OWNER’S MANUAL YZF600R YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 . 6 - 0.
Shiro.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM INTRODUCTION EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of a YZF600R, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your YZF600R.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM 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! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM IMPORTANT MANUAL INFORMATION EAU04229 YZF600R OWNER’S MANUAL © 2001 by Yamaha Motor Co., Ltd. 1st edition, May 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U4TVE6.
U4TVE6.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ................................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM GIVE SAFETY THE RIGHT OF WAY EAU00021 1- Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls and instruments ...................................................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM DESCRIPTION EAU00026 2- Left view 2 1. Air intake duct 2. Fuel tank 3. Shock absorber assembly spring preload adjusting ring 4. Shock absorber assembly rebound damping force adjusting knob 5. Shock absorber assembly compression damping force adjusting screw 6. Storage compartment 7. Helmet holder 8. Grab bar 9. Shift pedal 10.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM DESCRIPTION Right view 2 11. Luggage strap holders 12. Rear brake fluid level check window 13. Coolant reservoir 14. Front fork spring preload adjusting bolt 15. Front fork rebound damping force adjusting screw 16. Radiator cap 17. Front fork compression damping force adjusting screw 18. Engine oil level check window 19. Brake pedal 20.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM DESCRIPTION Controls and instruments 2 1. Clutch lever 2. Left handlebar switches 3. Starter (choke) lever 4. Speedometer unit 5. Tachometer 6. Coolant temperature gauge 7. Right handlebar switches 8. Brake lever 9. Throttle grip 10.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .....................................3-1 Indicator and warning lights ................................3-2 Speedometer unit ................................................3-3 Tachometer ..........................................................3-4 Self-diagnosis device ...........................................3-4 Coolant temperature gauge .................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029 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. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00040 LOCK The steering is locked, and all electrical systems are off. The key can be removed.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS 1. Set the engine stop switch to “ ” and turn the key to “ON”. 2. Shift the transmission into the neutral position or pull the clutch lever. 3. Push the start switch. If the warning light does not come on while pushing the start switch, have a Yamaha dealer check the electrical circuit. EAU01590 (Parking) The steering is locked, and the taillight and auxiliary light are on, but all other electrical systems are off.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS 3. Push the start switch. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: This model is equipped with a self-diagnosis device for the fuel level warning light circuit. (See page 3-4 for an explanation of the self-diagnosis device.) _ 3 1. 2. 3. 4. 5.
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00105 Self-diagnosis device This model is equipped with a self-diagnosis device for the following electrical circuits: ● throttle position sensor ● fuel level warning light If any of those circuits are defective, the tachometer will repeatedly display the following error code: 1. Tachometer 2.
U4TVE6.book Page 5 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Anti-theft alarm (optional) This motorcycle can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. 3 1. Coolant temperature gauge 2. Coolant temperature gauge red zone 1. 2. 3. 4.
U4TVE6.book Page 6 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU03889 EAU00143 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, 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. Start switch “ ” Push this switch to crank the engine with the starter.
U4TVE6.book Page 7 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Clutch lever 1. Shift pedal EAU00152 EAU00157 Clutch lever Shift pedal 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.
U4TVE6.book Page 8 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. 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. _ 1. Brake pedal EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. _ 1.
U4TVE6.book Page 9 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS _ 3 1. Fuel tank filler tube 2. Fuel level EAU00186 ECA00104 CAUTION: ● Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. ● For Germany only: Whenever replacement is necessary, use a fuel tank cap of the same special design as the original. CAUTION: Use only unleaded gasoline.
U4TVE6.book Page 10 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU00196 Fuel tank breather hose (for Germany only) Before operating the motorcycle: ● Check the fuel tank breather hose connection. ● Check the fuel tank breather hose for cracks or damage, and replace it if damaged. ● Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary. 3 1.
U4TVE6.book Page 11 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS ECA00038 CAUTION: Do not use the starter (choke) for more than 3 minutes as the exhaust pipe may discolor from excessive heat. In addition, extended use of the starter (choke) will cause afterburning. If this occurs, turn off the starter (choke). _ 3 1. Starter (choke) lever “ ” _ 1. Unlock.
U4TVE6.book Page 12 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Seat holder 2. Projection (× 2) To install the seat 1. Insert the projections on the front of the seat into the seat holder as shown. 2. Push the rear of the seat down to lock it in place. 3. Remove the key. NOTE: Make sure that the seat is properly secured before riding. 1. Helmet holder 2. Unlock.
