Yamaha Thundercat YZF600R Owner's Manual
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Yamaha Thundercat YZF600R Owner's Manual

Thundercat 2001
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OWNER'S MANUAL
YZF600R
4TV-28199-E6

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  • Page 1 OWNER’S MANUAL YZF600R 4TV-28199-E6...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Important Manual Information

    IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
  • Page 6 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.

  • Page 7: Table Of Contents

    EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX...

  • Page 9: Give Safety The Right Of Way

    GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ..........1-1...
  • Page 10 G IVE SAFETY THE RIGHT OF WAY EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.

  • Page 11: Description

    DESCRIPTION Left view ..................... 2-1 Right view................... 2-2 Controls and instruments ..............2-3...

  • Page 12: Left View

    D ESCRIPTION EAU00026 Left view 1. Air intake duct (page 6-19) 2. Fuel tank (page 3-8) 3. Shock absorber assembly spring preload adjusting ring (page 3-15) 4. Shock absorber assembly rebound damping force adjusting knob (page 3-15) 5. Shock absorber assembly compression damping force adjusting screw (page 3-16) 6.

  • Page 13: Right View

    DESCRIPTION Right view 11. Luggage strap holders (page 3-18) 12. Rear brake fluid level check window (page 6-28) 13. Coolant reservoir (page 6-13) 14. Front fork spring preload adjusting bolt (page 3-13) 15. Front fork rebound damping force adjusting screw (page 3-14) 16.

  • Page 14: Controls And Instruments

    DESCRIPTION Controls and instruments 1. Clutch lever (page 3-7) 2. Left handlebar switches (page 3-5) 3. Starter (choke) lever (page 3-11) 4. Speedometer unit (page 3-3) 5. Tachometer (page 3-4) 6. Coolant temperature gauge (page 3-5) 7. Right handlebar switches (page 3-6) 8.

  • Page 15: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock ........3-1 Fuel ..............3-9 Indicator and warning lights ........3-2 Fuel tank breather hose (for Germany only) ..3-10 Speedometer unit ..........3-3 Starter (choke) lever .......... 3-11 Tachometer ............3-4 Seat ..............3-11 Self-diagnosis device ...........3-4 Helmet holder ............

  • Page 16: Main Switch/Steering Lock

    I NSTRUMENT AND CONTROL FUNCTIONS EAU00027 1. Push. 2. Turn. EAU00029 EAU00040 Main switch/steering lock LOCK EW000016 The steering is locked, and all electrical WARNING The main switch/steering lock controls systems are off. The key can be re- the ignition and lighting systems, and is Never turn the key to “OFF”...

  • Page 17: Instrument And Control Functions

    The steering must be locked before the pushing the start switch, have a key can be turned to “ ”. Yamaha dealer check the electri- ECA00043 cal circuit. CAUTION: 1. Neutral indicator light “...

  • Page 18: Speedometer Unit

    INSTRUMENT AND CONTROL FUNCTIONS 3. Push the start switch. If the warn- ing light does not come on, have a Yamaha dealer check the electri- cal circuit. NOTE: This model is equipped with a self-di- agnosis device for the fuel level warn- ing light circuit.

  • Page 19: Tachometer

    If the tachometer displays such an er- Self-diagnosis device ror code, note the circuit-specific num- This model is equipped with a self-di- ber of r/min, and then have a Yamaha agnosis device for the following electri- dealer check the motorcycle. cal circuits:...

  • Page 20: Coolant Temperature Gauge

    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. 1. Coolant temperature gauge 1. Pass switch “PASS” 2. Coolant temperature gauge red zone 2.
  • Page 21 INSTRUMENT AND CONTROL FUNCTIONS EAU03889 EAU00143 Turn signal switch “ ” Start switch “ ” To signal a right-hand turn, push this Push this switch to crank the engine switch to “ ”. To signal a left-hand with the starter. turn, push this switch to “...

  • Page 22: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS 1. Clutch lever 1. Shift pedal 1. Arrow mark 2. Brake lever position adjusting dial EAU00152 EAU00157 3. Brake lever Clutch lever Shift pedal a. Distance between brake lever and handlebar The clutch lever is located at the left The shift pedal is located on the left grip handlebar grip.

  • Page 23: Brake Pedal

    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 un- less the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.

  • Page 24: Fuel

    Your Yamaha engine has been de- 1. Fuel tank filler tube cial design as the original. 2. Fuel level...

  • Page 25: Fuel Tank Breather Hose (For Germany Only)

    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.

  • Page 26: Starter (Choke) Lever

    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 after- burning. If this occurs, turn off the starter (choke).

