Yamaha YZFR6SW User Manual

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Page 1

OWNER’S MANUAL

YZFR6SW(C)

LIT-11626-20-35

4P6-28199-11

Page 2

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Page 3

INTRODUCTION

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Congratulations on your purchase of the Yamaha YZFR6SW(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer. The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

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IMPORTANT MANUAL INFORMATION

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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WARNING

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

to the

cycle.

CAUTION:

NOTE:

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

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 you have any questions concerning this manual, please consult your Yamaha dealer.

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WARNING

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES

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IMPORTANT MANUAL INFORMATION

AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.

*Product and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

YZFR6SW(C)

OWNER’S MANUAL

1st edition, June 2006

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan.

P/N LIT-11626-20-35

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Page 7

SAFETY INFORMATION ..................1-1

Location of important labels ...........1-5

DESCRIPTION ..................................2-1

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

Right view........................................2-2

Controls and instruments ................2-3

INSTRUMENT AND CONTROL

FUNCTIONS.......................................3-1

Main switch/steering lock ................3-1

Indicator and warning lights ............3-2

Tachometer ....................................3-5

Multi-function display ......................3-6

Handlebar switches ........................3-9

Clutch lever ..................................3-10

Shift pedal ....................................3-11

Brake lever ...................................3-11

Brake pedal ..................................3-11

Fuel tank cap ................................3-12

Fuel ..............................................3-12

Catalytic converter ........................3-13

Seats ............................................3-14

Helmet holders .............................3-15

Storage compartment ...................3-15

Adjusting the front fork .................3-16

Adjusting the shock absorber

assembly ...................................3-17

Luggage strap holders ..................3-19

Sidestand .....................................3-19

Ignition circuit cut-off system ........3-20

PRE-OPERATION CHECKS ............. 4-1

Pre-operation check list ................. 4-2

OPERATION AND IMPORTANT

RIDING POINTS ................................ 5-1

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

Shifting ........................................... 5-2

Engine break-in .............................. 5-3

Parking ........................................... 5-4

PERIODIC MAINTENANCE AND

MINOR REPAIR................................. 6-1

PERIODIC MAINTENANCE .......... 6-1

Owner’s tool kit .............................. 6-1

Periodic maintenance chart for the

emission control system ............. 6-3

General maintenance and

lubrication chart .......................... 6-4

Removing and installing cowlings

and panels .................................. 6-8

Checking the spark plugs ............ 6-10

Canister (for California only) ........ 6-11

Engine oil and oil filter cartridge ... 6-11

Coolant ........................................ 6-14

Checking the air filter element ..... 6-18

Air intake duct .............................. 6-20

Checking the throttle cable

free play .................................... 6-20

Valve clearance ........................... 6-21

Tires ............................................. 6-21

Cast wheels ................................. 6-24

Accessories and replacement

parts ..........................................6-24

Adjusting the clutch lever free

play ...........................................6-25

Adjusting the rear brake light

switch ........................................6-26

Checking the front and rear brake

pads ..........................................6-26

Checking the brake fluid level ......6-27

Changing the brake fluid .............. 6-28

Drive chain slack ..........................6-28

Cleaning and lubricating the drive

chain .........................................6-29

Checking and lubricating the

cables .......................................6-30

Checking and lubricating the

throttle grip and cable ...............6-30

Checking and lubricating the brake

and shift pedals .........................6-31

Checking and lubricating the brake

and clutch levers ....................... 6-31

Checking and lubricating the

sidestand ..................................6-32

Lubricating the swingarm pivots ... 6-32

Checking the front fork .................6-33

Checking the steering ..................6-33

Checking the wheel bearings .......6-34

Battery ..........................................6-34

Replacing the fuses ...................... 6-36

Replacing a headlight bulb ...........6-37

Tail/brake light .............................. 6-38

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TABLE OF CONTENTS

Replacing a turn signal light

bulb ...........................................6-38

Replacing the license plate light

bulb ...........................................6-39

Supporting the motorcycle ............6-39

Front wheel ...................................6-40

Rear wheel ...................................6-42

Troubleshooting ............................6-44

Troubleshooting charts .................6-45

MOTORCYCLE CARE AND

STORAGE ..........................................7-1

Matte color caution .........................7-1

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

Storage ...........................................7-3

SPECIFICATIONS .............................8-1

CONSUMER INFORMATION.............9-1

Identification numbers ....................9-1

Reporting safety defects .................9-3

Motorcycle noise regulation ............9-4

Maintenance record ........................9-5

YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO

MOTORCYCLE LIMITED

WARRANTY ................................9-7

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................9-9

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SAFETY INFORMATION

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MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.

● OBSERVE THE WARNINGS AND

MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.

● OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING TECHNIQUES.

● OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding

● Always make pre-operation

checks. Careful checks may help prevent an accident.

● This motorcycle is designed to car-

ry the operator and a passenger.

● The failure of motorists to detect

and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

• Wear a brightly colored jacket.

• Use extra caution when you are

approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.

• Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

● Many accidents involve inexperi-

enced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license.

• Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.

• Know your skills and limits. Staying within your limits may help you to avoid an accident.

• We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls.

● Many accidents have been caused

by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn

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SAFETY INFORMATION

due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).

• Always obey the speed limit and never travel faster than warranted by road and traffic conditions.

• Always signal before turning or changing lanes. Make sure that other motorists can see you.

● The posture of the operator and

passenger is important for proper control.

• The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.

• The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.

• Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

● Never ride under the influence of

alcohol or other drugs.

● This motorcycle is designed for on-

road use only. It is not suitable for off-road use.

Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.

● Always wear an approved helmet.

● Wear a face shield or goggles.

Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.

● The use of a jacket, heavy boots,

trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.

● Never wear loose-fitting clothes,

otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident.

● Never touch the engine or exhaust

system during or after operation. They become very hot and can

cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

● A passenger should also observe

the above precautions.

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:

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SAFETY INFORMATION

Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit.

Maximum load:

YZFR6SW 193 kg (425 lb) YZFR6SWC 192 kg (423 lb)

When loading within this weight limit, keep the following in mind:

● Cargo and accessory weight

should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.

● Shifting weights can create a sud-

den imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

● Never attach any large or heavy

items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping

bags, duffel bags, or tents, can create unstable handling or a slow

steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Load- ing” when mounting accessories.

● Never install accessories or carry

cargo that would impair the perfor-

mance of your motorcycle. Care-

fully inspect the accessory before

using it to make sure that it does

not in any way reduce ground

clearance or cornering clearance,

limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

• Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.

• Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles.

• Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the opera-

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SAFETY INFORMATION

tor and may limit control ability, therefore, such accessories are not recommended.

● Use caution when adding electri-

cal accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.

Gasoline and exhaust gas

● GASOLINE IS HIGHLY FLAMMA-

BLE:

• Always turn the engine off when refueling.

• Take care not to spill any gasoline on the engine or exhaust system when refueling.

• Never refuel while smoking or in the vicinity of an open flame.

● Never start the engine or let it run

for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.

● Always turn the engine off before

leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following:

• The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.

• Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.

• Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire.

● When transporting the motorcycle

in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the fuel tank.

● If you should swallow any gaso-

line, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin

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or clothing, immediately wash the affected area with soap and water and change your clothes.

Page 13

Location of important labels

Please read the following important labels carefully before operating this vehicle.

SAFETY INFORMATION

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SAFETY INFORMATION

CAUTION

Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield.

Use neutral detergent.

5JW-00

Cold tire normal pressure should be set as follows.

Improper loading can cause loss of control. Read owner’s manual for proper loading.

PREMIUM UNLEADED GASOLINE ONLY

WARNING

3JJ-28446-A1

91 Min. Pump Octane (R+M) 2

5PW-2415E-11

3 kg {7 lbs}

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SAFETY INFORMATION

California only 10 California only8

California only9

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Page 16

DESCRIPTION

Left view

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1. Front fork rebound damping force adjusting screw (page 3-16)

2. Front fork spring preload adjusting bolt (page 3-16)

3. Fuse box (page 6-36)

4. Coolant reservoir (page 6-14)

5. Shock absorber assembly spring preload adjusting ring (page 3-17)

6. Shock absorber assembly compression damping force adjusting screw (page 3-17)

7. Owner’s tool kit (page 6-1)

8. Shock absorber assembly rebound damping force adjusting screw (page 3-17)

9. Shift pedal (page 3-11)

10.Engine oil drain bolt (page 6-11)

11.Engine oil filter cartridge (page 6-11)

12.Front fork compression damping force adjusting screw (page 3-16)

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Right view

DESCRIPTION

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1. Luggage strap holder (page 3-19)

2. Helmet holder (page 3-15)

3. Main fuse (page 6-36)

4. Battery (page 6-34)

5. Air filter element (page 6-18)

6. Front brake fluid reservoir (page 6-27)

7. Radiator cap (page 6-14)

8. Coolant drain bolt (page 6-15)

9. Engine oil filler cap (page 6-11)

10.Brake pedal (page 3-11)

11.Dipstick (page 6-11)

12.Rear brake fluid reservoir (page 6-27)

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DESCRIPTION

Controls and instruments

1. Clutch lever (page 3-10)

2. Left handlebar switches (page 3-9)

3. Multi-function display (page 3-6)

4. Main switch/steering lock (page 3-1)

5. Tachometer (page 3-5)

6. Right handlebar switches (page 3-9)

7. Throttle grip (page 6-20)

8. Brake lever (page 3-11)

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2-3

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INSTRUMENT AND CONTROL FUNCTIONS

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Main switch/steering lock

The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.

