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

Thundercat 1999
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OWNER'S MANUAL
YZF600R
4TV-28199-E4

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Summary of Contents for Yamaha Thundercat YZF600R

  • Page 1 OWNER’S MANUAL YZF600R 4TV-28199-E4...
  • Page 2 EAU00001 Welcome to the Yamaha world of motorcycling! As the owner of a YZF600R, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
  • Page 3 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 4: Important Manual Information

    IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
  • Page 5 IMPORTANT MANUAL INFORMATION EAU00008 YZF600R OWNER’S MANUAL © 1999 by Yamaha Motor Co., Ltd. 1st Edition, August 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS EAU00009 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 8: Give Safety The Right Of Way

    GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY..........1-1...
  • Page 9 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 your motorcycle’s value and operating condition.

  • Page 10: Description

    DESCRIPTION Left view ..................... 2-1 Right view................... 2-2 Controls/Instruments ................2-3...
  • Page 11 D ESCRIPTION EAU00026 Left view 1. Air intake duct (page 6-17) 5. Rear shock absorber compression 2. Fuel tank (page 3-11) damping force adjusting screw (page 3-19) 3. Rear shock absorber spring preload 6. Storage compartment (page 3-15) adjusting ring (page 3-18) 7.
  • Page 12 DESCRIPTION Right view 11. Luggage strap holders (page 3-21) 15. Front fork rebound damping force 12. Rear brake fluid inspection window (page 6-25) adjusting screw (page 3-17) 13. Coolant reservoir tank (page 6-12) 16. Front fork compression damping 14. Front fork spring preload adjusting force adjusting screw (page 3-17) bolt...
  • Page 13 DESCRIPTION Controls/Instruments 18. Clutch lever (page 3-9) 23. Coolant temperature gauge (page 3-8) 19. Left handlebar switches (page 3-8) 24. Right handlebar switches (page 3-9) 20. Starter (choke) “ ” (page 3-13) 25. Front brake lever (page 3-10) 21. Speedometer (page 3-6) 26.

  • Page 14: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock........3-1 Fuel tank cap ............. 3-11 Indicator lights ............3-2 Fuel ..............3-11 Oil level indicator circuit check......3-4 Fuel tank breather hose (for Germany only) ..3-13 Fuel indicator circuit check ........3-5 Starter (choke) “ ”...

  • Page 15: 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 in this position WARNING The main switch controls the ignition and all electrical circuits are switched and lighting systems. Its operation is Never turn the key to “OFF”...

  • Page 16: Indicator Lights

    INSTRUMENT AND CONTROL FUNCTIONS EAU01590 EAU01313 (Parking) Oil level indicator light “ ” The steering is locked in this position, This indicator comes on when the oil and the taillight and auxiliary light come level is low. This light circuit can be on but all other circuits are off.
  • Page 17 INSTRUMENT AND CONTROL FUNCTIONS 1. Neutral indicator light “ ” 2. Oil level indicator light “ ” 3. Fuel indicator light “ ” 4. Turn indicator light “ ” 5. High beam indicator light “ ” EAU00057 Turn indicator light “ ”...

  • Page 18: Oil Level Indicator Circuit Check

    Oil level indicator light Oil level Oil level comes on. does not come on. is OK. is low. Ask a Yamaha dealer to Engine oil level and Supply inspect electrical circuit. electrical circuit are OK. engine oil. Go ahead with riding.

  • Page 19: Fuel Indicator Circuit Check

    Fuel indicator light Fuel indicator light Fuel level Fuel level comes on. does not come on. is OK. is low. Fuel level and electrical Ask a Yamaha dealer to Supply fuel. circuit are OK. inspect electrical circuit. Go ahead with riding.

  • Page 20: Speedometer

    INSTRUMENT AND CONTROL FUNCTIONS 1. Odometer 1. Tachometer 2. Reset knob 2. Red zone 3. Trip odometer EAU00101 Tachometer EAU00095 Speedometer This model is equipped with an electric The speedometer shows riding speed. tachometer so the rider can monitor the This speedometer is equipped with an engine speed and keep it within the odometer and trip odometer.

  • Page 21: Diagnosis Device

    Fuel indicator light circuit To prevent engine damage, be sure If some trouble should occur in any of to consult a Yamaha dealer as soon these circuits, the tachometer will re- as possible if the tachometer dis- peatedly display as follows: plays a repeated change in r/min.