  • Page 27: Helmet Holder

    This storage compartment is designed key into the lock, and then turn the key shown. to hold an optional genuine Yamaha U- as shown. 2. Push the rear of the seat down to LOCK. (Other locks may not fit.) When To lock the helmet holder, turn the key lock it in place.

  • Page 28: Adjusting The Front Fork

    INSTRUMENT AND CONTROL FUNCTIONS EAU01862 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts, rebound damp- ing force adjusting screws and com- pression damping force adjusting screws. EW000035 WARNING Always adjust both fork legs equal- 1.

  • Page 29: Rebound/Compression Damping Force

    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 1. Rebound damping force adjusting screw 1. Compression damping force adjusting screw may not exactly match the above spec- ifications due to small differences in Rebound damping force...

  • Page 30: Adjusting The Shock Absorber Assembly

    INSTRUMENT AND CONTROL FUNCTIONS EAU03643 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust- ing ring, a rebound damping force ad- justing knob and a compression damping force adjusting screw. ECA00071 1. Spring preload adjusting ring 1.
  • Page 31 Do not deform or damage the CI-10E gas cylinder in any way, as this Setting will result in poor damping per- Minimum (soft) formance. Standard Always have a Yamaha dealer Maximum (hard) service the shock absorber. 3-16...

  • Page 32: Matching The Front And Rear Suspension Settings

    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. CI-05E Load condition Front fork adjustment Shock absorber assembly adjustment Compression...

  • Page 33: Luggage Strap Holders

    Therefore, ier access. check this system regularly as de- scribed below and have a Yamaha dealer repair it if it does not function properly. 3-18...

  • Page 34: Ignition Circuit Cut-Off System

    Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EW000045 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-19...
  • Page 35 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.

  • Page 37: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation check list ..............4-1...

  • Page 38: Pre-Operation Check List

    • If necessary, add recommended coolant to specified level. 6-13–6-14 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. Front brake • Check fluid level in reservoir. 6-27–6-28 • If necessary, add recommended brake fluid to specified level.
  • Page 39 PAGE • Make sure that operation is smooth. Throttle grip • Check free play. 6-20 • If necessary, have Yamaha dealer make adjustment or lubricate. • Make sure that operation is smooth. Control cables 6-31 • Lubricate if necessary. • Check chain slack.
  • Page 40 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.

  • Page 41: Operation And Important Riding Points

    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) ......5-4 Tips for reducing fuel consumption ........... 5-4 Engine break-in ................. 5-5 Parking ....................5-6...

  • Page 42: Starting The Engine

    Before starting engine, are poisonous, and inhaling Yamaha dealer check the electrical cir- check the function of the igni- them can cause loss of con- cuit. tion circuit cut-off system ac- sciousness and death within a 3.
  • Page 43 Yamaha dealer check the off when the start switch is re- electrical circuit. leased.

  • Page 44: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine CAUTION: Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm.

  • Page 45: Recommended Shift Points (For Switzerland Only)

    OPERATION AND IMPORTANT RIDING POINTS EAU02937 EAU00424 Recommended shift points Tips for reducing fuel (for Switzerland only) consumption The recommended shift points during Fuel consumption depends largely on acceleration are shown in the table be- your riding style. Consider the following low.

  • Page 46: Engine Break-In

    8,000 r/min. Since the engine is brand new, do not Yamaha dealer check the vehi- EC000052* put an excessive load on it for the first cle. CAUTION: 1,600 km. The various parts in the en-...

  • Page 47: Parking

    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 pedestri- ans or children are not likely to touch them.

  • Page 49: Periodic Maintenance And Minor Repair

    PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ............6-1 Checking and lubricating the cables ....6-31 Periodic maintenance and lubrication chart ..6-2 Checking and lubricating the throttle grip and cable ............... 6-31 Removing and installing cowlings ......6-5 Checking and lubricating the brake and shift Checking the spark plugs ........6-8 pedals .............

  • Page 50: Owner's Tool Kit

    Periodic inspection, adjustment and lu- ence required for a particular job, have brication will keep your vehicle in the a Yamaha dealer perform it for you. safest and most efficient condition pos- EW000063 sible. The most important points of in-...

  • Page 51: Periodic Maintenance And Minor Repair

    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 techni- cal skills.
  • Page 52 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ • Check for cracks or damage. Brake hoses • Replace. (See NOTE on page 6-4.) Every 4 years √...
  • Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Change. √ √ √ √ √ √ Engine oil • Check oil level and vehicle for oil leakage. √ √ √ Engine oil filter cartridge • Replace. √...