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All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed.

NOTE:

The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls.

OFF

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All electrical systems are off. The key can be removed.

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LOCK

The steering is locked, and all electrical systems are off. The key can be removed.

To lock the steering

1. Push.

2. Turn.

1. Turn the handlebars all the way to the left.

2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it.

3. Remove the key.

To unlock the steering

1. Push.

2. Turn.

Push the key in, and then turn it to “OFF” while still pushing it.

EWA10060

WARNING

Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”.

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INSTRUMENT AND CONTROL FUNCTIONS

Indicator and warning lights

1. Right turn signal indicator light “”

2. Fuel level warning light “”

3. Oil level warning light “”

4. Neutral indicator light “”

5. Engine trouble warning light “”

6. High beam indicator light “”

7. Left turn signal indicator light “”

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1. Shift timing indicator light

2. Coolant temperature warning light “”

3. Coolant temperature display

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Turn signal indicator lights “” and “”

The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.

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Neutral indicator light “”

This indicator light comes on when the transmission is in the neutral position.

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High beam indicator light “”

This indicator light comes on when the high beam of the headlight is switched on.

Oil level warning light “”

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This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.

NOTE:

● Even if the oil level is sufficient, the

warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction.

● This model is also equipped with a

self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5 seconds. If this occurs, have a Yamaha dealer check the vehicle.

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INSTRUMENT AND CONTROL FUNCTIONS

Fuel level warning light “”

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This warning light comes on when the fuel level drops below approximately

3.5 L (0.92 US gal) (0.77 Imp.gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, and then go off, have a Yamaha dealer check the electrical circuit.

NOTE:

This model is also equipped with a selfdiagnosis device for the fuel level detection circuit. If the fuel level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The fuel level warning light will flash eight times, and then go off for

3.0 seconds. If this occurs, have a Yamaha dealer check the vehicle.

Coolant temperature warning light

EAU11423

“”

This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.

ECA10020

CAUTION:

Do not operate the engine if it is overheated.

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INSTRUMENT AND CONTROL FUNCTIONS

Coolant

temperature

Under 39 °C

(Under 103 °F)

Display Conditions What to do

Message “Lo” is displayed. OK. Go ahead with riding.

40–116 °C

(104–241 °F)

117–139 °C

(242–283 °F)

Above 140 °C

(Above 284 °F)

Temperature is displayed. OK. Go ahead with riding.

Temperature display flashes. Warning light comes on.

Message “HI” flashes. Warning light comes on.

Stop the vehicle and allow it to idle until the coolant temperature goes down. If the temperature does not go down, stop the engine. (See page 6-45.)

Stop the engine and allow it to cool. (See page 6-45.)

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INSTRUMENT AND CONTROL FUNCTIONS

Engine trouble warning light “”

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This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. (See page 3-6 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.

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Shift timing indicator light

This indicator light can be set to come on and go off at the desired engine speeds and is used to inform the rider when it is time to shift to the next higher gear. The electrical circuit of the indicator light can be checked by turning the key to “ON”. If the indicator light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir-

cuit. (See page 3-6 for a detailed explanation of the function of this indicator light and on how to set it.)

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Tachometer

1. Tachometer

2. Tachometer red zone

The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. When the key is turned to “ON”, the ta- chometer needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit.

ECA10031

CAUTION:

Do not operate the engine in the tachometer red zone. Red zone: 15500 r/min and above

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INSTRUMENT AND CONTROL FUNCTIONS

Multi-function display

1. Multi-function display

2. “SELECT” button

3. “RESET” button

The multi-function display is equipped with the following:

● a speedometer (which shows the

riding speed)

● an odometer (which shows the to-

tal distance traveled)

● two tripmeters (which show the

distance traveled since they were last set to zero)

● a fuel reserve tripmeter (which

shows the distance traveled since the fuel level warning light came on)

● a clock

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● a self-diagnosis device

● a display brightness and shift tim-

ing indicator light control mode

NOTE:

● Be sure to turn the key to “ON” be-

fore using the “SELECT” and “RE- SET” buttons.

● To switch the speedometer and

odometer/tripmeter displays between kilometers and miles, press the “SELECT” button and “RESET” button together for at least two seconds.

Odometer and tripmeter modes

Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: ODO → TRIP 1 → TRIP 2 → ODO If the fuel level warning light comes on (see page 3-2), the odometer display will automatically change to the fuel reserve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case, pushing

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the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: F-TRIP → TRIP 1 → TRIP 2 → ODO → F-TRIP To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3 mi).

Clock mode

Turn the key to “ON”. To change the display to the clock mode, push the “SELECT” button for at least one second. To change the display back to the prior mode, push the “SELECT” button.

To set the clock:

1. Push the “SELECT” button and “RESET” button together for at least two seconds.

2. When the hour digits start flashing, push the “RESET” button to set the hours.

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INSTRUMENT AND CONTROL FUNCTIONS

3. Push the “SELECT” button, and the minute digits will start flashing.

4. Push the “RESET” button to set the minutes.

5. Push the “SELECT” button and then release it to start the clock.

Self-diagnosis devices

This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on, and then the multi-function display will indicate a two-digit error code (e.g., 11, 12, 13). If the multi-function display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle.

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CAUTION:

If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage.

Display brightness and shift timing indicator light control mode

1. Shift timing indicator light

2. “SELECT” button

3. “RESET” button

This mode cycles through five control functions, allowing you to make the following settings in the order listed below.

● Display brightness:

This function allows you to adjust the brightness of the multi-function display to suit the outside lighting conditions.

● Shift timing indicator light activity:

This function allows you to choose whether or not the indicator light should be activated and whether it should blink or stay on when activated.

● Shift timing indicator light activa-

tion: This function allows you to select the engine speed at which the indicator light will be activated.

● Shift timing indicator light deactiva-

tion: This function allows you to select the engine speed at which the indicator light will be deactivated.

● Shift timing indicator light bright-

ness: This function allows you to adjust the brightness of the indicator light to suit your preference.

NOTE:

● To make any settings in this mode,

you have to cycle through all of its functions. However, if the key is turned to “OFF” or the engine is started before completing the pro-

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INSTRUMENT AND CONTROL FUNCTIONS

cedure, only the settings made before the “SELECT” button was last pushed will be applied.

● In this mode, the multi-function dis-

play shows the current setting for each function (except the shift timing indicator light activity function).

To adjust the display brightness

1. Turn the key to “OFF”.

2. Push and hold the “SELECT” button.

3. Turn the key to “ON”, and then, after five seconds, release the “SE- LECT” button.

4. Push the “RESET” button to select the desired display brightness level.

5. Push the “SELECT” button to confirm the selected display brightness level. The control mode changes to the shift timing indicator light activity function.

To set the shift timing indicator light activity function

1. Push the “RESET” button to select one of the following indicator light activity settings:

● The indicator light will stay on

when activated. (This setting is selected when the indicator light stays on.)

● The indicator light will flash

when activated. (This setting is selected when the indicator light flashes four times per second.)

● The indicator light is deacti-

vated; in other words, it will not come on or flash. (This setting is selected when the indicator light flashes once every two seconds.)

2. Push the “SELECT” button to con- firm the selected indicator light activity. The control mode changes to the shift timing indicator light activation function.

To set the shift timing indicator light activation function

NOTE:

The shift timing indicator light activation function can be set between 10000 r/min and 16000 r/min. From 10000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 16000 r/min, the indicator light can be set in increments of 200 r/min.

1. Push the “RESET” button to select the desired engine speed for activating the indicator light.

2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the shift timing indicator light deactivation function.

To set the shift timing indicator light deactivation function

NOTE:

● The indicator light deactivation

function can be set between 10000 r/min and 16000 r/min. From 10000 r/min to 12000 r/min,

3-8

Page 27

INSTRUMENT AND CONTROL FUNCTIONS

the indicator light can be set in increments of 500 r/min. From 12000 r/min to 16000 r/min, the indicator light can be set in increments of 200 r/min.

● Be sure to set the deactivation

function to a higher engine speed than for the activation function, otherwise the shift timing indicator light will remain deactivated.

1. Push the “RESET” button to select the desired engine speed for deactivating the indicator light.

2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the shift timing indicator light brightness function.

To adjust the shift timing indicator light brightness

1. Push the “RESET” button to select the desired indicator light brightness level.

2. Push the “SELECT” button to confirm the selected indicator light brightness level. The multi-function display will return to the odometer, tripmeter or clock mode.

EAU12346

Handlebar switches

Left

1. Dimmer switch “ / ”

2. Turn signal switch “ / ”

3. Horn switch “”

Right

3-9

1. Engine stop switch “ / ”

2. Start switch “”

Page 28

INSTRUMENT AND CONTROL FUNCTIONS

Dimmer switch “ / ”

Set this switch to “” for the high beam and to “” for the low beam.

Turn signal switch “ / ”

To signal a right-hand turn, push this switch to “”. To signal a left-hand

turn, push this switch to “”. When re- leased, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position.

Horn switch “”

Press this switch to sound the horn.

