING
If the sidestand does not move
smoothly, consult a Yamaha dealer.
@

6-31
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU02939

Front fork inspection


Visual check
EW000115

@
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
@

Check for scratches or damage on the


inner tube and excessive oil leakage
from the front fork.
Operation check EAU00794

1. Place the motorcycle on a level Steering inspection


place. Periodically inspect the condition of the
2. Hold the motorcycle in an upright steering. Worn out or loose steering
position and apply the front brake. bearings may be dangerous. Place a
6
3. Push down hard on the handle- stand under the engine to raise the
bars several times and check if the front wheel off the ground. Hold the
fork rebounds smoothly. lower end of the front forks and try to
EC000098 move them forward and backward. If
CAUTION: any free play can be felt, ask a Yamaha
@

If any damage or unsmooth move- dealer to inspect and adjust the steer-
ment is found with the front fork, ing. Inspection is easier if the front
consult a Yamaha dealer. wheel is removed.
@
EW000115

@
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
@

6-32
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01144 EAU01291 EW000116

Wheel bearings Battery WARNING


@

If there is play in the front or rear wheel This motorcycle is equipped with a Battery electrolyte is poisonous and
hub or if the wheel does not turn sealed-type battery. Therefore it is not dangerous, causing severe burns,
smoothly, have a Yamaha dealer in- necessary to check the electrolyte or fill etc. It contains sulfuric acid. Avoid
spect the wheel bearings. the battery with distilled water. contact with skin, eyes or clothing.
● If the battery seems to have dis- ANTIDOTE:
charged, consult a Yamaha deal- ● EXTERNAL: Flush with water.
er. ● INTERNAL: Drink large quanti-
● If the motorcycle is equipped with ties of water or milk. Follow with
optional electrical accessories, the milk of magnesia, beaten egg,
battery tends to discharge more or vegetable oil. Call a physi-
quickly, so be sure to recharge it cian immediately.
periodically. ● EYES: Flush with water for
6 15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or
using in an enclosed space. Always
shield your eyes when working near
batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
@

6-33
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PERIODIC MAINTENANCE AND MINOR REPAIR


Battery storage
This motorcycle is equipped with a dig-
ital speedometer and the odometer
memory tends to drain the battery.
When the motorcycle is not used for a
month or longer, be sure to remove the
battery, fully charge it and store it in a
cool, dry place.
EC000102

1. Ignition fuse 1. Main fuse


CAUTION:
@ 2. Headlight fuse 2. Spare fuse
● Completely recharge the bat- 3. Signaling system fuse EC000103

tery before storing. Storing a 4. Spare fuse (× 3) CAUTION:


5. Radiator fan fuse @

discharged battery can cause Do not use fuses of higher amper-


6. Odometer fuse
permanent battery damage. EAU01754 age rating than those recommend-
● Use a battery charger designed Fuse replacement 6
ed. Substitution of a fuse of
for a sealed-type (MF) battery. The fuse boxes are located under the improper rating can cause extensive
Using a conventional battery rider seat. If any fuse is blown, turn off electrical system damage and pos-
charger will cause battery dam- the main switch and the switch of the sibly a fire.
age. If you do not have a sealed- circuit in question. Install a new fuse of @

type battery charger, contact specified amperage. Turn on the


your Yamaha dealer. switches and see if the electrical device
● Always make sure the connec- operates. If the fuse immediately blows
tions are correct when reinstall- again, consult a Yamaha dealer.
ing the battery.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR


Specified fuses:
Main fuse: 30 A
Headlight fuse: 20 A
Signaling system fuse: 20 A
Radiator fan fuse: 7.5 A
Ignition fuse: 15 A
Odometer fuse: 7.5 A

1. Connector 1. Bulb holder


2. Bulb holder cover 3. Unhook the bulb holder and re-
EAU01822*
move the defective bulb.
Headlight bulb replacement EW000119
This motorcycle is equipped with a
WARNING
quartz bulb headlight. @