U4TVE6.book Page 13 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU01862 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. EW000035 3 WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. _ _ 1.
U4TVE6.book Page 14 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EC000015 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.
U4TVE6.book Page 15 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU03643 Adjusting the shock absorber assembly 3 This shock absorber assembly is equipped with a spring preload adjusting ring, a rebound damping force adjusting knob and a compression damping force adjusting screw. ECA00071 CAUTION: Never attempt to turn the spring preload and rebound damping force adjusting mechanisms beyond the maximum or minimum settings. _ _ 1. Spring preload adjusting ring 2.
U4TVE6.book Page 16 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS NOTE: Although the total number of clicks of the rebound 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.
U4TVE6.book Page 17 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU01580 Matching the front and rear suspension settings Use this table as a guide to match the suspension and damping adjustments of the front fork and shock absorber assembly according to various load conditions.
U4TVE6.book Page 18 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS Left EAU00330 Right Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle 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.) _ 1.
U4TVE6.book Page 19 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS EAU03720 Ignition circuit cut-off system 3 The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
U4TVE6.book Page 20 Saturday, August 4, 2001 12:14 PM INSTRUMENT AND CONTROL FUNCTIONS CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. NO The neutral switch may be defective.
U4TVE6.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM PRE-OPERATION CHECKS Pre-operation check list .....................................................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM PRE-OPERATION CHECKS EAU01114 4- 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.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check free play. • If necessary, have Yamaha dealer make adjustment or lubricate. 6-20 Control cables • Make sure that operation is smooth. • Lubricate if necessary. 6-31 Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 6-29, 6-30 Wheels and tires • • • • Check for damage.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle 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. _ _ EWA00033 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS Starting the engine ............................................................................ 5-1 Starting a warm engine ..................................................................... 5-3 Shifting .............................................................................................. 5-3 Recommended shift points (for Switzerland only) .............................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- EAU00373 _ 5 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 operate 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.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS not go off after starting with sufficient engine oil, have a Yamaha dealer check the electrical circuit. ● If the fuel level warning light remains on after starting, stop the engine, and then check the fuel level. If necessary, refuel as soon as possible, and then check the warning light again.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine _ Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. 1. Shift pedal N. Neutral position EAU00423 5 Shifting 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.
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS EAU02937 EAU00424 Recommended shift points (for Switzerland only) Tips for reducing fuel consumption The recommended shift points during acceleration are shown in the table below. Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Thoroughly warm up the engine. ● Turn the starter (choke) off as soon as possible.
U4TVE6.book Page 5 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS EAU01128 Engine break-in 5 There is never a more important period in the life of your engine than the period between 0 and 1,600 km. 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 1,600 km. The various parts in the engine wear and polish themselves to the correct operating clearances.
U4TVE6.book Page 6 Saturday, August 4, 2001 12:14 PM OPERATION AND IMPORTANT RIDING POINTS EAU00460 Parking When parking, stop the engine, and then remove the key from the main switch. EW000058 _ 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 motorcycle may overturn.
U4TVE6.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ....................................................6-1 Periodic maintenance and lubrication chart .........6-2 Removing and installing cowlings ........................6-5 Checking the spark plugs ....................................6-8 Engine oil and oil filter cartridge ........................6-10 Coolant ..............................................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 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 inspection, adjustment, and lubrication are explained on the following pages.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03685 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50,000 km, repeat the maintenance intervals starting from 10,000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. _ _ CP-03E NO.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR NO. CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 1 10 √ • Check for cracks or damage. 20 30 40 ANNUAL CHECK √ √ √ √ 9 * Brake hoses 10 * Wheels • Check runout and for damage. √ √ √ √ 11 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √ √ √ √ 12 * Wheel bearings • Check bearing for looseness or damage.
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECK OR MAINTENANCE JOB • Change. • Check oil level and vehicle for oil leakage. 23 Engine oil 24 Engine oil filter cartridge • Replace. 25 * Cooling system 26 * switches Front and rear brake 1 10 20 30 40 ANNUAL CHECK √ √ √ √ √ √ √ √ √ • Check coolant level and vehicle for coolant leakage. √ • Change. Moving parts and cables • Lubricate.