Engine stop switch “ / ”

Set this switch to “” before starting the engine. Set this switch to “” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.

EAU12400

EAU12460

EAU12500

EAU12660

ECA10050

CAUTION:

See page 5-1 for starting instructions prior to starting the engine.

EAU41700

The engine trouble warning light will come on when the key is turned to “ON” and the start switch is pushed, but this does not indicate a malfunction.

EAU12820

Clutch lever

1. Clutch lever

The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-20.)

Start switch “”

EAU12710

Push this switch to crank the engine with the starter.

3-10

Page 29

INSTRUMENT AND CONTROL FUNCTIONS

EAU12870

Shift pedal

1. Shift pedal

The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle.

EAU12930

Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip.

1. Brake lever

2. Arrow mark

3. Brake lever position adjusting dial

4. Distance between brake lever and handlebar grip

The brake lever is equipped with a position adjusting dial. To adjust the distance between the brake lever and the handlebar grip, turn the adjusting dial while holding the lever pushed away from the handlebar grip. Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever.

3-11

EAU12941

Brake pedal

1. Brake pedal

The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.

Page 30

INSTRUMENT AND CONTROL FUNCTIONS

Fuel tank cap

1. Fuel tank cap lock cover

2. Unlock.

To open the fuel tank cap

Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened.

To close the fuel tank cap

1. Push the fuel tank cap into position with the key inserted in the lock.

2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover.

EAU13070

NOTE:

The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.

EWA11090

WARNING

Make sure that the fuel tank cap is properly closed before riding.

EAU13220

Fuel

1. Fuel tank filler tube

2. Fuel level

Make sure that there is sufficient fuel in the tank. When refueling, be sure to insert the pump nozzle into the fuel tank filler hole and to fill the tank to the bottom of the filler tube as shown.

EWA10880

WARNING

● Do not overfill the fuel tank, oth-

erwise it may overflow when the fuel warms up and expands.

● Avoid spilling fuel on the hot en-

gine.

3-12

Page 31

INSTRUMENT AND CONTROL FUNCTIONS

ECA10070

CAUTION:

Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.

EAU13380

Recommended fuel:

PREMIUM UNLEADED GASOLINE ONLY

Fuel tank capacity:

17.0 L (4.49 US gal) (3.74 Imp.gal)

Fuel reserve amount (when the fuel level warning light comes on):

3.5 L (0.92 US gal) (0.77 Imp.gal)

ECA11400

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system.

Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research

octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

3-13

EAU13441

Catalytic converter

This vehicle is equipped with catalytic converters in the exhaust system.

EWA10860

WARNING

The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work.

ECA10700

CAUTION:

The following precautions must be observed to prevent a fire hazard or other damages.

● Use only unleaded gasoline.

The use of leaded gasoline will cause unrepairable damage to the catalytic converter.

● Never park the vehicle near pos-

sible fire hazards such as grass or other materials that easily burn.

● Do not allow the engine to idle

too long.

Page 32

INSTRUMENT AND CONTROL FUNCTIONS

Seats

Rider seat

To remove the rider seat Pull back the rear of the rider seat as shown, remove the bolts, and then pull

the seat off.

1. Bolt

To install the rider seat Insert the projection on the front of the rider seat into the seat holder as shown, place the seat in the original position, and then install the bolts.

EAU14091

1. Projection

2. Seat holder

Passenger seat

To remove the passenger seat

1. Insert the key into the seat lock, and then turn it counterclockwise.

1. Passenger seat lock

2. Unlock.

2. While holding the key in that position, lift the front of the passenger seat and pull it forward.

To install the passenger seat

1. Insert the projection on the rear of the passenger seat into the seat holder as shown, and then push the front of the seat down to lock it in place.

1. Projection

2. Seat holder

2. Remove the key.

NOTE:

Make sure that the seats are properly secured before riding.

3-14

Page 33

INSTRUMENT AND CONTROL FUNCTIONS

Helmet holders

EAU14380

CAUTION:

ECA11600

Storage compartment

Some helmets may contact the muffler when secured to the right side helmet holder because of their size or shape. Be sure that your helmet does not contact the muffler when it is secured to the helmet holder.

To release a helmet from a helmet

1. Helmet holder 1. Storage compartment

The helmet holders are located on the bottom of the passenger seat.

holder

Remove the passenger seat, remove the helmet from the helmet holder, and then install the seat.

The storage compartment is located under the passenger seat. (See page 3-14.)

To secure a helmet to a helmet holder

1. Remove the passenger seat. (See page 3-14.)

2. Attach the helmet to a helmet holder, and then securely install the passenger seat.

EWA11040

WARNING

● Do not exceed the load limit of 3

kg (7 lb) for the storage compartment.

● Do not exceed the maximum

load of YZFR6SW 193 kg (425 lb) YZFR6SWC 192 kg (423 lb) for

the vehicle. Never ride with a helmet attached to a helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.

EAU14461

EWA10961

3-15

Page 34

INSTRUMENT AND CONTROL FUNCTIONS

Adjusting the front fork

This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting screws.

WARNING

Always adjust both fork legs equally, otherwise poor handling and loss of stability may result.

Spring preload

1. Spring preload adjusting bolt

To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each fork leg in direction (a). To decrease the spring pre-

EAU14761

EWA10180

load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b).

NOTE:

Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt.

1. Current setting

2. Front fork cap bolt

Spring preload setting:

Minimum (soft):

Standard:

Maximum (hard):

3-16

Rebound damping force

1. Rebound damping force adjusting screw

To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw on each fork leg in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting screw on each fork leg in direction (b).

Rebound damping setting:

Minimum (soft):

10 click(s) in direction (b)*

Standard:

9 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

* With the adjusting screw fully turned

in direction (a)

Page 35

INSTRUMENT AND CONTROL FUNCTIONS

Compression damping force

1. Compression damping force adjusting screw

To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw on each fork leg in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw on each fork leg in direction (b).

Compression damping setting:

Minimum (soft):

9 click(s) in direction (b)*

Standard:

7 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

* With the adjusting screw fully turned

in direction (a)

ECA10100

CAUTION:

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

NOTE:

Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary.

EAU15051

Adjusting the shock absorber assembly

This shock absorber assembly is equipped with a spring preload adjusting ring and rebound and compression damping force adjusting screws.

ECA10100

CAUTION:

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

Spring preload

1. Spring preload adjusting ring

2. Special wrench

3. Position indicator

3-17

Page 36

INSTRUMENT AND CONTROL FUNCTIONS

To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a). To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b).

Spring preload setting:

Minimum (soft):

Standard:

Maximum (hard):

Rebound damping force

1. Rebound damping force adjusting screw

To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw in direction

(a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting screw in direction (b).

Rebound damping setting:

Minimum (soft):

20 click(s) in direction (b)*

Standard:

10 click(s) in direction (b)*

Maximum (hard):

5 click(s) in direction (b)*

* With the adjusting screw fully turned

in direction (a)

Compression damping force

1. Compression damping force adjusting screw

To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw

3-18

in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).

Compression damping setting:

Minimum (soft):

20 click(s) in direction (b)*

Standard:

10 click(s) in direction (b)*

Maximum (hard):

1 click(s) in direction (b)*

* With the adjusting screw fully turned

in direction (a)

NOTE:

Page 37

INSTRUMENT AND CONTROL FUNCTIONS

EWA10220

WARNING

This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.

● Do not tamper with or attempt to

open the gas cylinder.

● Do not subject the shock ab-

sorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure.

● Do not deform or damage the

gas cylinder in any way, as this will result in poor damping performance.

● Always have a Yamaha dealer

service the shock absorber.

EAU15181

Luggage strap holders

1. Luggage strap holder

2. Hook

There are four luggage strap holders on the bottom of the passenger seat. To use the strap holders, remove the passenger seat, unhook the straps from the hooks, and then install the seat with the straps hanging out from under the passenger seat. (See page 3-14.)

EAU15301

Sidestand

The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.

NOTE:

The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.)

EWA10240

WARNING

The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described

3-19

Page 38

INSTRUMENT AND CONTROL FUNCTIONS

below and have a Yamaha dealer repair it if it does not function properly.

EAU15311

Ignition circuit cut-off system

The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions.

● It prevents starting when the trans-

mission is in gear and the sidestand is up, but the clutch lever is not pulled.

● It prevents starting when the trans-

mission is in gear and the clutch lever is pulled, but the sidestand is still down.

● It cuts the running engine when the

transmission is in gear and the sid-

estand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure.

EWA10250

WARNING

If a malfunction is noted, have a Yamaha dealer check the system before riding.

3-20

Page 39

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is turned on.

3. Turn the key on.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

YES NO

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

YES NO

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

YES NO

The system is OK. The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with a warmed-up engine.

The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.

The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.

The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.

3-21

Page 40

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished 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 list is not working properly, have it inspected and repaired before operating the vehicle.

EAU15591

EWA11150

4-1

Page 41

Pre-operation check list

ITEM CHECKS PAGE

Fuel

Engine oil

Coolant

Front brake

Rear brake

Clutch

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check coolant level in reservoir.

• If necessary, add recommended coolant to specified level.

• Check cooling system for leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

PRE-OPERATION CHECKS

EAU15605

3-12

6-11

6-14

6-26, 6-27

6-25

4-2

Page 42

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

• Make sure that operation is smooth.