  • Page 22: Coolant Temperature Gauge

    INSTRUMENT AND CONTROL FUNCTIONS EAU00127 Turn signal switch To signal a right-hand turn, push the switch to “ ”. To signal a left-hand turn, push the switch to “ ”. Once the switch is released it will return to the center position.

  • Page 23: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch “ ” The starter motor cranks the engine when pushing the start switch. EC000005 CAUTION: See starting instructions prior to starting the engine. 1. Engine stop switch 1. Clutch lever 2. Lights switch EAU00152 3.

  • Page 24: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Arrow mark 1. Rear brake pedal 2. Brake lever adjusting dial EAU00157 EAU00162 3. Front brake lever Shift pedal Rear brake pedal a. Lever distance This motorcycle is equipped with a con- The rear brake pedal is on the right EAU00161 stant-mesh 6-speed transmission.

  • Page 25: Fuel Tank Cap

    INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. EW000023 WARNING Be sure the cap is properly installed and locked in place before riding the 1.
  • Page 26 INSTRUMENT AND CONTROL FUNCTIONS EAU00186 EAU00191 CAUTION: Recommended fuel: Always wipe off spilled fuel im- Regular unleaded gasoline with a mediately with a dry and clean research octane number of 91 or soft cloth. Fuel may deteriorate higher. painted surfaces plastic Fuel tank capacity: parts.

  • Page 27: Fuel Tank Breather Hose (For Germany Only)

    INSTRUMENT AND CONTROL FUNCTIONS EAU00196 Fuel tank breather hose (for Germany only) This model is equipped with a fuel tank breather hose. Before using this motor- cycle, be sure to: Check hose connection. Check hose for cracks or damage. Replace if damaged. 1.

  • Page 28: Seat

    INSTRUMENT AND CONTROL FUNCTIONS ECA00038 CAUTION: Do not use the starter (choke) for more than 3 minutes as the exhaust pipe may discolor from excessive heat. Also, longer use of the starter (choke) will cause afterburning. If af- terburning occurs, turn off the starter (choke).

  • Page 29: Helmet Holder

    To open the helmet holder, insert the This compartment is designed to store key in the lock and turn it as shown. To a genuine Yamaha U-LOCK. (Other lock the helmet holder, turn the key to locks may not fit.) Be sure the lock is its original position.

  • Page 30: Front Fork Adjustment

    INSTRUMENT AND CONTROL FUNCTIONS EAU01862* Front fork adjustment This front fork is equipped with spring preload and damping force adjusters. EW000037 WARNING Each fork leg must be set to the same pressure. Uneven setting can cause poor handling and loss of sta- bility.
  • Page 31 INSTRUMENT AND CONTROL FUNCTIONS EC000015 CAUTION: Never attempt to turn an adjuster beyond the maximum or minimum setting. NOTE: Although the number of clicks between the minimum and maximum settings 1. Rebound damping force adjusting screw 1. Compression damping force adjusting screw may vary with each individual shock absorber and may not exactly match Adjusting rebound damping force...

  • Page 32: Rear Shock Absorber Adjustment

    INSTRUMENT AND CONTROL FUNCTIONS EAU01592* Rear shock absorber adjustment This shock absorber is equipped with spring preload and damping force ad- justers. EC000015 CAUTION: Never attempt to turn an adjuster 1. Spring preload adjusting ring 1. Rebound damping force adjusting knob beyond the maximum or minimum 2.
  • Page 33 CI-15E excessive gas pressure. Soft Standard Hard Do not deform or damage the Adjusting cylinder in any way. Cylinder position damage will result in poor damping performance. Take your shock absorber to a Yamaha dealer for any service. 3-19...

  • Page 34: Recommended Combinations Of The Front Fork And The Rear Shock Absorber Settings

    INSTRUMENT AND CONTROL FUNCTIONS EAU01580 Recommended combinations of the front fork and the rear shock absorber settings Use this table as a guide for specific settings according to motorcycle load conditions. CI-31E Loading condition Front fork adjustment Rear shock absorber adjustment Compression Rebound Compression...

  • Page 35: Luggage Strap Holders

    Yamaha dealer immediately for repair. 3-21...