U4TVE6.book Page 5 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 2. Cowling B EAU01065 Removing and installing cowlings 6 1. Cowling C 2. Cowling D 1. Bolt (× 3 on each side) Refer to this section each time a cowling needs to be removed and installed. Cowlings A and C To remove one of the cowlings 1. Remove the bolts. EAU04277 The cowlings shown above need to be removed to perform some of the maintenance jobs described in this chapter.
U4TVE6.book Page 6 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Left side Bolt (× 6) Right side Bolt (× 7) 1. Bolt (× 5 on each side) 1. Auxiliary light coupler 2. Turn signal connector (× 2) 2. Disconnect the turn signal connectors (and, for the left-side cowling, also the auxiliary light coupler), and then take the cowling off. To install the cowling 1. Connect the turn signal connectors (and, for the left-side cowling, also the auxiliary light coupler). 2.
U4TVE6.book Page 7 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR To install the cowling 1. Place the cowling in the original position, and then install the screw. 2. Install the grab bar by installing the bolts. 3. Install the cowling and the seat. 1. Screw (× 2) EAU03595 6 Cowling B To remove the cowling 1. Remove the seat. (See page 3-11 for seat removal and installation procedures.) 2. Remove the screws, and then pull the cowling off as shown.
U4TVE6.book Page 8 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Spark plug cap (× 2 on each side) 1. Spark plug wrench EAU03329 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart.
U4TVE6.book Page 9 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf) Specified spark plug: CR9E (NGK) or U27ESR-N (DENSO) _ a. Spark plug gap 6 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.
U4TVE6.book Page 10 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04279 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 motorcycle on a level surface and hold it in an upright position.
U4TVE6.book Page 11 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Left side 1. Engine oil drain bolt 4. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 6 NOTE: Skip steps 5–7 if the oil filter cartridge is not being replaced. _ 1. Oil filter cartridge 2. Oil filter wrench 1. O-ring 5. Remove the oil filter cartridge with an oil filter wrench. 6. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
U4TVE6.book Page 12 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the engine oil drain bolt, and then tighten it to the specified torque. 10. 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. Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.6 L With oil filter cartridge replacement: 2.
U4TVE6.book Page 13 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03987 Coolant Coolant reservoir capacity: 0.55 L 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. To check the coolant level 1. Place the motorcycle on a level surface and hold it in an upright position.
U4TVE6.book Page 14 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000067 WARNING Never attempt to remove the radiator cap when the engine is hot. _ _ 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. _ _ 1. Bolt (× 2) 2. Coolant reservoir 1. Fuel tank bolt (× 2) 7. Remove the fuel tank bolts, and then lift the fuel tank.
U4TVE6.book Page 15 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Clamp screw (× 2) 2. Right air intake duct 8. Remove the right air intake duct by loosening the clamp screws. 1. Radiator cap 1. Water pump drain bolt 2. Cylinder drain bolt (× 2) 9. Remove the radiator cap. EW000067 WARNING Never attempt to remove the radiator cap when the engine is hot. _ 6 _ 10. Place a container under the engine to collect the used coolant. 6-15 11.
U4TVE6.book Page 16 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA00041 Tightening torques: Water pump drain bolt: 10 Nm (1.0 m·kgf) Cylinder drain bolt: 7.0 Nm (0.7 m·kgf) 15. Install the coolant reservoir by installing the bolts. 16. Pour the specified amount of recommended coolant into the radiator and reservoir.
U4TVE6.book Page 17 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuel tank bolt (× 2) EAU04281* 1. Air filter case cover 2. Screw (× 8) Cleaning the air filter element 6 The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-11 for seat removal and installation procedures.) 2.
U4TVE6.book Page 18 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000082* _ CAUTION: ● Make sure that the air filter element is properly seated in the air filter case. ● The engine should never be operated without the air filter element installed, otherwise the pistons and/or cylinders may become excessively worn. 1. Air vent hose _ 7. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out. 9.
U4TVE6.book Page 19 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00630 Adjusting the carburetors 1. Air intake duct EAU01335 Air intake duct 6 Check that the screen of the intake duct is not blocked. Clean the screen if necessary. The carburetors are important parts of the engine and require very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
U4TVE6.book Page 20 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Adjusting the 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. 1. Throttle stop screw 2.