Throttle grip

Control cables

Drive chain

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals and switches

Sidestand switch

Air intake duct

• Check cable free play.

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

• Make sure that operation is smooth.

• Lubricate if necessary.

• Check chain slack.

• Adjust if necessary.

• Check chain condition.

• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Lubricate pedal pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check operation.

• Correct if necessary.

• Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

• Check that the screen is not clogged.

• Clean if necessary.

6-20, 6-30

6-30

6-28, 6-29

6-21, 6-24

6-31

6-32

—

3-19

6-20

4-3

Page 43

OPERATION AND IMPORTANT RIDING POINTS

EAU15950

EWA10270

WARNING

● Become thoroughly familiar

with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand.

● Never start the engine or oper-

ate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation.

● Before starting out, make sure

that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.

EAU16251

Starting the engine

In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met:

● The transmission is in the neutral

position.

● The transmission is in gear with

the clutch lever pulled and the sidestand up.

EWA10290

WARNING

● Before starting the engine,

check the function of the ignition circuit cut-off system according to the procedure described on page 3-20.

● Never ride with the sidestand

down.

1. Turn the key to “ON” and make sure that the engine stop switch is set to “”.

ECA11830

CAUTION:

The following warning lights and indicator light should come on for a few seconds, then go off.

● Oil level warning light

● Fuel level warning light

5-1

● Coolant temperature warning

light

● Shift timing indicator light

● Engine trouble warning light

If a warning or indicator light does not go off, see page 3-2 for the corresponding warning and indicator light circuit check.

2. Shift the transmission into the neutral position.

NOTE:

When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit.

3. Start the engine by pushing the start switch.

NOTE:

If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.

Page 44

OPERATION AND IMPORTANT RIDING POINTS

CAUTION:

For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold!

NOTE:

The engine is warm when it quickly responds to the throttle.

ECA11130

EAU16671

Shifting

1. Shift pedal

2. Neutral position

Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.

NOTE:

To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.

5-2

ECA10260

CAUTION:

● Even with the transmission in

the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.

● Always use the clutch while

changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.

EAU16680

To start out and accelerate

1. Pull the clutch lever to disengage the clutch.

2. Shift the transmission into first gear. The neutral indicator light should go out.

3. Open the throttle gradually, and at the same time, release the clutch lever slowly.

Page 45

OPERATION AND IMPORTANT RIDING POINTS

4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in.

5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.)

6. Open the throttle part way and gradually release the clutch lever.

7. Follow the same procedure when shifting to the next higher gear.

NOTE:

Always shift gears at the recommended shift points.

EAU16700

To decelerate

1. Apply both the front and the rear brakes to slow the motorcycle.

2. Shift the transmission into first gear when the motorcycle reaches 25 km/h (15.5 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle.

3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.

EAU16740

Recommended shift points

The recommended shift points during acceleration and deceleration are shown in the table below.

Shift up points:

1st → 2nd: 20 km/h (12.5 mi/h) 2nd → 3rd: 30 km/h (18.8 mi/h) 3rd → 4th: 40 km/h (25.0 mi/h) 4th → 5th: 50 km/h (31.3 mi/h) 5th → 6th: 60 km/h (37.5 mi/h)

Shift down points:

6th → 5th: 25 km/h (15.5 mi/h) 5th → 4th: 25 km/h (15.5 mi/h) 4th → 3rd: 25 km/h (15.5 mi/h) 3rd → 2nd: 25 km/h (15.5 mi/h) 2nd → 1st: —

EAU16841

Engine break-in

There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided.

EAU17091

0–1000 km (0–600 mi)

Avoid prolonged operation above 7000 r/min.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 9000 r/min.

5-3

Page 46

OPERATION AND IMPORTANT RIDING POINTS

CAUTION:

After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced.

1600 km (1000 mi) and beyond

The vehicle can now be operated normally.

CAUTION:

● Keep the engine speed out of

the tachometer red zone.

● If any engine trouble should oc-

cur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.

ECA10301

ECA10310

EAU17212

Parking

When parking, stop the engine, and then remove the key from the main switch.

EWA10310

WARNING

● Since the engine and exhaust

system can become very hot, park in a place where pedestrians or children are not likely to touch them.

● Do not park on a slope or on soft

ground, otherwise the vehicle may overturn.

ECA10380

CAUTION:

Never park in an area where there are fire hazards such as grass or other flammable materials.

5-4

Page 47

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17231

Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).

EWA10320

WARNING

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

EAU17301

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL. THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES.

EAU17480

Owner’s tool kit

1. Owner’s tool kit

The owner’s tool kit is located inside the storage compartment under the passenger seat. (See page 3-14.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

6-1

Page 48

PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10340

WARNING

Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.

6-2

Page 49

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Fuel line

2 * Spark plugs

3 * Valve clearance

Crankcase breather

4 *

system

5 * Fuel injection

6 * Exhaust system

Evaporative emis-

7 *

sion control system (For California only)

Air induction sys-

8 *

tem

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Check fuel hoses for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Replace every 8000 mi (13000

km) or 12 months.

• Check and adjust valve clearance when engine is cold.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check and adjust engine idle

speed and synchronization.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Check control system for dam-

age.

• Replace if necessary.

• Check the air cut-off valve, reed

valve, and hose for damage.

• Replace any damaged parts.

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(7000 km)

6 months

√√√√√

√ Replace. √ Replace. √

√√√√√

8000 mi

(13000 km)

12 months

Every 26600 mi (42000 km)

√√

12000 mi

(19000 km)

18 months

√

16000 mi

(25000 km)

24 months

EAU17600

20000 mi

(31000 km)

30 months

6-3

Page 50

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Air filter element

2 * Clutch

3 * Front brake

4 * Rear brake

5 * Brake hoses

6 * Wheels

7 * Tires

8 * Wheel bearings

• Check condition and damage.

• Replace if necessary.

• Check operation.

• Adjust or replace cable.

• Check operation, fluid level, and

for fluid leakage.

• Replace brake pads if necessary.

• Check operation, fluid level, and

for fluid leakage.

• Replace brake pads if necessary.

• Check for cracks or damage. √√√√√

• Replace. Every 4 years

• Check runout and for damage.

• Replace if necessary.

• Check tread depth and for dam-

age.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check bearings for smooth oper-

ation.

• Replace if necessary.

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(7000 km)

6 months

EAU32183

8000 mi

(13000 km)

12 months

√√√√√

12000 mi

(19000 km)

18 months

16000 mi

(25000 km)

24 months

20000 mi

(31000 km)

30 months

6-4

Page 51

PERIODIC MAINTENANCE AND MINOR REPAIR

No. ITEM ROUTINE

Swingarm pivot

9 *

bearings

10 Drive chain

11 * Steering bearings

12 * Chassis fasteners

Brake and clutch le-

ver pivot shafts

Brake and shift ped-

al pivot shafts

15 Sidestand pivot

16 * Sidestand switch

• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease.

• Check chain slack, alignment and condition.

• Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.

• Check bearing assemblies for looseness.

• Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.

• Check all chassis fitting and fasteners.

• Correct if necessary.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Apply lithium-soap-based grease (all-purpose grease) lightly.

• Check operation.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Check operation and replace if necessary.

INITIAL ODOMETER READINGS

600 mi

(1000 km)

1 month

Every 500 mi (800 km) and after washing the motorcycle or riding in the rain

√√√√Repack. √

√√√√√√

4000 mi

(7000 km)

6 months

√√√√√

8000 mi

(13000 km)

12 months

√ Repack.

12000 mi

(19000 km)

18 months

16000 mi

(25000 km)

24 months

20000 mi

(31000 km)

30 months

6-5

Page 52

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

17 * Front fork

Shock absorber as-

18 *

sembly

Rear suspension

19 *

link pivots

20 Engine oil

Engine oil filter car-

21 *

tridge

22 * Cooling system

Front and rear brake

23 *

switches

24 * Control cables

• Check operation and for oil leakage.

• Replace if necessary.

• Check operation and for oil leak-

age.

• Replace if necessary.

• Check operation.

• Correct if necessary.

• Change (warm engine before

draining).

• Replace. √√√

• Check hoses for cracks or dam-

age.

• Replace if necessary.

• Change with ethylene glycol anti-

freeze coolant every 24 months.

• Check operation. √√√√√√

• Apply Yamaha chain and cable

lube or engine oil SAE 10W-30 thoroughly.

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(7000 km)

6 months

8000 mi

(13000 km)

12 months

√√√√√

√√

√√√√√

12000 mi

(19000 km)

18 months

16000 mi

(25000 km)

24 months

Change.

20000 mi

(31000 km)

30 months

6-6

Page 53

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

• Check operation and free play.

Throttle grip hous-

25 *

ing and cable

Lights, signals and

26 *

switches

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

• Check operation.

• Adjust headlight beam.

600 mi

(1000 km)

1 month

√√√√√√

NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

NOTE:

● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

● Hydraulic brake service

• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

• Replace the brake hoses every four years and if cracked or damaged.

4000 mi

(7000 km)

6 months

√√√√√

8000 mi

(13000 km)

12 months

12000 mi

(19000 km)

18 months

16000 mi

(25000 km)

24 months

20000 mi

(31000 km)

30 months

EAU17630

6-7

Page 54

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU18712

Removing and installing cowlings and panels

The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed.