  • Page 36: Sidestand/Clutch Switch Operation Check

    CD-11E WARNING TURN THE MAIN SWITCH TO “ON” If improper operation is noted, con- AND THE ENGINE STOP SWITCH TO sult a Yamaha dealer immediately. “ ”. TRANSMISSION IS IN GEAR AND SIDESTAND IS UP. PULL IN CLUTCH LEVER AND PUSH THE START SWITCH.

  • Page 38: Pre-Operation Checks

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

  • Page 39: Pre-Operation Check List

    P RE-OPERATION CHECKS EAU01114 Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
  • Page 40 PRE-OPERATION CHECKS ITEM CHECKS PAGE • Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners — • Tighten if necessary. • Check fuel level. Fuel 3-11 ~ 3-13 • Fill with fuel if necessary. Lights, signals and •...

  • Page 42: Operation And Important Riding Points

    OPERATION AND IMPORTANT RIDING POINTS Starting the engine................5-1 Starting a warm engine ..............5-4 Shifting ....................5-4 Recommended shift points (for Switzerland only) ......5-5 Tips for reducing fuel consumption ............ 5-5 Engine break-in .................. 5-5 Parking ....................5-6...

  • Page 43: Starting The Engine

    Consult The engine can be started only under Yamaha dealer regarding any one of the following conditions: control or function that you do The transmission is in neutral. not thoroughly understand. The sidestand is up, the transmis-...

  • Page 44: Operation And Important Riding Points

    OPERATION AND IMPORTANT RIDING POINTS CF-28E TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “ ”. IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN, SIDESTAND IS UP, PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH START ENGINE WILL START.
  • Page 45 (choke) turned off. Yamaha dealer to inspect it. is released. If the oil level indicator light flickers or remains on, immedi- 3. Turn on the starter (choke) and completely close the throttle grip.

  • Page 46: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine CAUTION: The starter (choke) is not required Do not coast for long periods when the engine is warm. with the engine off, and do not EC000046 tow the motorcycle a long dis- CAUTION: tance.

  • Page 47: Recommended Shift Points (For Switzerland Only)

    OPERATION AND IMPORTANT RIDING POINTS EAU02937 EAU00424 EAU00436 Recommended shift points Tips for reducing fuel Engine break-in (for Switzerland only) consumption There is never a more important period in the life of your motorcycle than the The recommended shift points are Your motorcycle’s fuel consumption period between zero and 1,000 km.

  • Page 48: Parking

    If any engine trouble should oc- one set throttle position. motorcycle in a place where pedes- cur during the break-in period, trians or children are not likely to consult a Yamaha dealer imme- 150 ~ 500 km touch the motorcycle. Do not park diately. Avoid...

  • Page 50: Periodic Maintenance And Minor Repair

    PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit..............6-1 Drive chain slack check........6-27 Periodic maintenance and lubrication....6-2 Drive chain slack adjustment ......6-27 Cowling and panel removal and installation..6-5 Drive chain lubrication........6-28 Cowling A and B ...........6-5 Cable inspection and lubrication ......6-28 Cowling C .............6-7 Throttle cable and grip lubrication ......

  • Page 51: Tool Kit

    If you do not have necessary tools re- brication will keep your motorcycle in quired during a service operation, take the safest and most efficient condition your motorcycle to a Yamaha dealer for possible. Safety is an obligation of the service. motorcycle owner. The maintenance...

  • Page 52: Periodic Maintenance And Lubrication

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION CP-01E EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) • Check fuel hoses and vacuum hose for cracks or damage. Fuel line •...
  • Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) • Check bearing for looseness or damage. Wheel bearings • Replace if necessary. •...
  • Page 54 Cooling system • Change coolant every 24,000 km or 24 months (whichever comes first). * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. EAU02970* NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 55: Cowling And Panel Removal And Installation

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Cowling B 1. Bolt ( 3 on each side) 2. Panel D 2. Cowling C EAU03036* Cowling A and B EAU01139* Refer to this section each time a cowl- Cowling and panel removal To remove ing or panel has to be removed or rein- and installation...
  • Page 56 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt ( 13) 1. Bolt ( 5 on each side) 1. Auxiliary light coupler 2. Turn signal connectors 2. Disconnect the auxiliary light cou- To install 2. Place the cowling in the original pler and the turn signal connec- 1.

