Yamaha 1999 YZF-R6 Manuals

Manuals and User Guides for Yamaha 1999 YZF-R6. We have 2 Yamaha 1999 YZF-R6 manuals available for free PDF download: Service Manual

Yamaha 1999 YZF-R6 Service Manual

Yamaha 1999 YZF-R6 Service Manual (425 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9.67 MB

Table of Contents

Gen Info

10
- Important Manual Information
  4
- How to Use this Manual
  5
- Table of Contents
  10
- Chapter 1
  12
- General Information
  12
- Motorcycle Identification
  12
  - Vehicle Identification Number
    12
  - Model Code
    12
- Important Information
  13
  - Preparation for Removal and Disassembly
    13
  - Replacement Parts
    13
  - Gaskets, Oil Seals and O-Rings
    13
  - Using a Dynamometer
    14
  - Lock Washers/Plates and Cotter Pins
    14
  - Bearings and Oil Seals
    14
  - Circlips
    14
- Checking the Connections
  15
- Features
  16
  - Air Intake System
    16
  - Thermostat
    16
  - Ignition System
    17
- Special Tools
  19
2 Spec

25
- Chapter 2. Specifications
  27
- General Specifications
  27
- Engine Specifications
  28
- Chassis Specifications
  37
- Electrical Specifications
  43
- Conversion Table
  44
- Tightening Torques
  44
- Lubrication Points and Lubricant Types
  49
  - Engine Lubrication Points and Lubricant Types
    49
  - Chassis Lubrication Points and Lubricant Types
    50
- Oil Flow Diagrams
  51
- Coolant Flow Diagrams
  55
- Cable Routing
  59
Table of Contents

68
- Chapter 3
  70
- Introduction
  70
- Periodic Checks and Adjustments
  70
- Periodic Maintenance and Lubrication Intervals
  70
- Rider and Passenger Seats
  72
- Fuel Tank
  73
- Cowlings
  75
  - Removal
    76
  - Installation
    76
- Air Filter Case and Ignition Coils
  77
  - Removal
    79
  - Installation
    79
- Engine
  80
  - Adjusting the Valve Clearance
    80
  - Synchronizing the Carburetors
    85
  - Adjusting the Engine Idling Speed
    87
  - Adjusting the Throttle Cable Free Play
    89
  - Checking the Spark Plugs
    91
  - Checking the Ignition Timing
    92
  - Measuring the Compression Pressure
    93
  - Checking the Engine Oil Level
    95
  - Changing the Engine Oil
    96
  - Measuring the Engine Oil Pressure
    98
  - Adjusting the Clutch Cable Free Play
    99
  - Cleaning the Air Filter Element
    100
  - Checking the Carburetor Joints
    101
  - Checking the Fuel Hoses and Fuel Filter
    101
  - Checking the Crankcase Breather Hose
    102
  - Checking the Exhaust System
    102
  - Cleaning the Air Intake System
    102
  - Checking the Coolant Level
    104
  - Checking the Cooling System
    104
  - Changing the Coolant
    105
- Chassis
  108
  - Adjusting the Front Brake
    108
  - Adjusting the Rear Brake
    108
  - Checking the Brake Fluid Level
    110
  - Checking the Brake Pads
    111
  - Adjusting the Rear Brake Light Switch
    111
  - Checking the Brake Hoses
    112
  - Bleeding the Hydraulic Brake System
    112
  - Adjusting the Shift Pedal
    114
  - Adjusting the Drive Chain Slack
    114
  - Lubricating the Drive Chain
    116
  - Checking and Adjusting the Steering Head
    116
  - Checking the Front Fork
    119
  - Adjusting the Front Fork Legs
    120
  - Adjusting the Rear Shock Absorber Assembly
    122
  - Checking the Tires
    124
  - Checking the Wheels
    126
  - Checking and Lubricating the Cables
    127
  - Lubricating the Levers and Pedals
    127
  - Lubricating the Sidestand
    127
  - Lubricating the Rear Suspension
    127
- Electrical System
  128
  - Checking and Charging the Battery
    128
  - Checking the Fuses
    133
  - Replacing the Headlight Bulbs
    135
  - Adjusting the Headlight Beams
    136
Table of Contents