U4TVE6.book Page 21 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00658 CE-01E 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. EW000082 _ 6 WARNING ● The tire air pressure must be checked and adjusted on cold tires (i.e.
U4TVE6.book Page 22 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides. ● Adjust the suspension and tire air pressure with regard to the load. ● Check the tire condition and air pressure before each ride. _ EW000079 _ 1. Tire sidewall a. Tire tread depth Tire inspection The tires must be checked before each ride.
U4TVE6.book Page 23 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000080 _ ● ● 1. Tire air valve 2. Tire valve core 3. Tire valve cap with seal 6 ● Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves. ● WARNING The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed.
U4TVE6.book Page 24 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00684 WARNING This motorcycle is fitted with super-high-speed tires. Note the following points in order to make the most efficient use of these tires. ● Use only the specified replacement tires. Other tires may run the danger of bursting at super high speeds. ● Brand-new tires can have a relatively poor grip on certain road surfaces until they have been “broken in”.
U4TVE6.book Page 25 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. _ _ 1. Locknut 2. Clutch lever free play adjusting bolt c. Clutch lever free play a.
U4TVE6.book Page 26 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EW000109 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. _ _ 1. Rear brake light switch 2.
U4TVE6.book Page 27 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Front Rear 1. Brake pad wear indicator (× 2) 1. Brake pad wear indicator (× 2) EAU00715 Checking the front and rear brake pads 6 Front The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake.
U4TVE6.book Page 28 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Rear 1. Minimum level mark 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. ● Be careful that water does not enter the brake fluid reservoir when refilling.
U4TVE6.book Page 29 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position. NOTE: When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it. _ 6 _ a. Drive chain slack 2.
U4TVE6.book Page 30 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same position for proper wheel alignment. _ _ EC000096 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.
U4TVE6.book Page 31 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02962 EAU04034 EAU03370 Checking and lubricating the cables Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals 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.
U4TVE6.book Page 32 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03164 EAU03165 EAU04282 Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand Lubricating the rear suspension The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U4TVE6.book Page 33 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 EAU00794 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 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.
U4TVE6.book Page 34 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 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 smoothly, have a Yamaha dealer check the wheel bearings. 2. Hold the lower ends of the front fork legs and try to move them forward and backward.
U4TVE6.book Page 35 Saturday, August 4, 2001 12:14 PM 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 hydrogen 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 BATTERIES OUT OF THE REACH OF CHILDREN.
U4TVE6.book Page 36 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000102 _ _ CAUTION: keep the battery ● Always 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. 1. 2. 3. 4. 5.
U4TVE6.book Page 37 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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. 1. Headlight coupler 2. Headlight bulb cover 1. Headlight bulb holder EAU04160 Replacing the headlight bulb 6 This motorcycle is equipped with a quartz bulb headlight.
U4TVE6.book Page 38 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EC000104 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.
U4TVE6.book Page 39 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1. Screw EAU03497 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the 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.
U4TVE6.book Page 40 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Left side 6. Remove the brake calipers on each side by removing the bolts. 7. Pull the wheel axle out, remove the speedometer gear unit, and then remove the wheel. Right side ECA00046 CAUTION: Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut. _ 1. 2. 3. 4. 5. 6.
U4TVE6.book Page 41 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the brake calipers by installing the bolts. NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs. _ _ 6. Tighten the wheel axle, then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques. 1. Speedometer gear unit 2. Slot 3. Speedometer gear unit retainer EAU04196 6 To install the front wheel 1.
U4TVE6.book Page 42 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. Cotter pin Nut Bolt Brake torque rod 1. Loosen the wheel axle nut, the brake torque rod nut at the brake caliper bracket, and the brake caliper bolts. 2. Lift the rear wheel off the ground according to the procedure on page 6-39. 1. Bolt (× 2) 2. Right wheel axle guide 3. Remove the axle nut and the left wheel axle guide, and then remove the brake caliper by removing the bolts. 4.
U4TVE6.book Page 43 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Adjust the drive chain slack. (See page 6-29 for drive chain slack adjustment procedures.) 5. Lower the rear wheel so that it is on the ground. 6. Tighten the axle nut, the brake caliper bolts and the brake torque rod nut to the specified torques. Tightening torques: Axle nut: 117 Nm (11.7 m·kgf) Brake caliper bolt: 40 Nm (4.0 m·kgf) Brake torque rod nut: 30 Nm (3.