6 Keep flammable products and your


If the headlight bulb burns out, replace
hands away from a bulb while it is
the bulb as follows:
on, as it is hot. Do not touch a bulb
1. Remove panel C. (See page 6-8
until it cools down.
for panel removal and installation @

procedures.) 4. Put a new bulb into position and


2. Remove the headlight connector secure it in place with the bulb
and the bulb holder cover. holder.

6-35
E_5eb_Periodic.fm Page 36 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EC000104

CAUTION:
@

To prevent damage to the following:


● Headlight bulb
Avoid touching the glass part of
the bulb. Keep it free from oil;
otherwise, the transparency of
the glass, life of the bulb, and il-
luminous flux will be adversely
1. Bulb socket 1. Screw
affected. If oil gets on the bulb, EAU01823 EAU01095
thoroughly clean it with a cloth Tail/brake light bulb Turn signal light bulb
moistened with alcohol or lac- replacement replacement
quer thinner. 1. Remove the passenger seat. (See 1. Remove the screw and the lens.
● Headlight lens
page 3-15 for seat removal and in- 2. Remove the defective bulb by 6
• Do not affix any type of tinted stallation procedures.) pushing it inward and turning it
film or stickers to the head- 2. To remove the socket, turn it coun- counterclockwise.
light lens. terclockwise. 3. Install a new bulb by pushing it in-
• Do not use headlight bulbs of 3. To remove the defective bulb, turn ward and turning it clockwise.
wattage higher than speci- it counterclockwise. 4. Install the lens and tighten the
fied. 4. Push a new bulb into the socket screw.
@

5. Install the bulb holder cover and and turn it clockwise.


reconnect the headlight connec- 5. Install the socket and turn it clock-
tor. wise.
If the headlight beam adjustment is 6. Install the passenger seat.
necessary, ask a Yamaha dealer to
make that adjustment.
6-36
E_5eb_Periodic.fm Page 37 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01579
Rear wheel service
Supporting the motorcycle Use a motorcycle stand or motorcycle
Since the Yamaha YZF-R6 has no cen- jack to elevate the motorcycle so the
terstand, follow these precautions rear wheel is off the ground. Alterna-
when removing the front and rear tively, two jacks can be placed under
wheel or performing other mainte- the frame or swingarm.
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A 1. Wheel axle
2. Pinch bolt
strong wooden box can be placed un- EAU01617
der the engine for added stability. Front wheel removal
EW000122

Front wheel service WARNING


@

6 To stabilize the rear of the motorcycle, ● It is advisable to have a Yamaha


either use a motorcycle stand or place dealer service the wheel.
a motorcycle jack under the frame in ● Securely support the motor-
front of the rear wheel to prevent it from cycle so there is no danger of it
moving from side to side. Then use a falling over.
motorcycle stand to elevate the front @

1. Loosen the pinch bolt and caliper


wheel off of the ground.
bolts.
2. Loosen the wheel axle by using a
19-mm hexagon wrench.

6-37
E_5eb_Periodic.fm Page 38 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01638

Front wheel installation


1. Lift up the wheel between the front
fork legs.
2. Install the wheel axle and let the
motorcycle down.
3. Push down hard on the handle-
bars several times to check for
proper fork operation.
1. Brake hose holder bolt 4. Install the calipers, caliper bolts
2. Caliper bolt (× 2)
and brake hose holders. Make
3. Elevate the front wheel.
sure there is enough gap between
4. Remove the brake hose holders
the brake pads before installing
and calipers.
the calipers onto the brake discs.
NOTE:
@
5. Tighten the wheel axle, pinch bolt 6
Do not depress the brake lever when and caliper bolts to the specified
the calipers are off the discs as the torques.
brake pads will be forced shut.
@

Tightening torque:
5. Pull out the wheel axle and re-
Wheel axle:
move the wheel by pulling it back-
72 Nm (7.2 m·kg)
wards.
Pinch bolt:
20 Nm (2.0 m·kg)
Caliper bolt:
40 Nm (4.0 m·kg)

