Yamaha Thundercat YZF600R Owner's Manual Page 1

PRINTED IN JAPAN2002.04-1.2×1 CR(E)PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.5AH-28199-16LIT-11626-16-10YZF600RRYZF600RRCOWNER’S MANUAL

SAFETY INFORMATION11-24. Many accidents involve inexperienced operators. In fact, many operators who have been involved inaccidents do not even have a

MOTORCYCLE CARE AND STORAGE7Care ... 7-1Storage ...

7-17EAU034267-MOTORCYCLE CARE AND STORAGECare While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it mor

MOTORCYCLE CARE AND STORAGE7-27●Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been inconta

MOTORCYCLE CARE AND STORAGE7-37After cleaning1. Dry the motorcycle with a chamoisor an absorbing cloth.2. Immediately dry the drive chainand lubricate

MOTORCYCLE CARE AND STORAGE7-47Storage Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a por

MOTORCYCLE CARE AND STORAGE7-576. Lubricate all control cables andthe pivoting points of all levers andpedals as well as of the sidestand/centerstand.

SPECIFICATIONS8Specifications ... 8-1U5AH16.book Page 1 Wednesday,

8-18EAU010388-SPECIFICATIONSSpecifications CS-01EModel YZF600R/YZF600RCDimensionsOverall length 2,060 mm (81.1 in)Overall width 725 mm (28.5 in)Overal

SPECIFICATIONS8-28Cooling system capacity (total amount)1.95 L (1.72 lmp qt, 2.06 US qt)Air filter Wet elementFuelType UNLEADED GASOLINE ONLYFuel tank

SPECIFICATIONS8-38RearType Tubeless tireSize 160/60 ZR17 (69W)160/60 ZR17 M/C (69W)Manufacturer/model Bridgestone / BT57RDunlop / D204GMetzeler / MEZ1

SAFETY INFORMATION11-3Protective apparelThe majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safetyhelme

SPECIFICATIONS8-48Wheel travelFront 130 mm (5.1 in)Rear 120 mm (4.7 in)Electrical systemIgnition system T.C.I. (digital)Charging systemType A.C. magne

CONSUMER INFORMATION9Identification numbers ... 9-1Key identification number ...

9-19EAU010399-CONSUMER INFORMATIONEAU02944Identification numbers Record the key identification number,vehicle identification number and mod-el label i

CONSUMER INFORMATION9-29EAU01050Model label The model label is affixed to the frameunder the seat. (See page 3-9 for seatremoval and installation proc

CONSUMER INFORMATION9-39EAU01051Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury

CONSUMER INFORMATION9-49EAU01053Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or

CONSUMER INFORMATION9-59EAU01874Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be

CONSUMER INFORMATION9-6928,000 mi(43,000 km) or42 months32,000 mi(49,000 km) or48 months36,000 mi(55,000 km) or54 months40,000 mi(61,000 km) or60 mont

CONSUMER INFORMATION9-79EAU02918YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5AH16.book Page 7 Wednesday, May 8,

CONSUMER INFORMATION9-89U5AH16.book Page 8 Wednesday, May 8, 2002 9:16 AM

SAFETY INFORMATION11-4LoadingThe total weight of the operator, passenger, accessories and cargo must not exceed the maximumload limit of YZF600R 182 k

CONSUMER INFORMATION9-99EAU01063YAMAHA EXTENDED SERVICE (Y.E.S.) U5AH16.book Page 9 Wednesday, May 8, 2002 9:16 AM

CONSUMER INFORMATION9-109U5AH16.book Page 10 Wednesday, May 8, 2002 9:16 AM

10-INDEXAAccessories and replacement parts ...6-26Air filter element, cleaning...6-19Air intake duct ...

INDEXShift pedal ... 3-6Shock absorber assembly, adjusting ... 3-13Sidestand ...

PRINTED IN JAPAN2002.04-1.2×1 CR(E)PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.5AH-28199-16LIT-11626-16-10YZF600RRYZF600RRCOWNER’S MANUAL

SAFETY INFORMATION11-5a. Accessories fitted to the handlebar or the front fork area can create instability due to improperweight distribution or aerod

SAFETY INFORMATION11-6a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe-destrians or children are not li

SAFETY INFORMATION11-7EAU02977Location of important labels Please read the following important labels carefully before operating this motorcycle. U5AH

SAFETY INFORMATION11-81234567CAUTIONCleaning with alkaline oracid cleaner, gasoline orsolvent will damagewindshield.Use neutral detergent.5J

DESCRIPTION2Left view ... 2-1Right view...