  • Page 54: Removing And Installing Cowlings

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Cowling C 1. Bolt (× 3 on each side) 2. Cowling B 2. Cowling D EAU04277 Cowlings A and C Refer to this section each time a cowl- EAU01065 Removing and installing To remove one of the cowlings ing needs to be removed and installed.
  • Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR Left side Right side Bolt (× 6) Bolt (× 7) 1. Bolt (× 5 on each side) 1. Auxiliary light coupler 2. Turn signal connector (× 2) 2. Disconnect the turn signal connec- tors (and, for the left-side cowling, also the auxiliary light coupler), and then take the cowling off.
  • Page 56 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) 1.

  • Page 57: Checking The Spark Plugs

    If any spark plug shows a distinctly dif- ferent color, the engine could be defec- To remove a spark plug tive. Do not attempt to diagnose such 1. Remove the spark plug cap. problems yourself. Instead, have a Yamaha dealer check the motorcycle.

  • Page 58: To Install Spark Plug

    PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for elec- Tightening torque: trode erosion and excessive car- Spark plug: bon or other deposits, and replace 12.5 Nm (1.25 m·kgf) it if necessary. NOTE: Specified spark plug: If a torque wrench is not available when CR9E (NGK) or installing a spark plug, a good estimate U27ESR-N (DENSO)

  • Page 59: Engine Oil And Oil Filter Cartridge

    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 car- tridge replaced at the intervals speci- fied in the periodic maintenance and lubrication chart.
  • Page 60 NOTE: An oil filter wrench is available at a Skip steps 5–7 if the oil filter cartridge is Make sure that the O-ring is properly Yamaha dealer. not being replaced. seated. 7. Install the new oil filter cartridge, and then tighten it to the specified torque with a torque wrench.
  • Page 61 If the oil level warning light flickers ECA00105 or remains on, immediately turn the CAUTION: engine off and have a Yamaha deal- In order to prevent clutch slip- er check the vehicle. page (since the engine oil also lubricates the clutch), do not 11.

  • Page 62: Coolant

    If water has been added to the minimum level mark, remove the coolant, have a Yamaha dealer checking the coolant level. A slight seat (See page 3-11 for seat re- check the antifreeze content of tilt to the side can result in a false...
  • Page 63 PERIODIC MAINTENANCE AND MINOR REPAIR EW000067 WARNING Never attempt to remove the radia- tor cap when the engine is hot. NOTE: The radiator fan is automatically switched on or off according to the coolant temperature in the radia- 1. Bolt (× 2) 1.
  • Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Clamp screw (× 2) 1. Radiator cap 1. Water pump drain bolt 2. Right air intake duct 2. Cylinder drain bolt (× 2) 9. Remove the radiator cap. 8. Remove the right air intake duct by 11.
  • Page 65 20. Start the engine, and then check Coolant reservoir capacity: the vehicle for coolant leakage. If 0.55 L coolant is leaking, have a Yamaha dealer check the cooling system. 21. Install the right air intake duct, and then tighten the clamp screws.

  • Page 66: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuel tank bolt (× 2) 1. Air filter case cover 1. Air filter element 2. Screw (× 8) 5. Pull the air filter element out. EAU04281* Cleaning the air filter element EW000071 6. Clean the air filter element with WARNING The air filter element should be cleaned solvent, and then squeeze the re-...

  • Page 67: Checking The Air Vent Hose

    If any fuel CAUTION: hose is damaged, do not start Do not operate the motorcycle with Recommended oil: the engine but have a Yamaha the air vent hose removed. Engine oil dealer replace the hose, other- wise fuel may leak.

  • Page 68: Air Intake Duct

    Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.

  • Page 69: Adjusting The Throttle Cable Free Play

    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 a.

  • Page 70: Tires

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00658 CE-01E EWA00012 Tires Tire air pressure WARNING (measured on cold tires) To maximize the performance, durabil- Because loading has an enormous Load* Front Rear ity, and safe operation of your motor- impact on the handling, braking, 225 kPa 250 kPa cycle,...
  • Page 71 Yamaha dealer replace the tire immediately. CE-08E Minimum tire tread depth 1.6 mm...
  • Page 72 120/60 ZR17 M/C (55W) 1. Tire air valve proved this model REAR 2. Tire valve core Yamaha Motor Co., Ltd. 3. Tire valve cap with seal Manufacturer Size Model Always make sure that the valve 160/60 ZR17 (69W) Tire information...

  • Page 73: Cast Wheels

    Other tires may run fore each ride. If any damage is the danger of bursting at super found, have a Yamaha dealer re- high speeds. place the wheel. Do not attempt Brand-new tires can have a rela-...

