1994-2007 Yamaha YZF600, YZF600R Thundercat manual

Product Information

Table of Contents

1. General Information

• Model Identification
• Serial Number Location
• Specifications
• Torque Specifications
• Special Tools
• Maintenance and Tune-Up Overview

2. Daily or (Pre-Ride) Checks

• Engine/Transmission Oil Level Check
• Coolant Level Check
• Brake Fluid Level Checks
• Tyre Checks
• Suspension, Steering, and Final Drive Checks
• Legal and Safety Checks

3. Maintenance and Adjustments

• Periodic Maintenance Chart
• Engine Oil and Filter Change
• Air Filter Cleaning/Replacement
• Spark Plug Inspection/Replacement
• Valve Clearance Adjustment
• Throttle Cable Adjustment
• Clutch Adjustment
• Brake Adjustment
• Suspension Adjustment
• Drive Chain Maintenance

4. Engine Overhaul

• Engine Removal and Installation
• Cylinder Head Removal and Installation
• Piston and Cylinder Inspection
• Crankshaft and Connecting Rods
• Camshaft and Timing Chain
• Engine Reassembly

5. Fuel System

• Carburetor Removal and Installation
• Carburetor Disassembly and Cleaning
• Carburetor Reassembly
• Fuel Pump Inspection
• Fuel Tank and Lines

6. Cooling System

• Radiator and Hoses
• Water Pump Removal and Installation
• Thermostat Inspection and Replacement
• Coolant Replacement

7. Electrical System

• Battery Maintenance
• Charging System
• Ignition System
• Lighting System
• Switches and Controls
• Wiring Diagrams

8. Chassis

• Frame Inspection and Repair
• Swingarm and Linkage
• Front Forks Removal and Installation
• Rear Shock Absorber Removal and Installation

9. Brake System

• Front Brake System
• Rear Brake System
• Brake Disc Inspection
• Brake Pad Replacement
• Brake Fluid Replacement
• Brake Line Inspection and Replacement

10. Suspension and Steering

• Front Suspension Overhaul
• Rear Suspension Overhaul
• Steering Head Bearing Inspection and Adjustment

11. Wheels and Tyres

• Wheel Removal and Installation
• Tyre Inspection and Replacement
• Wheel Bearing Inspection and Replacement

12. Body and Exhaust System

• Fairing and Body Panels Removal and Installation
• Seat and Helmet Holder
• Exhaust System Inspection and Replacement

Appendix

• Troubleshooting Guide
• Maintenance Records
• Index

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