1. Cowling A

2. Panel A

1. Cowling B

2. Panel B

EAU19012

Cowlings A and B

To remove one of the cowlings Remove the bolts and quick fasteners, slide the cowling forward (for A) or backward (for B), and then pull it off as shown.

6-8

1. Quick fastener

1. Bolt

2. Cowling A

Page 55

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt

2. Cowling B

1. Cowling A

2. Cowling B

To install the cowling

1. Fit the slots and projections at the rear bottom of each cowling together, and then slide the cowling into place.

1. Slot

2. Projection

2. Place the cowling in the original position, and then install the bolts and quick fasteners.

NOTE:

Make sure that the tabs at the front of each cowling fit side by side as shown and that all slots and projections fit together.

6-9

1. Tab

EAU19461

Panels A and B

To remove one of the panels Remove the bolts, slide the panel forward, and then take it off.

1. Bolt

Page 56

PERIODIC MAINTENANCE AND MINOR REPAIR

To install the panel

1. Fit the tabs on the panel into the slots and slide it backward.

1. Tab

2. Slot

2. Install the bolts.

EAU19652

Checking the spark plugs

The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine. The porcelain insulator around the center electrode of each spark plug should be a medium-to-light tan (the ideal color when the vehicle is ridden normally), and all spark plugs installed in the engine should have the same color. If any spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. If a spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced.

Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification.

1. Spark plug gap

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads.

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

Specified spark plug:

NGK/CR9EK, CR10EK

6-10

Page 57

PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

ECA10840

CAUTION:

Do not use any tools to remove or install the spark plug cap, otherwise the ignition coil coupler may get damaged. The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly. To remove the spark plug cap, simply twist it back and forth while pulling it out; to install it, twist it back and forth while pushing it in.

EAU19681

Canister (for California only)

This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this vehicle, make sure to check the following:

● Check each hose connection.

● Check each hose and canister for

cracks or damage. Replace if damaged.

● Make sure that the canister breath-

er is not blocked, and if necessary, clean it.

EAU19932

Engine oil and oil filter cartridge

The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart.

To check the engine oil level

1. Place the vehicle on a level surface and hold it in an upright position.

NOTE:

Make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading.

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Wait a few minutes until the oil settles.

6-11

Page 58

PERIODIC MAINTENANCE AND MINOR REPAIR

4. Remove the engine oil dipstick and wipe it clean, insert it back into the hole (without screwing it in), and then remove it again to check the oil level.

1. Engine oil filler cap 1. Engine oil drain bolt

1. Dipstick

2. Maximum level mark

3. Minimum level mark

NOTE:

The engine oil should be between the minimum and maximum level marks.

5. If the engine oil is at or below the minimum level mark, remove the oil filler cap, and then add sufficient oil of the recommended type to raise it to the correct level.

6. Insert and tighten the engine oil dipstick, and then install and tighten the oil filler cap.

To change the engine oil (with or without oil filter cartridge replacement)

1. Remove cowling B. (See page 6-8.)

2. Start the engine, warm it up for several minutes, and then turn it off.

3. Place an oil pan under the engine to collect the used oil.

4. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase.

6-12

NOTE:

Skip steps 5–9 if the oil filter cartridge is not being replaced.

5. Remove the coolant reservoir cover by removing the bolts.

1. Coolant reservoir cover

2. Bolt

Page 59

6. Remove the oil filter cartridge with an oil filter wrench.

PERIODIC MAINTENANCE AND MINOR REPAIR

1. O-ring 1. Torque wrench

1. Oil filter wrench

2. Engine oil filter cartridge

NOTE:

An oil filter wrench is available at a Yamaha dealer.

7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.

NOTE:

Make sure that the O-ring is properly seated.

8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.

6-13

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

9. Install the coolant reservoir cover by installing the bolts.

10. Install the engine oil drain bolt, and then tighten it to the specified torque.

NOTE:

Check the washer for damage and replace it if necessary.

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

Page 60

PERIODIC MAINTENANCE AND MINOR REPAIR

11. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge replacement:

2.40 L (2.54 US qt) (2.11 Imp.qt)

With oil filter cartridge replacement:

2.60 L (2.75 US qt) (2.29 Imp.qt)

CAUTION:

● In order to prevent clutch slip-

page (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.

● Make sure that no foreign mate-

rial enters the crankcase.

ECA11620

12. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause.

NOTE:

After the engine is started, the engine oil level warning light should go off if the oil level is sufficient.

ECA10400

CAUTION:

If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle.

13. Turn the engine off, and then check the oil level and correct it if necessary.

14. Install the cowling.

EAU20070

Coolant

The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.

EAU38171

To check the coolant level

1. Place the vehicle on a level surface and hold it in an upright position.

NOTE:

● The coolant level must be checked

on a cold engine since the level varies with engine temperature.

● Make sure that the vehicle is posi-

tioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading.

2. Check the coolant level in the coolant reservoir.

NOTE:

The coolant should be between the minimum and maximum level marks.

6-14

Page 61

1. Maximum level mark

2. Minimum level mark

3. If the coolant is at or below the minimum level mark, remove the coolant reservoir cover by removing the bolts, remove the reservoir cap, and then add coolant to the maximum level mark.

1. Coolant reservoir cover

2. Bolt

PERIODIC MAINTENANCE AND MINOR REPAIR

● If water has been added to the

coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.

EWA10380

WARNING

Never attempt to remove the radiator

1. Coolant reservoir cap

Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.26 US qt) (0.22 Imp.qt)

ECA10471

CAUTION:

● If coolant is not available, use

distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.

● If water has been used instead

of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion.

6-15

cap when the engine is hot.

4. Install the reservoir cap, and then install the coolant reservoir cover by installing the bolts.

NOTE:

● The radiator fan is automatically

switched on or off according to the coolant temperature in the radiator.

● If the engine overheats, see page

6-45 for further instructions.

EAU20344

To change the coolant

1. Place the vehicle on a level surface and let the engine cool if necessary.

Page 62

PERIODIC MAINTENANCE AND MINOR REPAIR

2. Remove panel A, and cowlings A and B. (See page 6-8.)

3. Place a container under the engine to collect the used coolant.

4. Loosen the clamp screw, and then disconnect the air intake duct.

1. Clamp screw

2. Air intake duct

5. Remove the radiator cap.

WARNING

Never attempt to remove the radiator cap when the engine is hot.

EWA10380

1. Radiator cap

6. Remove the coolant drain bolt to drain the cooling system.

7. Loosen the clamp screw, and then disconnect the radiator hose to drain the radiator.

8. Remove the coolant reservoir cover by removing the bolts.

1. Coolant reservoir cover

2. Bolt

9. Pull the fuel hoses upward to remove them from the guide.

1. Coolant drain bolt

2. Clamp screw

1. Fuel tank breather hose (except for California)

2. Fuel tank overflow hose

3. Guide

6-16

Page 63

PERIODIC MAINTENANCE AND MINOR REPAIR

10. Remove the coolant reservoir by removing the bolts.

11. Remove the coolant reservoir cap, and then turn the coolant reservoir upside down to empty it.

1. Coolant reservoir cap

2. Coolant reservoir

3. Bolt

12. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water.

13. Install the coolant reservoir by installing the bolts.

14. Connect the radiator hose, and then tighten the clamp screw.

15. Install the coolant drain bolt, and then tighten it to the specified torque.

NOTE:

Check the washer for damage and replace it if necessary.

Tightening torque:

Coolant drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

16. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the coolant reservoir cap.

17. Insert the fuel hoses into the guide, place them in their original positions, and then install the coolant reservoir cover by installing the bolts.

1. Fuel tank breather hose (except for California)

2. Fuel tank overflow hose

18. Pour the recommended coolant

into the radiator until it is full.

Antifreeze/water mixture ratio:

1:1

Recommended antifreeze:

High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Coolant quantity:

Radiator capacity (including all routes):

2.15 L (2.27 US qt) (1.89 Imp.qt) Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.26 US qt) (0.22 Imp.qt)

6-17

Page 64

PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

● If coolant is not available, use

distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine.

● If water has been used instead

of coolant, replace it with coolant as soon as possible, otherwise the cooling system will not be protected against frost and corrosion.

● If water has been added to the

coolant, have a Yamaha dealer

check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced.

19. Install the radiator cap, start the engine, let it idle for several minutes, and then turn it off.

20. Remove the radiator cap to check the coolant level in the radiator. If necessary, add sufficient coolant until it reaches the top of the radiator, and then install the radiator cap.

ECA10471

21. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system.

22. Connect the air intake duct, and then tighten the clamp screw.

23. Install the panel and the cowlings.

EAU21162

Checking the air filter element

The air filter element should be checked at the intervals specified in the periodic maintenance and lubrication chart. Check the air filter element more frequently if you are riding in unusually wet or dusty areas.

1. Remove the rider seat. (See page 3-14.)

2. Remove the fuel tank bolts.

1. Bolt

3. Lift the front of the fuel tank, and then tilt it back and away from the air filter case. (Do not disconnect the fuel hoses!)

6-18

Page 65

PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10410

WARNING

● Make sure that the fuel tank is

well supported.

● Do not tilt or pull the fuel tank

too much, otherwise the fuel hoses may come loose, which could cause fuel leakage.