2-12EAU000262-DESCRIPTION Left view1. Air intake duct (page 6-21)2. Fuel tank (page 3-7)3. Shock absorber assembly spring preload adjusting ring (page

DESCRIPTION2-22Right view11. Luggage strap holders (page 3-17)12. Rear brake fluid level check window (page 6-30)13. Coolant reservoir (page 6-17)14.

EAU03438

DESCRIPTION2-32Controls and instruments1. Clutch lever (page 3-6)2. Left handlebar switches (page 3-5)3. Starter (choke) lever (page 3-9)4. Speedomete

3INSTRUMENT AND CONTROL FUNCTIONSMain switch/steering lock ...3-1Indicator and warning lights ...

3-13EAU000273-INSTRUMENT AND CONTROL FUNCTIONSEAU00029Main switch/steering lock The main switch/steering lock controlsthe ignition and lighting system

INSTRUMENT AND CONTROL FUNCTIONS3-23EAU03034Indicator and warning lights EAU00061Neutral indicator light “” This indicator light comes on when thetra

INSTRUMENT AND CONTROL FUNCTIONS3-33EAU00095Speedometer unit The speedometer unit is equipped witha speedometer, an odometer and atripmeter. The speed

INSTRUMENT AND CONTROL FUNCTIONS3-43If the tachometer displays such an er-ror code, note the circuit-specific num-ber of r/min, and then have a Yamaha

INSTRUMENT AND CONTROL FUNCTIONS3-53EAU00118Handlebar switches EAU03888Dimmer switch “ / ” Set this switch to “” for the highbeam and to “” for the lo

INSTRUMENT AND CONTROL FUNCTIONS3-63EAU00152Clutch lever The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever

INSTRUMENT AND CONTROL FUNCTIONS3-73EAU00162Brake pedal The brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, press down on t

INSTRUMENT AND CONTROL FUNCTIONS3-83EAU03753Fuel Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tub

EAU00002INTRODUCTIONCongratulations on your purchase of the Yamaha YZF600R/YZF600RC. This modelis the result of Yamaha’s vast experience in the produc

INSTRUMENT AND CONTROL FUNCTIONS3-93EAU02973Starter (choke) lever “” Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe

INSTRUMENT AND CONTROL FUNCTIONS3-103To install the seat1. Insert the projections on the frontof the seat into the seat holder asshown.2. Push the rea

INSTRUMENT AND CONTROL FUNCTIONS3-113EAU04101Storage compartment The storage compartment is locatedunder the seat. (See page 3-9 for seatremoval and i

INSTRUMENT AND CONTROL FUNCTIONS3-123Spring preloadTo increase the spring preload andthereby harden the suspension, turnthe adjusting bolt on each for

INSTRUMENT AND CONTROL FUNCTIONS3-133Compression damping forceTo increase the compression dampingforce and thereby harden the compres-sion damping, tu

INSTRUMENT AND CONTROL FUNCTIONS3-143Spring preloadTo increase the spring preload andthereby harden the suspension, turnthe adjusting ring in directio

INSTRUMENT AND CONTROL FUNCTIONS3-153Compression damping forceTo harden the compression damping,decrease the setting by turning the ad-justing screw.

INSTRUMENT AND CONTROL FUNCTIONS3-163EAU01580Matching the front and rear suspension settings Use this table as a guide to match the suspension and dam

INSTRUMENT AND CONTROL FUNCTIONS3-173EAU04276Luggage strap holders There are four luggage strap holders,two of which can be turned out for eas-ier acc

INSTRUMENT AND CONTROL FUNCTIONS3-183EAU03720Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidestand switch, cl

EAU00003IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following notations:The Safety Alert Sym

INSTRUMENT AND CONTROL FUNCTIONS3-193CD-01EWith the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to “”

PRE-OPERATION CHECKS4Pre-operation check list ... 4-1U5AH16.book Page 1 Wednesday,

4-14EAU011144-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unex

PRE-OPERATION CHECKS4-24Throttle grip• Make sure that operation is smooth.• Check cable free play.• If necessary, have Yamaha dealer adjust cable free

PRE-OPERATION CHECKS4-34NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a verys

OPERATION AND IMPORTANT RIDING POINTS5Starting and warming up a cold engine ... 5-1Starting a warm engine .