6-38
E_5eb_Periodic.fm Page 39 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Axle nut 1. Caliper bolt (× 2)


2. Adjusting bolt 3. Remove the axle nut, caliper bolts NOTE:
@

3. Locknut
and caliper. ● Do not depress the brake pedal
EAU01247

Rear wheel removal 4. Loosen the locknuts on each side when the caliper is off the disc as
EW000122 of the swingarm. the brake pads will be forced shut.
6 WARNING 5. Turn the chain adjusting bolts fully ● You do not have to disassemble
@

● It is advisable to have a Yamaha inward. the chain in order to remove or in-


dealer service the wheel. 6. Push the wheel forward and re- stall the rear wheel.
@

● Securely support the motor- move the drive chain.


cycle so there is no danger of it 7. Pull out the wheel axle and re-
falling over. move the wheel assembly by pull-
@
ing backwards.
1. Loosen the axle nut and caliper
bolts.
2. Elevate the rear wheel.

6-39
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PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01246 EAU01008

Rear wheel installation Troubleshooting


1. Install the wheel assembly and in- Although Yamaha motorcycles receive
sert the axle. a rigid inspection before shipment from
2. Install and adjust the drive chain. the factory, trouble may occur during
(See page 6-28 for details about operation.
adjusting the drive chain slack.) Any problem in the fuel, compression,
3. Install the axle nut and let the or ignition systems can cause poor
motorcycle down. starting and loss of power. The trouble-
4. Install the caliper and caliper bolts. shooting chart describes a quick, easy
Make sure there is enough gap procedure for making checks.
between the brake pads before in- If your motorcycle requires any repair,
stalling the caliper onto the brake bring it to a Yamaha dealer. The skilled
disc. technicians at a Yamaha dealership
5. Tighten the axle nut and caliper have the tools, experience, and know- 6
bolts to the specified torques. how to properly service your motor-
cycle. Use only genuine Yamaha parts
Tightening torque: on your motorcycle. Imitation parts may
Axle nut: look like Yamaha parts, but they are of-
150 Nm (15.0 m·kg) ten inferior. Consequently, they have a
Caliper bolt: shorter service life and can lead to ex-
40 Nm (4.0 m·kg) pensive repair bills.

6-40
E_5eb_Periodic.fm Page 41 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU02990

Troubleshooting chart
EW000125

@
WARNING
Never check the fuel system while smoking or in the vicinity of an open flame.
@

1. Fuel
Enough fuel. Go to compression check.
Check if there is fuel
in the fuel tank.
No fuel. Supply fuel. Engine doesn’t start, go to compression check.

2. Compression
There is compression. Go to ignition check.
Use the electric starter.
Ask a Yamaha dealer to
6 No compression.
inspect.

3. Ignition Wipe clean with dry cloth and correct Open throttle half-way and start
Wet.
spark gap or replace spark plugs. the engine.
Remove spark plugs
and check electrodes.
Engine doesn’t start, go to battery
Dry. Ask a Yamaha dealer to inspect.
check.

4. Battery Engine turns over


Battery good.
quickly.
Engine doesn’t start, ask a Yamaha
Use the electric starter.
dealer to inspect.
Engine turns over Check connections or
slowly. recharge.

6-41
E_5eb_Periodic.fm Page 42 Thursday, November 18, 1999 4:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR


5. Engine overheating
EW000070

@
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown
out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
@

Ask a Yamaha dealer to inspect


Leakage.
and repair the cooling system.
Level is low, check the
cooling system for leakage.
No
Wait until the Check the coolant level in the leakage.
Add coolant. (See NOTE.) 6
engine has cooled. reservoir tank and/or radiator.

Restart the engine. If the engine overheats again, ask a


Level is OK.
Yamaha dealer to inspect and repair the cooling system.