4. Remove the air filter case cover by removing the screws.

1. Screw

2. Air filter case cover

5. Pull the air filter element out.

1. Air filter element

6. Check the condition of the air filter element and replace it if it is damaged or excessively dusty.

7. Insert the element into the air filter case.

ECA10480

CAUTION:

● Make sure that the air filter ele-

ment is properly seated in the air filter case.

● The engine should never be op-

erated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.

8. Install the air filter case cover by installing the screws.

9. Place the fuel tank in the original position, and then install the bolts.

EWA11360

WARNING

● Before placing the fuel tank in

the original position, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, otherwise fuel may leak.

● Make sure that the fuel hoses

are properly connected and routed, and not pinched.

6-19

Page 66

PERIODIC MAINTENANCE AND MINOR REPAIR

● Be sure to place the fuel tank

breather hose and the fuel tank overflow hose in the original position.

1. Fuel tank breather hose (except for Califor-

nia)

2. Fuel tank overflow hose

10. Install the rider seat.

EAU21210

Air intake duct

1. Air intake duct

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

EAU21381

Checking the throttle cable free play

1. Throttle cable free play

The throttle cable free play should measure 6.0–8.0 mm (0.24–0.31 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it.

6-20

Page 67

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21401

Valve clearance

The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.

EAU21750

Tires

To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.

Tire air pressure

The tire air pressure should be checked and, if necessary, adjusted before each ride.

EWA10500

WARNING

● The tire air pressure must be

checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).

● The tire air pressure must be ad-

justed in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model.

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

250 kPa (36 psi) (2.50 kgf/cm²)

YZFR6SW 90–193 kg (198–425 lb) YZFR6SWC 90–192 kg (198–423 lb):

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

High-speed riding:

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

250 kPa (36 psi) (2.50 kgf/cm²)

Maximum load*:

YZFR6SW 193 kg (425 lb) YZFR6SWC 192 kg (423 lb)

* Total weight of rider, passenger, car-

go and accessories

EWA10510

WARNING

Proper loading of your vehicle is important for several characteristics of your vehicle, such as handling, braking, performance and safety. Do not carry loosely packed items that

6-21

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PERIODIC MAINTENANCE AND MINOR REPAIR

can shift. Securely pack your heaviest items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle. Operation of an overloaded vehicle could cause tire damage, an

accident, or even injury.

Tire inspection

1. Tire sidewall

2. Tire wear indicator

3. Tire tread depth

Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced.

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)

EWA10580

WARNING

● It is dangerous to ride with a

worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.

● The replacement of all wheel-

and brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.

Tire information

6-22

1. Tire air valve

2. Tire air valve core

3. Tire air valve cap with seal

Page 69

PERIODIC MAINTENANCE AND MINOR REPAIR

This motorcycle is equipped with cast wheels and tubeless tires with valves.

EWA10480

WARNING

● The front and rear tires should

be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed.

● After extensive tests, only the

tires listed below have been approved for this model by Yamaha Motor Co., Ltd.

● Always make sure that the valve

caps are securely installed to prevent air pressure leakage.

● Use only the tire valves and

valve cores listed below to avoid tire deflation during a high-speed ride.

Front tire:

Size:

120/60 ZR17M/C (55W)

Manufacturer/model:

DUNLOP/D208F J

Rear tire:

Size:

180/55 ZR17M/C (73W)

Manufacturer/model:

DUNLOP/D208A J

FRONT and REAR:

Tire air valve:

TR412

Val ve c ore:

#9100 (original)

EWA10600

WARNING

This motorcycle is fitted with superhigh-speed tires. Note the following points in order to make the most efficient use of these tires.

● Use only the specified replace-

ment tires. Other tires may run the danger of bursting at super high speeds.

● Brand-new tires can have a rela-

tively poor grip on certain road surfaces until they have been “broken in”. Therefore, it is advisable before doing any high-

6-23

speed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire.

● The tires must be warmed up

before a high-speed run.

● Always adjust the tire air pres-

sure according to the operating conditions.

Page 70

PERIODIC MAINTENANCE AND MINOR REPAIR

Cast wheels

To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels.

● The wheel rims should be checked

for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.

● The wheel should be balanced

whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life.

● Ride at moderate speeds after

changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics.

EAU21960

EAU22011

Accessories and replacement parts

EWA10621

WARNING

This vehicle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine Yamaha Parts and Accessories before making a purchase. Use of nonYamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for

any consequences caused by the use of items which have not been approved by Yamaha.

6-24

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22060

Adjusting the clutch lever free play

1. Clutch lever free play adjusting bolt

2. Clutch lever free play

The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. To increase the clutch lever free play, turn the adjusting bolt at the clutch lever in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b).

NOTE:

If the specified clutch lever free play cannot be obtained as described above, proceed as follows.

1. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable.

2. Remove cowling A. (See page 6-8.)

3. Loosen the locknut at the crankcase.

4. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b).

5. Tighten the locknut.

6. Install the cowling.

1. Locknut

2. Clutch lever free play adjusting nut (crankcase)

6-25

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PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the rear brake light switch

1. Rear brake light switch

2. Rear brake light switch adjusting nut

The rear brake light switch, which is ac-

tivated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a). To make the brake light come on later, turn the adjusting nut in direction (b).

EAU22270

EAU22390

Checking the front and rear brake pads

The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.

EAU36890

Front brake pads

1. Brake pad wear indicator

Each front brake pad is provided with wear indicators, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicators while applying the brake. If a brake pad has worn to

the point that a wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set.

EAU22500

Rear brake pads

1. Lining thickness

Check each rear brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1.0 mm (0.04 in), have a Yamaha dealer replace the brake pads as a set.

6-26

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22580

Checking the brake fluid level

Front brake

1. Minimum level mark

Rear brake

1. Minimum level mark

Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions:

● When checking the fluid level,

make sure that the top of the brake fluid reservoir is level.

● Use only the recommended quality

brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance.

Recommended brake fluid:

DOT 4

● Refill with the same type of brake

fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance.

● Be careful that water does not en-

ter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

● Brake fluid may deteriorate paint-

ed surfaces or plastic parts. Always clean up spilled fluid immediately.

● As the brake pads wear, it is nor-

mal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.

6-27

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PERIODIC MAINTENANCE AND MINOR REPAIR

Changing the brake fluid

Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.

● Oil seals: Replace every two

years.

● Brake hoses: Replace every four

years.

EAU22730

EAU22760

Drive chain slack

The drive chain slack should be checked before each ride and adjusted if necessary.

EAU22772

To check the drive chain slack

1. Place the motorcycle on the sidestand.

NOTE:

When checking and adjusting the drive chain slack, there should be no weight on the motorcycle.

2. Shift the transmission into the neutral position.

3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown.

Drive chain slack:

35.0–45.0 mm (1.38–1.77 in)

1. Drive chain slack

4. If the drive chain slack is incorrect, adjust it as follows.

EAU34311

To adjust the drive chain slack

1. Loosen the axle nut and the locknut on each side of the swingarm.

2. To tighten the drive chain, turn the adjusting bolt on each side of the swingarm in direction (a). To loosen the drive chain, turn the adjusting bolt on each side of the swingarm in direction (b), and then push the rear wheel forward.

6-28

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PERIODIC MAINTENANCE AND MINOR REPAIR

NOTE:

Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment.

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

4. Alignment marks

ECA10570

CAUTION:

Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.

3. Tighten the locknuts, then the axle nut to their specified torques.

Tightening torques:

Locknut:

16 Nm (1.6 m·kgf, 11 ft·lbf)

Axle nut:

110 Nm (11.0 m·kgf, 80 ft·lbf)

EAU23022

Cleaning and lubricating the drive chain

The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

ECA10581

CAUTION:

The drive chain must be lubricated after washing the motorcycle and riding in the rain.

1. Clean the drive chain with kerosene and a small soft brush.

ECA11120

CAUTION:

To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents.

2. Wipe the drive chain dry.

3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

6-29

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PERIODIC MAINTENANCE AND MINOR REPAIR

CAUTION:

Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings.

ECA11110

EAU23091

Checking and lubricating the cables

The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.

Recommended lubricant:

Yamaha Chain and Cable Lube or engine oil SAE 10W-30

EWA10710

WARNING

Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.

EAU23111

Checking and lubricating the throttle grip and cable

The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.

6-30

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23131

Checking and lubricating the brake and shift pedals

The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-purpose grease)

EAU23140

Checking and lubricating the brake and clutch levers

Brake lever

Clutch lever

The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.

6-31

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PERIODIC MAINTENANCE AND MINOR REPAIR

Recommended lubricant:

Lithium-soap-based grease (all-purpose grease)

EAU23200

Checking and lubricating the sidestand

Lubricating the swingarm pivots

EAUM1650

The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.

Recommended lubricant:

Lithium-soap-based grease

The operation of the sidestand should be checked before each ride, and the

sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.

EWA10730

WARNING

If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it.

Recommended lubricant:

Lithium-soap-based grease (all-purpose grease)

6-32

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23271

Checking the front fork

The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

To check the condition

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

Check the inner tubes for scratches, damage and excessive oil leakage.

To check the operation

1. Place the vehicle on a level surface and hold it in an upright position.

2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly.

ECA10590

CAUTION:

If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it.