5-15EAU003725-OPERATION AND IMPORTANT RIDING POINTSEAU00373WARNING@ ●Become thoroughly familiarwith all operating controls andtheir functions before r

OPERATION AND IMPORTANT RIDING POINTS5-25EC000035CAUTION:@ If the fuel level warning light comeson, check the fuel level, and, if nec-essary, refuel a

OPERATION AND IMPORTANT RIDING POINTS5-356. When the engine is warm, turn thestarter (choke) off.NOTE:@ The engine is warm when it respondsnormally to

OPERATION AND IMPORTANT RIDING POINTS5-45EC000048CAUTION:@ ●Even with the transmission inthe neutral position, do notcoast for long periods of timewit

IMPORTANT MANUAL INFORMATIONEW000000WARNING@ PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDINGTIPS” BOOKLET CAREFULLY AND COMPLETELY BE

OPERATION AND IMPORTANT RIDING POINTS5-55EAU02989Recommended shift points The recommended shift points duringacceleration and deceleration areshown in

OPERATION AND IMPORTANT RIDING POINTS5-651,600 km (1,000 mi) and beyondThe vehicle can now be operated nor-mally.EC000053CAUTION:_ ●Keep the engine sp

6PERIODIC MAINTENANCE AND MINOR REPAIRPeriodic maintenance ...6-1Owner’s tool kit ...

6-16EAU004626-PERIODIC MAINTENANCE AND MINOR REPAIR EAU01790Safety is an obligation of the owner.Periodic inspection, adjustment and lu-brication will

PERIODIC MAINTENANCE AND MINOR REPAIR6-26NOTE:_ If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform

PERIODIC MAINTENANCE AND MINOR REPAIR6-36EAU00471Periodic maintenance chart for the emission control system * Since these items require special tools,

PERIODIC MAINTENANCE AND MINOR REPAIR6-46EAU00472General maintenance and lubrication chart No. ITEM ROUTINEINITIAL ODOMETER READINGS600 mi(1,000 km)or

PERIODIC MAINTENANCE AND MINOR REPAIR6-56* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the servic

PERIODIC MAINTENANCE AND MINOR REPAIR6-66EAU03234NOTE:_ ●The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

PERIODIC MAINTENANCE AND MINOR REPAIR6-76EAU01065Removing and installing cowlings The cowlings shown above need to beremoved to perform some of the ma

IMPORTANT MANUAL INFORMATIONAFFIX DEALERLABEL HEREEAU04247YZF600RR/YZF600RRCOWNER’S MANUAL©2002 by Yamaha Motor Corporation, U.S.A.1st edition, March

PERIODIC MAINTENANCE AND MINOR REPAIR6-862. Disconnect the turn signal connec-tors (and, for the left-side cowling,also the auxiliary light coupler),a

PERIODIC MAINTENANCE AND MINOR REPAIR6-96EAU03595Cowling BTo remove the cowling1. Remove the seat. (See page 3-9for seat removal and installationproce

PERIODIC MAINTENANCE AND MINOR REPAIR6-106EAU03329Checking the spark plugs The spark plugs are important enginecomponents, which are easy to check.Sin

PERIODIC MAINTENANCE AND MINOR REPAIR6-1163. Check each spark plug for elec-trode erosion and excessive car-bon or other deposits, and replaceit if ne

PERIODIC MAINTENANCE AND MINOR REPAIR6-126EAU01796Canister (for California only) This model is equipped with a canisterto prevent the discharging of f

PERIODIC MAINTENANCE AND MINOR REPAIR6-136EAU04627Engine oil and oil filter cartridge The engine oil level should be checkedbefore each ride. In addit

PERIODIC MAINTENANCE AND MINOR REPAIR6-1464. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.NOTE:_ Skip steps 5–7 i

PERIODIC MAINTENANCE AND MINOR REPAIR6-1568. Install the engine oil drain bolt, andthen tighten it to the specifiedtorque.9. Add the specified amount

PERIODIC MAINTENANCE AND MINOR REPAIR6-166EAU03987Coolant The coolant level should be checkedbefore each ride. In addition, the cool-ant must be chang

PERIODIC MAINTENANCE AND MINOR REPAIR6-176EW000067WARNING_ Never attempt to remove the radia-tor cap when the engine is hot. _NOTE:_ ●The radiator fan

TABLE OF CONTENTS1 SAFETY INFORMATION12 DESCRIPTION23 INSTRUMENT AND CONTROL FUNCTIONS34 PRE-OPERATION CHECKS45 OPERATION AND IMPORTANT RIDING POINTS5

PERIODIC MAINTENANCE AND MINOR REPAIR6-1868. Remove the right air intake duct byloosening the clamp screws.9. Remove the radiator cap.EW000067WARNING_

PERIODIC MAINTENANCE AND MINOR REPAIR6-19616. Pour the specified amount of rec-ommended coolant into the radia-tor and reservoir.ECA00041CAUTION:_ Har

PERIODIC MAINTENANCE AND MINOR REPAIR6-206EW000071WARNING_ ●Make sure that the fuel tank iswell supported.●Do not tilt or pull the fuel tanktoo much,