NOTE:
@

If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible.
@

6-42
E_5eb_Periodic.fm Page 43 Thursday, November 18, 1999 4:06 PM
E_5eb_CleaningTOC.fm Page 1 Thursday, November 18, 1999 4:07 PM

MOTORCYCLE CARE AND STORAGE

Care ................................................................................................... 7-1


Storage............................................................................................... 7-4

7
E_5eb_Cleaning.fm Page 1 Thursday, November 18, 1999 4:08 PM

MOTORCYCLE CARE AND STORAGE


7-
EAU01637

Care Before cleaning Cleaning


The exposure of its technology makes 1. Cover up the muffler outlet with a After normal use
a motorcycle charming but also vulner- plastic bag. Remove dirt with warm water, a neutral
able. Although high-quality compo- 2. Make sure that all caps and covers detergent and a soft clean sponge,
nents are used, they are not all rust- as well as all electrical couplers then rinse with plenty of clean water.
resistant. While a rusty exhaust pipe and connectors, including the Use a tooth or bottle brush for hard-to-
may remain unnoticed on a car, it does spark plug caps, are tightly in- reach parts. Tougher dirt and insects
look unattractive on a motorcycle. Fre- stalled. will come off more easily if the area is
quent and proper care, however, will 3. Remove extremely stubborn dirt, covered with a wet cloth for a few min-
keep your motorcycle looking good, ex- like oil burnt onto the crankcase, utes before cleaning. There is a special
tend its life and maintain its perfor- with a degreasing agent and a sponge included in the plastic bag con-
mance. Moreover, the warranty states brush, but never apply such prod- taining the owners manual. Use this
that the vehicle must be properly taken ucts onto seals, gaskets, sprock- sponge to clean the muffler and to re-
care of. For all these reasons, it is rec- ets, the drive chain and wheel move any discoloration from the muf-
ommended that you observe the follow- axles. Always rinse the dirt and fler.
ing cleaning and storing precautions. degreaser off with water.
7

7-1
E_5eb_Cleaning.fm Page 2 Thursday, November 18, 1999 4:08 PM

MOTORCYCLE CARE AND STORAGE


ECA00010
● Do not use any harsh chemical ● For motorcycles equipped with
CAUTION: products on plastic parts. Be a windshield: Do not use strong
@

● Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as
cleaners, especially on spoked sponges which have been in they will cause dulling or
wheels. If you do use such contact with strong or abrasive scratching. Some cleaning
products for hard-to-remove cleaning products, solvent or compounds for plastic may
dirt, do not leave it on any long- thinner, fuel (gasoline), rust re- leave scratches on the wind-
er than instructed, then thor- movers or inhibitors, brake flu- shield. Test the product on a
oughly rinse it off with water, id, antifreeze or electrolyte. small hidden part of the wind-
immediately dry the area and ● Do not use high-pressure wash- shield to make sure they do not
apply a corrosion protection ers or steam-jet cleaners since leave any marks. If the wind-
spray. they cause water seepage and shield is scratched, use a quali-
● Improper cleaning can damage deterioration in the following ar- ty plastic polishing compound
windshields, cowlings, panels eas: seals (of wheel bearings, after washing.
and other plastic parts. Use swingarm bearings, forks and @

only a soft, clean cloth or brakes), electric components


After riding in the rain, near the sea or
sponge with mild detergent and (couplers, connectors, instru- 7
on salt-sprayed roads
water to clean plastic. ments, switches and lights),
Since sea salt or salt sprayed on the
breather hoses and vents.
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

7-2
E_5eb_Cleaning.fm Page 3 Thursday, November 18, 1999 4:08 PM

MOTORCYCLE CARE AND STORAGE


1. Clean your motorcycle with cold After cleaning EWA00001

water and soap after the engine 1. Dry the motorcycle with a chamois @
WARNING
has cooled down. or an absorbing cloth. Make sure that there is no oil or wax
ECA00012
2. Immediately dry the drive chain on the brakes and tires. If neces-
CAUTION: and lubricate it to prevent it from sary, clean the brake discs and lin-
@

Do not use warm water since it in- rusting. ings with a regular brake disc
creases the corrosive action of the 3. Use a chrome polish to shine cleaner or acetone, and wash the
salt. chrome, aluminum and stainless- tires with warm water and mild soap.
@

steel parts, including the exhaust Then, carefully test the motorcycle
2. Be sure to apply a corrosion pro-
system. (Even the thermally in- for its braking performance and cor-
tection spray on all (even chrome-
duced discoloring of stainless- nering behavior.
and nickel-plated) metal surfaces @

steel exhaust systems can be re-


to prevent corrosion.
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even chrome-
7 and nickel-plated) metal surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing it or covering it.