EAU23280

Checking the steering

Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.

1. Place a stand under the engine to raise the front wheel off the ground.

EWA10750

WARNING

Securely support the vehicle so that there is no danger of it falling over.

2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering.

6-33

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn

Battery

This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.

EAU23441

smoothly, have a Yamaha dealer check the wheel bearings.

To charge the battery

Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.

EWA10760

WARNING

● Electrolyte is poisonous and

dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID.

• EXTERNAL: Flush with plenty of water.

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PERIODIC MAINTENANCE AND MINOR REPAIR

• INTERNAL: Drink large quantities of water or milk and immediately call a physician.

• EYES: Flush with water for 15 minutes and seek prompt medical attention.

● Batteries produce explosive hy-

drogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

● KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF CHILDREN.

To store the battery

1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place.

2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary.

3. Fully charge the battery before installation.

4. After installation, make sure that the battery leads are properly connected to the battery terminals.

1. Positive battery terminal

2. Battery

3. Negative battery terminal

ECA10630

CAUTION:

● Always keep the battery

charged. Storing a discharged battery can cause permanent battery damage.

● To charge a sealed-type (MF)

battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a

sealed-type (MF) battery charger, have a Yamaha dealer charge your battery.

6-35

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PERIODIC MAINTENANCE AND MINOR REPAIR

Replacing the fuses

The main fuse is located under the rider seat. (See page 3-14.)

1. Spare main fuse

2. Main fuse

The fuse box, which contains the fuses for the individual circuits, is located under panel B. (See page 6-8.)

EAU27031

1. Fuse box

2. Headlight fuse

3. Radiator fan fuse

4. Ignition fuse

5. Signaling system fuse

6. Backup fuse (for odometer and clock)

7. Fuel injection system fuse

8. Spare fuse

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off the electrical circuit in question.

2. Remove the blown fuse, and then install a new fuse of the specified amperage.

Specified fuses:

Main fuse:

40.0 A

Headlight fuse:

20.0 A

Signaling system fuse:

15.0 A

Radiator fan fuse:

15.0 A

Ignition fuse:

15.0 A

Fuel injection system fuse:

15.0 A

Backup fuse:

10.0 A

ECA10640

CAUTION:

Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire.

3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates.

4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.

6-36

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23940

Replacing a headlight bulb

This model is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows.

1. Remove panel B (if replacing the left headlight bulb) or panel A (if replacing the right headlight bulb). (See page 6-8.)

2. Remove the headlight bulb cover by turning it counterclockwise.

1. Headlight bulb cover

3. Disconnect the headlight coupler.

1. Headlight coupler

4. Unhook the headlight bulb holder, and then remove the defective bulb.

1. Headlight bulb holder

EWA10790

WARNING

Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down.

5. Place a new headlight bulb into position, and then secure it with the bulb holder.

ECA10650

CAUTION:

Take care not to damage the following parts:

● Headlight bulb

Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner.

6-37

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PERIODIC MAINTENANCE AND MINOR REPAIR

● Headlight lens

Do not affix any type of tinted film or stickers to the headlight lens. Do not use a headlight bulb of a wattage higher than specified.

1. Do not touch the glass part of the bulb.

6. Connect the headlight coupler.

7. Install the headlight bulb cover by turning it clockwise.

8. Install the panel.

9. Have a Yamaha dealer adjust the headlight beam if necessary.

EAU24180

Tail/brake light

This model is equipped with an LED type of tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it.

EAU24202

Replacing a turn signal light bulb

1. Remove the turn signal light lens by removing the screw.

1. Screw

2. Remove the defective bulb by pushing it in and turning it counterclockwise.

3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops.

4. Install the lens by installing the screw.

ECA11190

CAUTION:

Do not overtighten the screw, otherwise the lens may break.

6-38

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24310

Replacing the license plate light bulb

1. Remove the license plate light unit by removing the screws.

1. Screw

2. Remove the socket (together with the bulb) by pulling it out.

1. License plate light bulb

2. License plate light unit

3. Remove the defective bulb by pulling it out.

4. Insert a new bulb into the socket.

5. Install the socket (together with the bulb) by pushing it in.

6. Install the license plate light unit by installing the screws.

6-39

EAU24350

Supporting the motorcycle

Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle by using a motorcycle stand or, if an additional motorcycle stand is not available, by placing a jack under the frame in front of the rear wheel.

2. Raise the front wheel off the ground by using a motorcycle stand.

To service the rear wheel

Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle stand is not available, by placing

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PERIODIC MAINTENANCE AND MINOR REPAIR

a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm.

EAU24360

Front wheel

EAU38160

To remove the front wheel

EWA10820

WARNING

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger of it falling over.

1. Loosen the wheel axle pinch bolts, the axle bolt, and then the brake caliper bolts.

1. Front wheel axle pinch bolt

3. Remove the brake hose holder on each side by removing the bolt and nut.

4. Remove the brake caliper (together with the reflector) on each side by removing the bolts.

1. Brake hose holder

2. Bolt and nut

3. Brake caliper bolt

4. Brake caliper

5. Axle bolt

6. Reflector

5. Remove the axle bolt, push the wheel axle out from the left side, and then remove the wheel.

2. Lift the front wheel off the ground according to the procedure on page 6-39.

6-40

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Wheel axle

ECA11050

CAUTION:

Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut.

EAU38180

To install the front wheel

1. Lift the wheel up between the fork legs.

2. Insert the wheel axle.

3. Lower the front wheel so that it is on the ground.

4. Install the brake caliper (together with the reflector) on each side by installing the bolts, and then tightening them to the specified torque.

NOTE:

Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs.

Tightening torque:

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

5. Install the brake hose holders by installing the bolts and nuts.

6. Secure the wheel axle by installing the axle bolt, and then tightening the axle bolt to the specified torque.

NOTE:

While tightening the axle bolt, hold the wheel axle with a 19-mm hexagon wrench to keep it from turning.

Tightening torque:

Axle bolt:

91 Nm (9.1 m·kgf, 66 ft·lbf)

7. Tighten wheel axle pinch bolt B, and then tighten pinch bolt A to the specified torque.

6-41

8. Retighten pinch bolt B to the specified torque.

Tightening torque:

Wheel axle pinch bolt:

18 Nm (1.8 m·kgf, 13 ft·lbf)

9. Tap the outer side of the right fork leg with a rubber mallet to align it with the end of the wheel axle.

10. Tighten wheel axle pinch bolt D, and then tighten pinch bolt C to the specified torque.

11. Retighten pinch bolt D to the specified torque.

Tightening torque:

Wheel axle pinch bolt:

18 Nm (1.8 m·kgf, 13 ft·lbf)

Page 88

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Front wheel axle pinch bolt A

2. Front wheel axle pinch bolt B

3. Front wheel axle pinch bolt C

4. Front wheel axle pinch bolt D

12. While applying the front brake,

push down hard on the handlebar several times to check for proper fork operation.

EAU25080

Rear wheel

EAU25311

To remove the rear wheel

EWA10820

WARNING

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger of it falling over.

1. Loosen the axle nut.

1. Axle nut

2. Drive chain slack adjusting bolt

3. Locknut

4. Brake caliper

5. Brake caliper bracket

2. Lift the rear wheel off the ground according to the procedure on page 6-39.

3. Remove the axle nut.

4. Loosen the locknut on each side of the swingarm.

5. Turn the drive chain slack adjusting bolts fully in direction (a) and push the wheel forward.

6. Remove the drive chain from the rear sprocket.

NOTE:

● If the drive chain is difficult to re-

move, remove the wheel axle first, and then lift the wheel upward enough to remove the drive chain from the rear sprocket.

6-42

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PERIODIC MAINTENANCE AND MINOR REPAIR

● The drive chain cannot be disas-

sembled.

7. While supporting the brake caliper bracket, pull the wheel axle out, and then remove the wheel.

1. Wheel axle

ECA11070

CAUTION:

Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.

EAU25661

To install the rear wheel

1. Install the wheel and the brake caliper bracket by inserting the wheel axle from the left-hand side.

NOTE:

● Be sure to insert the retainer on the

brake caliper bracket into the slot in the swingarm.

● Make sure that there is enough

space between the brake pads before installing the wheel.

1. Retainer

2. Slot

2. Install the drive chain onto the rear sprocket.

3. Install the axle nut, and then lower the rear wheel so that it is on the ground.

4. Adjust the drive chain slack. (See page 6-28.)

5. Tighten the axle nut to the specified torque.

6-43

Tightening torque:

Axle nut:

110 Nm (11.0 m·kgf, 80 ft·lbf)

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU25870

Troubleshooting

Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and

know-how to service the motorcycle properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

6-44

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Troubleshooting charts

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU42310

Starting problems or poor engine performance

WARNING

Keep away open flames and do not smoke while checking or working on the fuel system.

1. Fuel

Check the fuel level in

There is enough fuel.

the fuel tank.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start. Check the compression.

2. Compression

Operate the electric starter.

3. Ignition

Remove the spark plugs and check the electrodes.

4. Battery

Operate the electric starter.

There is compression.

There is no compression.

Wet

Dry

The engine turns over quickly.

The engine turns over slowly.

Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

Check the ignition.

Have a Yamaha dealer check the vehicle.

The battery is good.

Check the battery lead connections, and charge the battery if necessary.