  • Page 57: Cowling C

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling C 1. Bolt ( 3) 1. Spark plug cap ( 2 on each side) 2. Bolt ( 2) To install EAU03053 3. Right grab bar Spark plugs 1. Place the cowling in the original 4.
  • Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR Do not attempt to diagnose such prob- lems yourself. Instead, take the motor- cycle to a Yamaha dealer. You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode.

  • Page 59: Engine Oil

    PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 12.5 Nm (1.25 m·kg) NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the a.
  • Page 60 An oil filter wrench is available at a NOTE: 2. Remove the cowling stay. nearby Yamaha dealer. Wait a few minutes until the oil level 3. Warm up the engine for several settles before checking. 7. Reinstall the drain bolt and tighten minutes.
  • Page 61 Periodic oil change: Make sure the O-ring is seated proper- mains on, immediately stop the en- 2.6 L gine and consult with a Yamaha With oil filter replacement: 9. Install the oil filter and tighten it to dealer. 2.9 L the specified torque with an oil fil- 12.

  • Page 62: Cooling System

    You may use soft wa- ter if you can’t get distilled water. 1. Maximum level mark NOTE: 2. Minimum level mark If water is added, have a Yamaha EAU03024 dealer check the antifreeze con- Cooling system tent of the coolant as soon as pos- 1.

  • Page 63: Changing The Coolant

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt ( 2) 1. Bolt ( 2) 1. Screw clamp ( 2) 2. Coolant reservoir 2. Right air intake duct 7. Remove the fuel tank bolts, then EAU03025 8. Remove the right air intake duct by lift the fuel tank upward.
  • Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR Recommended anti-freeze: High quality ethylene glycol anti- freeze containing corrosion inhib- itors for aluminum engines. Antifreeze and water mix ratio: Total amount: 1.95 L Coolant reservoir capacity: 1. Radiator cap 1. Water pump drain bolt 2.

  • Page 65: Air Filter

    PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you find any leaks, ask a Yamaha dealer to inspect. 18. Install the right air intake duct, then install and tighten the screw clamps. 19. Install the fuel tank and fuel tank bolts.
  • Page 66 PERIODIC MAINTENANCE AND MINOR REPAIR EC000082 CAUTION: Make sure the air filter is prop- erly seated in the air filter case. The engine should never be run without the air filter installed. Excessive piston and/or cylin- der wear may result. 8.

  • Page 67: Air Vent Hose

    The carburetors are important parts of the engine and require very sophisti- cated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idle speed may be adjusted by the owner 1.

  • Page 68: Idle Speed Adjustment

    There should be a free play of 3 ~ speed and in direction b to de- 7 mm at the throttle grip. If the free play is incorrect, ask a Yamaha dealer to crease engine speed. make this adjustment. Standard idle speed:...

  • Page 69: Valve Clearance Adjustment

    (2.90 kg/cm 2.50 bar) 2.90 bar) should be left to a professional Always check and adjust the tire pres- 250 kPa 290 kPa Yamaha service technician. sure before operating the motorcycle. High speed riding (2.50 kg/cm (2.90 kg/cm EW000082 2.50 bar) 2.90 bar)
  • Page 70 Brakes, tires, and relat- your heaviest items close to the ed wheel parts replacement should 1. Side wall center of the motorcycle, and dis- be left to a Yamaha Service Techni- a. Tread depth tribute the weight evenly from side cian. Tire inspection to side.
  • Page 71 Dunlop 120/60 ZR17 (55 W) D204F mentioned below have been ap- Metzeler 120/60 ZR17 (55 W) MEZ1 ‘Front’ proved by Yamaha Motor Co., Bridgestone 120/60 ZR17 (55 W) BT57F Michelin 120/60 ZR17 (55 W) MACADAM 90X Ltd. for this model. No guaran-...

  • Page 72: Wheels

    If any ab- Never fail to use the specified normal condition exists in a wheel, tires in tire replacement. Other consult a Yamaha dealer. Do not tires may have a danger of attempt even small repairs to the bursting at super high-speeds.

  • Page 73: Clutch Lever Free Play Adjustment

    42 mm below the top of the The clutch lever free play should be ad- footrest. If not, ask a Yamaha dealer to justed to 10 ~ 15 mm. If the free play is adjust it. incorrect, adjust as follows.