7-3
E_5eb_Cleaning.fm Page 4 Thursday, November 18, 1999 4:08 PM

MOTORCYCLE CARE AND STORAGE


ECA00013
Storage Long-term
CAUTION: Short-term Before storing your motorcycle for sev-
@

● Apply spray oil and wax spar- Always store your motorcycle in a cool, eral months:
ingly and wipe off any excess. dry place and, if necessary, protect it 1. Follow all the instructions in the
● Never apply oil or wax on rub- against dust with a porous cover. “Care” section of this chapter.
ber and plastic parts, but treat ECA00014 2. Drain the carburetor float cham-
them with a suitable care prod- CAUTION: bers by loosening the drain bolts;
@

uct. ● Storing the motorcycle in a this will prevent fuel deposits from
● Avoid using abrasive polishing poorly ventilated room or cover- building up. Pour the drained fuel
compounds as they wear away ing it with a tarp while it is still into the fuel tank.
the paint. wet will allow water and humidi- 3. Only for motorcycles equipped
with a fuel cock which has an
@

ty to seep in and cause rust.


NOTE:
@ ● To prevent corrosion, avoid “OFF” position: Turn the fuel cock
Consult a Yamaha dealer for advice on damp cellars, stables (because to “OFF”.
what products to use. of the presence of ammonia) 4. Fill up the fuel tank and add fuel
@

and areas where strong chemi- stabilizer (if available) to prevent


cals are stored. the fuel tank from rusting and the 7
@
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.

7-4
E_5eb_Cleaning.fm Page 5 Thursday, November 18, 1999 4:08 PM

MOTORCYCLE CARE AND STORAGE


a. Remove the spark plug caps and 6. Lubricate all control cables and 9. Remove the battery and fully
spark plugs. the pivoting points of all levers and charge it. Store it in a cool, dry
b. Pour a teaspoonful of engine oil pedals as well as of the sidestand/ place and recharge it once a
into each spark plug bore. centerstand. month. Do not store the battery in
c. Install the spark plug caps onto the 7. Check and, if necessary, correct an excessively cold or warm place
spark plugs and place the spark the tire air pressure, then raise the (less than 0°C or more than 30°C).
plugs on the cylinder head so that motorcycle so that both of its For more information, see “Battery
the electrodes are grounded. (This wheels are off the ground. Alterna- storage” in the chapter “PERIOD-
will limit sparking during the next tively, turn the wheels a little every IC MAINTENANCE AND MINOR
step.) month in order to prevent the tires REPAIRS”.
d. Turn the engine over several times from becoming degraded in one
with the starter. (This will coat the spot. NOTE:
@

Make any necessary repairs before


cylinder walls with oil.) 8. Cover up the muffler outlet with a
storing the motorcycle.
e. Remove the spark plug caps from plastic bag to prevent moisture @

the spark plugs, install the spark from entering.


plugs and then the spark plug
7 caps.
EWA00003

@
WARNING
When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking.
@

7-5
E_5eb_SpecTOC.fm Page 1 Thursday, November 18, 1999 4:08 PM

SPECIFICATIONS

Specifications ..................................................................................... 8-1


HOW TO USE THE CONVERSION TABLE ....................................... 8-5

8
E_5eb_Spec.fm Page 1 Thursday, November 18, 1999 4:08 PM

SPECIFICATIONS
8-
EAU01038

Specifications
01E
Model YZF-R6 Engine oil
Dimensions Type
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C
Overall length 2,025 mm (except for N, S, SF)
SAE 10W/30
2,075 mm (for N, S, SF)
Overall width 690 mm SAE 10W/40