  • Page 74: Adjusting The Clutch Lever Free Play

    NOTE: If the specified free play cannot be ob- tained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. 1. Locknut a. Distance between brake pedal and footrest 2. Clutch lever free play adjusting bolt EAU00712 c.

  • Page 75: Adjusting The Rear Brake Light Switch

    If there is air in the hydraulic system, have a Yamaha dealer bleed the system be- fore operating the motorcycle. Air in the hydraulic system will diminish 1. Rear brake light switch the braking performance, which 2.

  • Page 76: Checking The Front And Rear Brake Pads

    Before riding, check that the brake fluid ified in the periodic maintenance and Yamaha dealer replace the brake pads is above the minimum level mark and lubrication chart. Each brake pad is as a set.

  • Page 77: Changing The Brake Fluid

    EAU03976 Rear Changing the brake fluid ter the brake fluid reservoir when Have a Yamaha dealer change the refilling. Water will significantly brake fluid at the intervals specified in lower the boiling point of the fluid the NOTE after the periodic mainte- and may result in vapor lock.

  • Page 78: Drive Chain Slack

    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 a.

  • Page 79: Lubricating The Drive Chain

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 ECA00052 NOTE: Lubricating the drive chain CAUTION: Using the alignment marks on each The drive chain must be cleaned and side of the swingarm, make sure that Do not use engine oil or any other lubricated at the intervals specified in both adjusting nuts are in the same po- lubricants for the drive chain, as...

  • Page 80: Checking And Lubricating The Cables

    If a cable is damaged the periodic maintenance chart. or does not move smoothly, have a Recommended lubricant: Yamaha dealer check or replace it. Lithium-soap-based grease (all-purpose grease) Recommended lubricant: Engine oil EW000112...

  • Page 81: Checking And Lubricating The Brake And Clutch Levers

    Recommended lubricant: EW000113 Recommended lubricant: WARNING Lithium-soap-based grease Lithium-soap-based grease If the sidestand does not move up (all-purpose grease) and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-32...

  • Page 82: Checking The Front Fork

    EC000098 CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or re- pair it. 6-33...

  • Page 83: Checking The Wheel Bearings

    2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steer- ing. 6-34...

  • Page 84: Battery

    Avoid any contact with To charge the battery skin, eyes or clothing and al- Have a Yamaha dealer charge the bat- ways shield your eyes when tery as soon as possible if it seems to working near batteries. In case have discharged.

  • Page 85: Replacing The Fuses

    Main fuse: 30 A 5. Spare fuse (× 2) sealed-type (MF) battery charg- Headlight fuse: 20 A EAU04246* er, have a Yamaha dealer charge Replacing the fuses Signaling system fuse: 15 A your battery. Radiator fan fuse: 7.5 A The main fuse and the fuse box, which Ignition fuse: 7.5 A...

  • Page 86: Replacing The Headlight Bulb

    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 1. Headlight bulb holder 2.

  • Page 87: Replacing The Tail/Brake Light Bulb

    4. Install the lens by installing the fied. screws. 4. Install the headlight bulb cover, EC000108 and then connect the coupler. CAUTION: 5. Have a Yamaha dealer adjust the Do not overtighten the screws, oth- headlight beam if necessary. erwise the lens may break. 6-38...

  • Page 88: Replacing A Turn Signal Light Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 To service the rear wheel Supporting the motorcycle Raise the rear wheel off the ground by Since this model is not equipped with a using a motorcycle stand or, if a motor- centerstand, follow these precautions cycle stand is not available, by placing when removing the front and rear a jack either under each side of the...

  • Page 89: Front Wheel

    EW000122 bolt, then the wheel axle and the WARNING brake caliper bolts. It is advisable to have a Yamaha 4. Lift the front wheel off the ground dealer service the wheel. according to the procedure on Securely support the motor- page 6-39.

  • Page 90: Rear Wheel

    EW000122 Brake caliper bolt: legs. WARNING 40 Nm (4.0 m·kgf) It is advisable to have a Yamaha NOTE: 7. Install the brake hose holders by Make sure that the slot in the speedom- dealer service the wheel. installing the bolts.
  • Page 91 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cotter pin 1. Bolt (× 2) 1. Brake caliper bracket 2. Nut 2. Right wheel axle guide 7. Pull the wheel axle out along with 3. Bolt 3. Remove the axle nut and the left the right wheel axle guide, remove 4.

  • Page 92: Troubleshooting

    1. Install the wheel, right wheel axle self. However, should your motorcycle Brake caliper bolt: guide, and caliper bracket by in- require any repair, take it to a Yamaha 40 Nm (4.0 m·kgf) serting the wheel axle from the dealer, whose skilled technicians have Brake torque rod nut: right-hand side.