Open the throttle halfway and operate the electric starter.

The engine does not start. Check the battery.

The engine does not start. Have a Yamaha dealer check the vehicle.

EWA10840

6-45

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PERIODIC MAINTENANCE AND MINOR REPAIR

Engine overheating

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. Be sure to wait until the engine has cooled.

● Place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the de-

tent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

There is

The coolant level is low. Check the cooling system for leakage.

Wait until the engine has cooled.

Check the coolant level in the reservoir and radiator.

The coolant level is OK.

Start the engine. If the engine overheats again, have a

Yamaha dealer check

leakage.

There is no leakage.

Have a Yamaha dealer check

and repair the cooling system.

Add coolant. (See NOTE.)

and repair the cooling system.

NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

EWAT1040

6-46

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MOTORCYCLE CARE AND STORAGE

EAU37832

Matte color caution

ECA15192

CAUTION:

Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.

EAU26031

Care

While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance.

Before cleaning

1. Cover the muffler outlet with a plastic bag after the engine has cooled down.

2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed.

3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod-

7-1

ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water.

Cleaning

ECA10770

CAUTION:

● Avoid using strong acidic wheel

cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray.

● Improper cleaning can damage

windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic.

● Do not use any harsh chemical

products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive

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MOTORCYCLE CARE AND STORAGE

cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.

● Do not use high-pressure wash-

ers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.

● For motorcycles equipped with

a windshield: Do not use strong cleaners or hard sponges as

they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.

After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. Use the special sponge, which is included in the plastic bag containing the owner’s manual, to clean the muffler and to remove any discoloration from it.

After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads.

NOTE:

Salt sprayed on roads in the winter may remain well into spring.

1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down.

7-2

ECA10790

CAUTION:

Do not use warm water since it increases the corrosive action of the salt.

2. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion.

After cleaning

1. Dry the motorcycle with a chamois or an absorbing cloth.

2. Immediately dry the drive chain and lubricate it to prevent it from rusting.

3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)

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MOTORCYCLE CARE AND STORAGE

4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces.

5. Use spray oil as a universal cleaner 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 or covering it.

EWA11130

WARNING

● Make sure that there is no oil or

wax on the brakes or tires.

● If necessary, clean the brake

discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before riding at higher speeds, test the motorcycle’s braking performance and cornering behavior.

ECA10800

CAUTION:

● Apply spray oil and wax spar-

ingly and make sure to wipe off any excess.

● Never apply oil or wax to any

rubber and plastic parts, but treat them with a suitable care product.

● Avoid using abrasive polishing

compounds as they will wear away the paint.

NOTE:

Consult a Yamaha dealer for advice on what products to use.

7-3

EAU26180

Storage

Short-term

Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.

ECA10810

CAUTION:

● Storing the motorcycle in a

poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.

● To prevent corrosion, avoid

damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.

Long-term

Before storing your motorcycle for several months:

1. Follow all the instructions in the “Care” section of this chapter.

2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.

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MOTORCYCLE CARE AND STORAGE

3. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps

and spark plugs.

b. Pour a teaspoonful of engine oil

into each spark plug bore.

c. Install the spark plug caps onto

the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.)

d. Turn the engine over several

times with the starter. (This will coat the cylinder walls with oil.)

e. Remove the spark plug caps

from the spark plugs, and then install the spark plugs and the spark plug caps.

WARNING

To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over.

EWA10950

4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand.

5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.

6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it.

7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 6-34.

NOTE:

Make any necessary repairs before storing the motorcycle.

7-4

Page 97

SPECIFICATIONS

Dimensions:

Overall length:

2025 mm (79.7 in)

Overall width:

690 mm (27.2 in)

Overall height:

1090 mm (42.9 in)

Seat height:

820 mm (32.3 in)

Wheelbase:

1380 mm (54.3 in)

Ground clearance:

135 mm (5.31 in)

Minimum turning radius:

3400 mm (133.9 in)

Weight:

With oil and fuel:

YZFR6SW 182.0 kg (401 lb) YZFR6SWC 183.0 kg (403 lb)

Engine:

Engine type:

Liquid cooled 4-stroke, DOHC

Cylinder arrangement:

Forward-inclined parallel 4-cylinder

Displacement:

600.0 cm³

Bore × stroke:

65.5 × 44.5 mm (2.58 × 1.75 in)

Compression ratio:

12.40 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0°

10° 30° 50° 70° 90°

YAMALUBE 4 (10W30)

or SAE 10W30

YAMALUBE 4 (20W40) or SAE 20W40

–20°

–10° 0° 10° 20° 30°

110°

40°

Recommended engine oil grade:

API service SG type or higher, JASO standard MA

Engine oil quantity:

Without oil filter cartridge replacement:

2.40 L (2.54 US qt) (2.11 Imp.qt)

With oil filter cartridge replacement:

2.60 L (2.75 US qt) (2.29 Imp.qt)

Cooling system:

Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.26 US qt) (0.22 Imp.qt)

Radiator capacity (including all routes):

2.15 L (2.27 US qt) (1.89 Imp.qt)

Air filter:

Air filter element:

Wet element

130°F

50°C

Fuel:

Recommended fuel:

Premium unleaded gasoline only

Fuel tank capacity:

17.0 L (4.49 US gal) (3.74 Imp.gal)

Fuel reserve amount:

3.5 L (0.92 US gal) (0.77 Imp.gal)

Fuel injector:

Manufacturer:

NIPPON INJECTOR

Model/quantity:

INP-250/4

Spark plug (s):

Manufacturer/model:

NGK/CR9EK, CR10EK

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

86/44 (1.955)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

48/16 (3.000)

Transmission type:

Constant mesh 6-speed

Operation:

Left foot operation

8-1

Page 98

SPECIFICATIONS

Gear ratio:

1st:

37/13 (2.846)

2nd:

37/19 (1.947)

3rd:

28/18 (1.556)

4th:

32/24 (1.333)

5th:

25/21 (1.190)

6th:

26/24 (1.083)

Chassis:

Frame type:

Diamond

Caster angle:

24.00 °

Trail:

86.0 mm (3.39 in)

Front tire:

Type:

Tubeless

Size:

120/60 ZR17M/C (55W)

Manufacturer/model:

DUNLOP/D208F J

Rear tire:

Type:

Tubeless

Size:

180/55 ZR17M/C (73W)

Manufacturer/model:

DUNLOP/D208A J

Loading:

Maximum load:

YZFR6SW 193 kg (425 lb) YZFR6SWC 192 kg (423 lb) (Total weight of rider, passenger, cargo and accessories)

Tire air pressure (measured on cold tires):

Loading condition:

0–90 kg (0–198 lb) Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

250 kPa (36 psi) (2.50 kgf/cm²)

Loading condition:

YZFR6SW 90–193 kg (198–425 lb) YZFR6SWC 90–192 kg (198–423 lb) Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

290 kPa (42 psi) (2.90 kgf/cm²)

High-speed riding:

Front:

250 kPa (36 psi) (2.50 kgf/cm²)

Rear:

250 kPa (36 psi) (2.50 kgf/cm²)

Front wheel:

Wheel type:

Cast wheel

Rim size:

17M/C x MT3.50

Rear wheel:

Wheel type:

Cast wheel

8-2

Rim size:

17M/C x MT5.50

Front brake:

Type:

Dual disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Rear brake:

Type:

Single disc brake

Operation:

Right foot operation

Recommended fluid:

DOT 4

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

120.0 mm (4.72 in)

Rear suspension:

Type:

Swingarm (link suspension)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

120.0 mm (4.72 in)

Electrical system:

Ignition system:

DC. CDI

Page 99

SPECIFICATIONS

Charging system:

AC magneto

Battery:

Model:

GT9B-4

Voltage, capacity:

12 V, 8.0 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage × quantity:

Headlight:

12 V, 55.0 W × 2

Tail/brake light:

LED

Front turn signal/position light:

12 V, 21 W/5.0 W × 2

Rear turn signal light:

12 V, 21.0 W × 2

License plate light:

12 V, 5.0 W × 1

Meter lighting:

LED

Neutral indicator light:

LED

High beam indicator light:

LED

Oil level warning light:

LED

Turn signal indicator light:

LED

Fuel level warning light:

LED

Coolant temperature warning light:

LED

Engine trouble warning light:

LED

Shift timing indicator light:

LED

Fuses:

Main fuse:

40.0 A

Headlight fuse:

20.0 A

Signaling system fuse:

15.0 A

Ignition fuse:

15.0 A

Radiator fan fuse:

15.0 A

Fuel injection system fuse:

15.0 A

Backup fuse:

10.0 A

8-3

Page 100

CONSUMER INFORMATION

Identification numbers

Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26351

Key identification number

1. Key identification number 1. Vehicle identification number

The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key.

EAU26381

Vehicle identification number

The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.

NOTE:

The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area.

EAU26400

9-1

Yamaha YZFR6SW User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

IMPORTANT MANUAL INFORMATION

TABLE OF CONTENTS

Safe riding

Location of important labels

Left view

Right view

Controls and instruments

Pre-operation check list

Starting the engine

Shifting

Engine break-in

Parking

PERIODIC MAINTENANCE

Periodic maintenance chart for the emission control system

General maintenance and lubrication chart

Troubleshooting

Care

Storage

Identification numbers