Overall height 1,105 mm SAE 15W/40


Seat height 820 mm SAE 20W/40
Wheelbase 1,380 mm
SAE 20W/50
Ground clearance 135 mm
Minimum turning radius 3,400 mm Recommended engine oil
classification API Service SE, SF, SG type or
Basic weight (with oil and full higher
fuel tank) 188 kg
Engine CAUTION:
Engine type Liquid-cooled 4-stroke, DOHC Be sure to use motor oils that do not contain anti-fric-
tion modifiers. Passenger car motor oils (often labeled
Cylinder arrangement Forward-inclined parallel “Energy Conserving”) contain anti-friction additives
4-cylinder which will cause clutch and/or starter clutch slippage,
8 Displacement 600 cm3 resulting in reduced component life and poor engine
performance.
Bore × Stroke 65.5 × 44.5 mm
Compression ratio 12.4:1 Quantity
Starting system Electric starter Periodic oil change 2.5 L
Lubrication system Wet sump With oil filter replacement 2.7 L
Total amount 3.5 L

8-1
E_5eb_Spec.fm Page 2 Thursday, November 18, 1999 4:08 PM

SPECIFICATIONS
Cooling system capacity Gear ratio
(total amount) 2.15 L
1st 2.846
Air filter Wet type element 2nd 1.947
Fuel
3rd 1.556
Type Regular unleaded gasoline
4th 1.333
Fuel tank capacity 17 L 5th 1.190
Fuel reserve amount 3.5 L
6th 1.083
Carburetor
Chassis
Type × quantity CVRD37 × 4 Frame type Diamond
Manufacturer KEIHIN
Caster angle 24°
Spark plug
Trail 81 mm
Manufacturer/Type NGK / CR10EK Tire
Gap 0.6 ~ 0.7 mm
Front
Clutch type Wet, multiple-disc Type Tubeless
Transmission
Size 120/60 ZR17 (55 W)
Primary reduction system Spur gear
Manufacturer/model Bridgestone / BT56FE
Primary reduction ratio 1.955 Dunlop / D207FJ
Secondary reduction system Chain drive 8
Rear
Secondary reduction ratio 3.000
Type Tubeless
Transmission type Constant mesh 6-speed Size 180/55 ZR17 (73 W)
Operation Left foot operation
Manufacturer/model Bridgestone / BT56RE
Dunlop / D207N
Maximum load* 187 kg

8-2
E_5eb_Spec.fm Page 3 Thursday, November 18, 1999 4:08 PM

SPECIFICATIONS
Air pressure (cold tire) Rear
Up to 90 kg load* Type Single disc brake
Front 250 kPa; 2.50 kg/cm2; 2.50 bar Operation Right foot operation
2
Rear 250 kPa; 2.50 kg/cm ; 2.50 bar Fluid DOT 4
90 kg load ~ maximum Suspension
load* Front
Front 250 kPa; 2.50 kg/cm2; 2.50 bar
Type Telescopic fork
Rear 290 kPa; 2.90 kg/cm2; 2.90 bar
Rear
High speed riding Type Swingarm (link suspension)
Front 250 kPa; 2.50 kg/cm2; 2.50 bar
Shock absorbers
Rear 250 kPa; 2.50 kg/cm2; 2.50 bar
Front Coil spring / oil damper
* Load is total weight of cargo, rider, passenger and accessories. Rear Coil spring / gas-oil damper
Wheels
Wheel travel
Front Front 130 mm
Type Cast
Rear 120 mm
Size 17 × MT 3.50
Electrical
Rear Ignition system C.D.I.
8 Type Cast
Charging system
Size 17 × MT 5.50
Type A.C. magneto
Brakes Standard output 14 V, 320 W@ 5,000 r/min
Front
Battery
Type Dual disc brake
Type GT12B-4
Operation Right hand operation Voltage, capacity 12 V, 10 AH
Fluid DOT 4
Headlight type Quartz bulb (halogen)