  • Page 74: Brake Light Switch Adjustment

    2. Adjusting nut control and an accident. Have a EAU00713 Yamaha dealer inspect and bleed Brake light switch adjustment the system if necessary. The rear brake light switch is activated by the brake pedal and is properly ad- justed when the brake light comes on just before braking takes effect.

  • Page 75: Checking The Front And Rear Brake Pads

    If the indicator is is above the minimum level and replen- ALMOST in contact with the disc plate, ish when necessary. ask a Yamaha dealer to replace the Observe these precautions: pads. When checking the fluid level,...

  • Page 76: Brake Fluid Replacement

    The brake fluid should be replaced only ing. Water will significantly lower by trained Yamaha service personnel. the boiling point of the fluid and Have the Yamaha dealer replace the may result in vapor lock. following components during periodic Brake fluid may deteriorate paint- maintenance or when they are dam- ed surfaces or plastic parts.

  • Page 77: Drive Chain Slack Check

    PERIODIC MAINTENANCE AND MINOR REPAIR EC000096 CAUTION: Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. 3. After adjusting, tighten the lock- nuts. Then tighten the axle nut to the specified torque. a.

  • Page 78: Drive Chain Lubrication

    Yamaha dealer to replace it. Wipe it dry, and thoroughly lubricate it with SAE 30 ~ 50W motor oil. Do not...

  • Page 79: Brake And Shift Pedal Lubrication

    Lubricate the pivoting parts. Lubricate the pivoting parts. Check that the sidestand moves up and down smoothly. Recommended lubricant: Recommended lubricant: Engine oil Engine oil Recommended lubricant: Engine oil EW000113 WARNING If the sidestand does not move smoothly, consult a Yamaha dealer. 6-29...

  • Page 80: Rear Suspension Lubrication

    3. Push down hard on the handle- bars several times and check if the fork rebounds smoothly. EC000098 CAUTION: If any damage or unsmooth move- ment is found with the front fork, consult a Yamaha dealer. 6-30...

  • Page 81: Steering Inspection

    Hold the lower end of the front forks and try to move them forward and backward. If any free play can be felt, ask a Yamaha dealer to inspect and adjust the steer- ing. Inspection is easier if the front wheel is removed.

  • Page 82: Battery

    EC000102 If the battery seems to have dis- CAUTION: ANTIDOTE: charged, consult a Yamaha deal- EXTERNAL: Flush with water. Completely recharge the bat- INTERNAL: Drink large quanti- tery before storing. Storing a If the motorcycle is equipped with ties of water or milk.

  • Page 83: Fuse Replacement

    Headlight fuse: 20 A device operates. If the fuse immediate- Signaling system fuse: 15 A ly blows again, consult a Yamaha deal- Fan fuse: 7.5 A er. It is recommended that the main Ignition fuse: 7.5 A...
  • Page 84 • Do not use headlight bulbs of wattage higher than speci- fied. 4. Install the bulb holder cover and reconnect the headlight connec- tor. If the headlight beam adjust- ment is necessary, ask a Yamaha dealer to make that adjustment. 6-34...

  • Page 85: Tail/Brake Light Bulb Replacement

    WARNING counterclockwise. counterclockwise. It is advisable to have a Yamaha 3. Install a new bulb by pushing it in- 3. Install a new bulb by pushing it in- dealer service the wheel. ward and turning it clockwise.

  • Page 86: Front Wheel Installation

    PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the calipers, caliper bolts and brake hose holders. Make sure there is enough gap between the brake pads before installing the calipers onto the brake discs. 5. Tighten the wheel axle, pinch bolt and caliper bolts to the specified torques.

  • Page 87: Rear Wheel Removal

    EW000122 and then remove the caliper. WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so there is no danger of it falling over.

  • Page 88: Rear Wheel Installation

    PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the left wheel axle guide and wheel axle nut and let the motorcycle down. 6. Tighten the wheel axle nut and caliper bolts to the specified torques. Tightening torque: Brake torque rod bolt: 1.

  • Page 89: Troubleshooting

    If your motorcycle requires any repair, bring it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, experience, and know- how to properly service your motor- cycle.

  • Page 90: Troubleshooting Chart

    Remove spark plugs and check electrodes. Engine doesn’t start, go to battery Dry. Ask a Yamaha dealer to inspect. check. 4. Battery Engine turns over Battery good. quickly. Engine doesn’t start, ask a Yamaha Use the electric starter.