PERIODIC MAINTENANCE AND MINOR REPAIR6-216EC000082*CAUTION:_ ●Make sure that the air filter ele-ment is properly seated in theair filter case.●The eng

PERIODIC MAINTENANCE AND MINOR REPAIR6-226EAU00628Adjusting the carburetors The carburetors are important parts ofthe engine and emission control sys-

PERIODIC MAINTENANCE AND MINOR REPAIR6-236EAU03581Tires To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the fol

PERIODIC MAINTENANCE AND MINOR REPAIR6-246Tire inspectionAlways check the tires before operatingthe motorcycle. If a tire tread showscrosswise lines (

PERIODIC MAINTENANCE AND MINOR REPAIR6-256EW000080WARNING@ ●The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingchar

PERIODIC MAINTENANCE AND MINOR REPAIR6-266EAU03773Cast wheels To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note t

PERIODIC MAINTENANCE AND MINOR REPAIR6-276EAU00692Adjusting the clutch lever free play The clutch lever free play should mea-sure 10–15 mm (0.4–0.6 in

SAFETY INFORMATION1Safe riding ... 1-1Protective apparel ...

PERIODIC MAINTENANCE AND MINOR REPAIR6-286EW000109WARNING@ A soft or spongy feeling in the brakepedal can indicate the presence ofair in the hydraulic

PERIODIC MAINTENANCE AND MINOR REPAIR6-296EAU00715Checking the front and rear brake pads The front and rear brake pads must bechecked for wear at the

PERIODIC MAINTENANCE AND MINOR REPAIR6-306Observe these precautions:●When checking the fluid level,make sure that the top of the brakefluid reservoir

PERIODIC MAINTENANCE AND MINOR REPAIR6-316EAU00744Drive chain slack The drive chain slack should bechecked before each ride and adjustedif necessary.T

PERIODIC MAINTENANCE AND MINOR REPAIR6-326NOTE:_ Using the alignment marks on eachside of the swingarm, make sure thatboth adjusting nuts are in the s

PERIODIC MAINTENANCE AND MINOR REPAIR6-336EAU03297Checking and lubricating the cables The operation of all control cables andthe condition of the cabl

PERIODIC MAINTENANCE AND MINOR REPAIR6-346EAU03164Checking and lubricating the brake and clutch levers The operation of the brake and clutchlevers sho

PERIODIC MAINTENANCE AND MINOR REPAIR6-356EAU02939Checking the front fork The condition and operation of the frontfork must be checked as follows at t

PERIODIC MAINTENANCE AND MINOR REPAIR6-3662. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can

PERIODIC MAINTENANCE AND MINOR REPAIR6-376EAU00800Battery This motorcycle is equipped with asealed-type (MF) battery, which doesnot require any mainte

11-11-SAFETY INFORMATION EAU00014MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION AREDEPENDENT UPON THE USE OF PROPER RIDING TECHNI

PERIODIC MAINTENANCE AND MINOR REPAIR6-386EC000102CAUTION:@ ●Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery da

PERIODIC MAINTENANCE AND MINOR REPAIR6-3963. Turn the key to “ON” and turn onthe electrical circuit in question tocheck if the device operates.4. If t

PERIODIC MAINTENANCE AND MINOR REPAIR6-406EW000119WARNING_ Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight

PERIODIC MAINTENANCE AND MINOR REPAIR6-416EAU03497Replacing a turn signal light bulb 1. Remove the turn signal light lensby removing the screw.2. Remo

PERIODIC MAINTENANCE AND MINOR REPAIR6-426EAU03582Front wheel To remove the front wheel EW000122WARNING@ ●It is advisable to have a Yamahadealer servi

PERIODIC MAINTENANCE AND MINOR REPAIR6-436EAU04196To install the front wheel 1. Install the speedometer gear unitinto the wheel hub so that the pro-je

PERIODIC MAINTENANCE AND MINOR REPAIR6-4461. Loosen the wheel axle nut, thebrake torque rod nut at the brakecaliper bracket, and the brake cal-iper bo

PERIODIC MAINTENANCE AND MINOR REPAIR6-456EAU04283To install the rear wheel 1. Install the wheel, right wheel axleguide, and caliper bracket by in-ser

PERIODIC MAINTENANCE AND MINOR REPAIR6-466EAU02990Troubleshooting charts Starting problems or poor engine performanceEW000125WARNING@ Keep away open f

PERIODIC MAINTENANCE AND MINOR REPAIR6-476Engine overheatingEW000070WARNING@ ●Do not remove the radiator cap when the engine and radiator are hot. Sca