8-3
E_5eb_Spec.fm Page 4 Thursday, November 18, 1999 4:08 PM

SPECIFICATIONS
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 2
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
Auxiliary light 12 V, 5 W × 2
Meter light 12 V, 1.4 W × 2
Neutral indicator light LED
High beam indicator light LED
Turn indicator light LED
Fuel indicator light LED
Oil level/coolant temperature
indicator light LED
Fuses
Main fuse 30 A
Headlight fuse 20 A
Signaling system fuse 20 A
Radiator fan fuse 7.5 A
Ignition fuse 15 A 8
Odometer fuse 7.5 A

8-4
E_5eb_Spec.fm Page 5 Thursday, November 18, 1999 4:08 PM

SPECIFICATIONS
EAU01064

HOW TO USE THE CONVERSION TABLE


CS-02E
CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC TO IMPERIAL
METRIC UNITS. Metric unit Multiplier Imperial unit
Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb
m·kg 86.794 in·lb
unit data. Torque
cm·kg 0.0723 ft·lb
Ex. cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
METRIC MULTIPLIER IMPERIAL g 0.03527 oz
Speed km/hr 0.6214 mph
**mm × 0.03937 = **in
km 0.6214 mi
m 3.281 ft
2 mm × 0.03937 = 0.08 in Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume / cc (cm3) 0.06102 cu·in
Capacity lt (liter) 0.8799 qt (IMP liq.)
lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Misc. kg/cm2 14.2234 psi (lb/in2)
8 Centigrade (°C) 9/5 + 32 Fahrenheit (°F)

8-5
E_5eb_ConsumerTOC.fm Page 1 Thursday, November 18, 1999 4:08 PM

CONSUMER INFORMATION

Identification number records............................................................. 9-1


Key identification number ................................................................... 9-1
Vehicle identification number.............................................................. 9-1
Model label......................................................................................... 9-2

9
E_5eb_Consumer.fm Page 1 Thursday, November 18, 1999 4:09 PM

CONSUMER INFORMATION
9-
EAU01039

EAU02944

Identification number records


Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION NUMBER: 1. Key identification number 1. Vehicle identification number
EAU01041 EAU01043
CA-02E
Key identification number Vehicle identification number
The key identification number is The vehicle identification number is
stamped on the key tag. Record this stamped into the steering head pipe.
number in the space provided and use Record this number in the space pro-
2. VEHICLE IDENTIFICATION it for reference when obtaining a new vided.
NUMBER:
CA-02E
key.
NOTE:
@

The vehicle identification number is


used to identify your motorcycle and
may be used to register your motor-
3. MODEL LABEL INFORMATION: cycle with the licensing authority in
9 CA-01E your state.
@

9-1
E_5eb_Consumer.fm Page 2 Thursday, November 18, 1999 4:09 PM

CONSUMER INFORMATION

1. Model label
EAU01049

Model label
The model label is affixed to the loca-
tion shown in the figure. Record the in-
formation on this label in the space
provided. This information will be need-
ed to order spare parts from your
Yamaha dealer.