  • Page 93: Troubleshooting Charts

    Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 94 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. 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.

  • Page 95: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE Care ....................7-1 Storage ....................7-4...
  • Page 96 M OTORCYCLE CARE AND STORAGE EAU03426 Care Before cleaning Cleaning 1. Cover the muffler outlet with a ECA00010 While the open design of a motorcycle CAUTION: plastic bag after the engine has reveals the attractiveness of the tech- Avoid using strong acidic wheel cooled down.

  • Page 97: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical For motorcycles equipped with After riding in the rain, near the sea or products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads sponges which have been in...
  • Page 98 MOTORCYCLE CARE AND STORAGE After cleaning EWA00001 NOTE: WARNING Consult a Yamaha dealer for advice on 1. Dry the motorcycle with a chamois Make sure that there is no oil or what products to use. or an absorbing cloth. wax on the brakes or tires. If 2.
  • Page 99 MOTORCYCLE CARE AND STORAGE Storage Long-term a. Remove the spark plug caps and Before storing your motorcycle for sev- spark plugs. eral months: b. Pour a teaspoonful of engine oil Short-term 1. Follow all the instructions in the into each spark plug bore. Always store your motorcycle in a cool, “Care”...
  • Page 100 MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and NOTE: Make any necessary repairs before the pivoting points of all levers and storing the motorcycle. 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.

  • Page 101: Specifications

    SPECIFICATIONS Specifications ..................8-1 Conversion table ................8-5...
  • Page 102 S PECIFICATIONS EAU01038 Specifications CS-01E Model YZF600R Engine oil Dimensions Type -20 -10 10 20 30 40 50 ˚C Overall length 2,145 mm (except for F, E, I, GR) SAE 10W-30 2,060 mm (for F, E, I, GR) SAE 10W-40...
  • Page 103 SPECIFICATIONS Cooling system capacity Gear ratio (total amount) 1.95 L 2.846 Air filter Wet element 1.947 Fuel 1.545 Type REGULAR UNLEADED 1.333 GASOLINE ONLY 1.190 Fuel tank capacity 19 L 1.074 Reserve amount 3.1 L Chassis Carburetor Frame type Diamond Manufacturer KEIHIN Caster angle...
  • Page 104 SPECIFICATIONS Rear Wheels Type Tubeless tire Front Size 160/60 ZR17 (69W) Type Cast wheel 17 × MT 3.50 160/60 ZR17 M/C (69W) Size 17 M/C × MT 3.50 Manufacturer/model Bridgestone / BT57 Dunlop / D204 Rear Metzeler / MEZ1 Type Cast wheel 17 ×...
  • Page 105 SPECIFICATIONS Wheel travel Fuses Front 130 mm Main fuse 30 A Rear 120 mm Headlight fuse 20 A Electrical system Signaling system fuse 15 A Ignition system T.C.I. (digital) Radiator fan fuse 7.5 A Charging system Ignition fuse 7.5 A Type A.C.

  • Page 106: Conversion Table

    SPECIFICATIONS EAU03941 Conversion table CS-03E Conversion table All specification data in this manual are listed in SI and METRIC SYSTEM TO IMPERIAL SYSTEM METRIC UNITS. Metric unit Conversion factor Imperial unit × m·kgf 7.233 ft·lb × m·kgf 86.794 in·lb Use this table to convert METRIC unit values to IMPERIAL Torque ×...

  • Page 107: Consumer Information

    CONSUMER INFORMATION Identification numbers ............... 9-1 Key identification number ..............9-1 Vehicle identification number ............. 9-1 Model label ..................9-2...

  • Page 108: Identification Numbers

    Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. 1. Key identification number 1.

  • Page 109: 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.
  • Page 110 INDEX Air filter element, cleaning ......6-17 Dimmer switch......... 3-5 Identification numbers ......9-1 Air intake duct ........6-19 Drive chain, lubricating ......6-30 Idling speed, adjusting ......6-19 Air vent hose, checking ......6-18 Drive chain slack ........6-29 Ignition circuit cut-off system ....3-19 Anti-theft alarm ........3-5 Adjusting ..........
  • Page 111 INDEX Shifting ............ 5-3 Shift pedal ..........3-7 Valve clearance, adjusting ....6-20 Shift points (for Switzerland only)..... 5-4 Vehicle identification number....9-1 Shock absorber assembly, adjusting ..3-15 Sidestand ..........3-18 Wheel bearings, checking ..... 6-34 Sidestand, checking and lubricating..6-32 Wheel (front) .........
  • Page 114 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 . 6 - 0.3 × 1 CR...

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