  • Page 91: Engine Overheating

    Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom- mended coolant as soon as possible.

  • Page 92: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE Care ....................7-1 Storage....................7-4...
  • Page 93 M OTORCYCLE CARE AND STORAGE EAU01516 Care Before cleaning Cleaning 1. Cover up the muffler outlet with a After normal use The exposure of its technology makes plastic bag. Remove dirt with warm water, a neutral a motorcycle charming but also vulner- 2.

  • Page 94: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE ECA00010 Do not use any harsh chemical For motorcycles equipped with CAUTION: products on plastic parts. Be a windshield: Do not use strong Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as cleaners, especially on spoked sponges which have been in they...
  • Page 95 MOTORCYCLE CARE AND STORAGE 1. Clean your motorcycle with cold After cleaning EWA00001 WARNING water and soap after the engine 1. Dry the motorcycle with a chamois Make sure that there is no oil or wax has cooled down. or an absorbing cloth. on the brakes and tires.
  • Page 96 NOTE: “OFF” position: Turn the fuel cock To prevent corrosion, avoid Consult a Yamaha dealer for advice on to “OFF”. damp cellars, stables (because what products to use. 4. Fill up the fuel tank and add fuel...
  • Page 97 MOTORCYCLE CARE AND STORAGE a. Remove the spark plug caps and 6. Lubricate all control cables and 9. Remove the battery and fully spark plugs. the pivoting points of all levers and charge it. Store it in a cool, dry b.

  • Page 98: Specifications

    SPECIFICATIONS Specifications ..................8-1 HOW TO USE THE CONVERSION TABLE ........8-5...

  • Page 99: Specifications

    S PECIFICATIONS EAU01038 Specifications Model YZF600R Engine oil Dimensions Type -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C Overall length 2,060 mm (for F, E, I, GR) 2,145 mm SAE 10W/30 (except for F, E, I, GR) SAE 10W/40 Overall width...
  • Page 100 SPECIFICATIONS Cooling system capacity Gear ratio (total amount) 1.95 L 2.846 Air filter Wet type element 1.947 Fuel 1.545 Type Regular unleaded gasoline 1.333 Fuel tank capacity 19 L 1.190 Carburetor 1.074 Type quantity CVKD36 Chassis Manufacturer KEIHIN Frame type Diamond Spark plug Caster angle...
  • Page 101 SPECIFICATIONS Rear Wheels Type Tubeless Front Size 160/60 ZR17 (69 W) Type Cast Manufacturer/model Bridgestone / BT57 Size MT 3.50 Dunlop / D204 Rear Metzeler / MEZ1 Type Cast Michelin / MACADAM 90X Size MT 5.00 Maximum load* 180 kg (except for A, CH, S) Brakes 178 kg (for A, CH, S) Front...
  • Page 102 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) Fan fuse 7.5 A Charging system Ignition fuse 7.5 A Type A.C.

  • Page 103: How To Use The Conversion Table

    SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CS-02E CONVERSION TABLE All specification data in this manual are listed in SI and METRIC TO IMPERIAL METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb...

  • Page 104: Consumer Information

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

  • Page 105: Identification Number Records

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

  • Page 106: Consumer Information

    The model label is affixed to the frame under the seat. (See page 3-14 for seat removal procedures.) Record the infor- mation on this label in the space pro- vided. This information will be needed to order spare parts from your Yamaha dealer.

  • Page 107: Left View

    I NDEX 1 0 - Air filter ..........6-15 Diagnosis device ........3-7 Handlebar switches........3-8 Air intake duct ........6-17 Dimmer switch......... 3-8 Dimmer switch ........3-8 Air vent hose..........6-17 Drive chain lubrication ......6-28 Engine stop switch......3-9 Antitheft alarm (optional) ......3-7 Drive chain slack adjustment ....6-27 Horn switch.........3-8 Drive chain slack check ......

  • Page 108: Right View

    INDEX Main switch/steering lock......3-1 Seat ............3-14 Valve clearance adjustment....6-19 Model label ..........9-2 Shifting............ 5-4 Vehicle identification number ....9-1 Shift pedal ..........3-10 Sidestand..........3-21 Neutral indicator light ....... 3-2 Wheel bearings........6-31 Sidestand/clutch switch operation Wheels ..........
  • Page 109 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 · 8 - 0.3...

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