9-2
E_5ebIX.fm Page 1 Thursday, November 18, 1999 4:09 PM

INDEX
10-

A E I
Air filter ..................................................6-17 Engine break-in ....................................... 5-5 Identification number records ...................9-1
Air intake duct ........................................6-19 Engine oil .............................................. 6-10 Idle speed adjustment ............................6-20
Antitheft alarm (optional) ........................3-12 Engine stop switch................................. 3-10 Indicator lights..........................................3-2
Fuel indicator light...............................3-2
B F
High beam indicator light ....................3-2
Battery ...................................................6-33 Front brake lever ................................... 3-11
Neutral indicator light ..........................3-2
Brake and clutch lever lubrication...........6-31 Front fork adjustment............................. 3-17
Oil level/coolant temperature
Brake fluid replacement .........................6-28 Front fork inspection .............................. 6-32
indicator light....................................3-3
Brake light switch adjustment.................6-25 Front wheel installation .......................... 6-38
Turn indicator light ..............................3-2
Brake pedal lubrication...........................6-30 Front wheel removal .............................. 6-37
Inspecting the brake fluid level ...............6-27
Fuel ....................................................... 3-13
C
Fuel indicator light ................................... 3-2 K
Cable inspection and lubrication ............6-30
Fuel indicator light circuit check ............... 3-6 Key identification number .........................9-1
Carburetor adjustment ...........................6-20
Fuel tank breather hose......................... 3-14
Care.........................................................7-1 L
Fuel tank cap......................................... 3-13
Changing the coolant .............................6-14 Left view...................................................2-1
Fuse replacement.................................. 6-34
Checking the front and rear brake Light switch ............................................3-10
pads ....................................................6-26 G Luggage strap holders ...........................3-23
Clutch lever............................................3-11 Give safety the right of way ..................... 1-1
M
Clutch lever free play adjustment ...........6-25
H Main switch/Steering lock.........................3-1
Controls/Instruments................................2-3
Handlebar switches ................................. 3-9 Model label ..............................................9-2
Cooling system ......................................6-13
Dimmer switch ................................... 3-9
Cowling and panel removal and N
Engine stop switch ........................... 3-10
installation .............................................6-6 Neutral indicator light ...............................3-2
Horn switch ...................................... 3-10
Cowlings A and B ....................................6-6
Light switch ...................................... 3-10 O
D Pass switch ........................................ 3-9 Oil level/coolant temperature indicator
Diagnosis device......................................3-9 Start switch ...................................... 3-10 light........................................................3-3
Digital speedometer .................................3-7 Turn signal switch ............................ 3-10 Oil level / coolant temperature indicator
Dimmer switch .........................................3-9 Headlight bulb replacement ................... 6-35 light circuit check ...................................3-5
Drive chain lubrication............................6-29 Helmet holder ........................................ 3-17
P
Drive chain slack adjustment..................6-29 High beam indicator light ......................... 3-2
Panel C ....................................................6-8
Drive chain slack check..........................6-28 Horn switch ........................................... 3-10
Parking.....................................................5-5
E_5ebIX.fm Page 2 Thursday, November 18, 1999 4:09 PM

INDEX
Pass switch ............................................. 3-9 T
Periodic maintenance and lubrication ...... 6-3 Tachometer............................................. 3-8
Pre-operation check list ........................... 4-1 Tail/brake light bulb replacement........... 6-36
R Throttle cable and grip lubrication.......... 6-30
Rear brake pedal ................................... 3-12 Throttle cable free play inspection ......... 6-21
Tips for reducing fuel consumption.......... 5-4
Rear shock absorber adjustment ........... 3-19
Tires...................................................... 6-21
Rear suspension lubrication................... 6-31
Rear wheel installation........................... 6-40 Tool kit .................................................... 6-1
Troubleshooting .................................... 6-40
Rear wheel removal............................... 6-39
Troubleshooting chart ........................... 6-41
Recommended combinations of the
front fork and the rear shock Turn indicator light................................... 3-2
Turn signal light bulb replacement......... 6-36
absorber settings................................. 3-22
Turn signal switch ................................. 3-10
Right view................................................ 2-2
S V
Seats ..................................................... 3-15 Valve clearance adjustment .................. 6-21
Vehicle identification number................... 9-1
Shifting .................................................... 5-4
Shift pedal ............................................. 3-11 W
Sidestand .............................................. 3-23 Wheel bearings ..................................... 6-33
Sidestand/clutch switch operation Wheels.................................................. 6-24
check .................................................. 3-24
Sidestand lubrication ............................. 6-31
Spark plug inspection .............................. 6-9
Specifications .......................................... 8-1
Starter (choke) “ ”.............................. 3-15
Starting a warm engine............................ 5-3
Starting the engine .................................. 5-1
Start switch............................................ 3-10
Steering inspection ................................ 6-32
Storage.................................................... 7-4
Storage compartment ............................ 3-17
Supporting the motorcycle ..................... 6-37
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
99 · 11 - 1.9 × 1 CR
(E)

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