U4TVE6.book Page 44 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02990 Troubleshooting charts Starting problems or poor engine performance EW000125 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. _ _ 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
U4TVE6.book Page 45 Saturday, August 4, 2001 12:14 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EW000070 _ WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM MOTORCYCLE CARE AND STORAGE EAU03426 7- 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.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM MOTORCYCLE CARE AND STORAGE ● 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 cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM MOTORCYCLE CARE AND STORAGE 7 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.) 4.
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 _ _ 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.
U4TVE6.book Page 5 Saturday, August 4, 2001 12:14 PM MOTORCYCLE CARE AND STORAGE 7 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7. 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. 8.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM SPECIFICATIONS Specifications .................................................................................... 8-1 Conversion table ...............................................................................
U4TVE6.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM SPECIFICATIONS Cooling system capacity (total amount) 1.95 L Air filter Wet element Gear ratio Fuel Type REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity 19 L Reserve amount 3.1 L 2.846 2nd 1.947 3rd 1.545 4th 1.333 5th 1.190 6th 1.
U4TVE6.book Page 3 Saturday, August 4, 2001 12:14 PM SPECIFICATIONS Rear Wheels Type Tubeless tire Size 160/60 ZR17 (69W) Type 160/60 ZR17 M/C (69W) Size Manufacturer/model Front Rear Metzeler / MEZ1 Type Michelin / MACADAM 90X Size Cast wheel 17 × MT 5.00 17 M/C × MT 5.00 180 kg (except for A, CH, S) 178 kg (for A, CH, S) Brakes Tire air pressure (measured on cold tires) Front Up to 90 kg* Front 225 kPa (2.25 kgf/cm2, 2.25 bar) Rear 250 kPa (2.50 kgf/cm2, 2.
U4TVE6.book Page 4 Saturday, August 4, 2001 12:14 PM SPECIFICATIONS Wheel travel Fuses Front 130 mm Main fuse 30 A Rear 120 mm Headlight fuse 20 A Electrical system Ignition system T.C.I. (digital) Charging system Type A.C. magneto Standard output 14 V, 18.5 A @ 5,000 r/min Signaling system fuse 15 A Radiator fan fuse 7.5 A Ignition fuse 7.
U4TVE6.book Page 5 Saturday, August 4, 2001 12:14 PM SPECIFICATIONS EAU03941 Conversion table CS-03E Conversion table All specification data in this manual are listed in SI and METRIC UNITS. METRIC SYSTEM TO IMPERIAL SYSTEM Metric unit Use this table to convert METRIC unit values to IMPERIAL unit values. Example: METRIC VALUE 2 mm CONVERSION FACTOR × 0.03937 Torque ft·lb in·lb ft·lb in·lb Weight kg g × 2.205 × 0.03527 lb oz Speed km/h × 0.6214 mi/h Distance km m m cm mm × 0.6214 × 3.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM CONSUMER INFORMATION Identification numbers ....................................................................... 9-1 Key identification number .................................................................. 9-1 Vehicle identification number ............................................................. 9-1 Model label ........................................................................................
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM CONSUMER INFORMATION EAU01039 9- EAU02944 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. 1. Key identification number 1. KEY IDENTIFICATION NUMBER: CA-02E 2.
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM CONSUMER INFORMATION 1. Model label EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-11 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U4TVE6.book Page 1 Saturday, August 4, 2001 12:14 PM INDEX A D I Air filter element, cleaning ......................6-17 Air intake duct ........................................6-19 Air vent hose, checking ..........................6-18 Anti-theft alarm ........................................3-5 Dimmer switch......................................... 3-5 Drive chain, lubricating .......................... 6-30 Drive chain slack ................................... 6-29 Adjusting ........................
U4TVE6.book Page 2 Saturday, August 4, 2001 12:14 PM INDEX Shifting .................................................... 5-3 Shift pedal ............................................... 3-7 Shift points (for Switzerland only)............. 5-4 Shock absorber assembly, adjusting ..... 3-15 Sidestand .............................................. 3-18 Sidestand, checking and lubricating....... 6-32 Spark plugs, checking ............................. 6-8 Specifications ..........................................
Shiro.
Shiro.
OWNER’S MANUAL YZF600R YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 . 6 - 0.