139
- Chapter 4. Overhauling the Engine
  141
- Engine
  141
  - Drive Sprocket
    141
  - Exhaust Assembly
    142
  - Engine
    145
  - Installing the Engine
    146
- Camshafts
  147
  - Cylinder Head Cover
    147
  - Removing the Camshafts
    150
  - Checking the Camshafts
    151
  - Checking the Camshaft Sprockets and Timing Chain Guides
    152
  - Checking the Timing Chain Tensioner
    153
  - Installing the Camshafts
    154
- Cylinder Head
  157
  - Removing the Cylinder Head
    158
  - Checking the Cylinder Head
    158
  - Installing the Cylinder Head
    159
- Valves and Valve Springs
  160
  - Removing the Valves
    162
  - Checking the Valves and Valve Guides
    163
  - Checking the Valve Seats
    165
  - Checking the Valve Springs
    167
  - Checking the Valve Lifters
    168
  - Installing the Valves
    168
- Pickup Coil and Pickup Coil Rotor
  171
  - Removing the Pickup Coil Rotor
    173
  - Installing the Pickup Coil Rotor
    173
- Starter Clutch and Generator
  175
  - Removing the Generator
    177
  - Removing the Starter Clutch
    178
  - Checking the Starter Clutch
    178
  - Installing the Starter Clutch
    179
  - Installing the Generator
    179
- Shift Shaft
  180
  - Checking the Shift Shaft
    182
  - Checking the Stopper Lever
    182
  - Installing the Shift Shaft
    182
- Clutch Clutch Cover
  183
  - Clutch
    186
  - Removing the Clutch
    188
  - Checking the Friction Plates
    188
  - Checking the Clutch Plates
    189
  - Checking the Clutch Springs
    189
  - Checking the Clutch Housing
    189
  - Checking the Clutch Boss
    190
  - Checking the Pressure Plate
    190
  - Checking the Pull Lever Shaft and Pull Rod
    190
  - Installing the Clutch
    191
- Oil Pan and Oil Pump
  193
  - Removing the Oil Pan
    196
  - Checking the Oil Pump
    196
  - Checking the Relief Valve
    197
  - Checking the Oil Delivery Pipe and Oil Pipe
    197
  - Checking the Oil Strainer
    197
  - Checking the Oil Nozzles
    197
  - Assembling the Oil Pump
    198
  - Installing the Oil Pump
    198
  - Installing the Oil Strainer
    198
  - Installing the Oil Pan
    198
- Crankcase
  199
  - Oil Baffle Plates and Oil Filter Bolt
    201
  - Disassembling the Crankcase
    202
  - Checking the Crankcase
    203
  - Checking the Bearings and Oil Seals
    203
  - Checking the Sprockets and Chains
    203
  - Assembling the Crankcase
    204
- Connecting Rods and Pistons
  206
- Crankshaft
  218
  - Removing the Crankshaft
    219
  - Checking the Crankshaft
    219
  - Checking the Crankshaft Journal Bearings
    219
  - Installing the Crankshaft
    222
- Transmission
  223
  - Removing the Transmission
    229
  - Checking the Shift Forks
    229
  - Checking the Shift Drum Assembly
    230
  - Checking the Transmission
    230
  - Installing the Transmission
    231
5 Cool

234
- Chapter 5. Cooling System
  236
- Radiator
  236
  - Checking the Radiator
    238
  - Installing the Radiator
    239
- Oil Cooler
  240
  - Checking the Oil Cooler
    242
  - Installing the Oil Cooler
    242
- Thermostat
  244
  - Checking the Thermostat
    246
  - Installing the Thermostat
    246
- Water Pump
  248
  - Disassembling the Water Pump
    249
  - Assembling the Water Pump
    249
6 Carb

255
- Carburetors
  257
- Chapter 6. Carburetors
  257
- Checking the Carburetors
  263
- Assembling the Carburetors
  265
- Installing the Carburetors
  267
- Measuring and Adjusting the Fuel Level
  268
- Checking and Adjusting the Throttle Position Sensor
  269
- Checking the Fuel Pump
  272
- Checking the Fuel Cock
  273
- Checking the Fuel Cock Operation
  273
7 Chas

276
- Chapter 7. Chassis
  278
- Front Wheel and Brake Discs
  278
  - Removing the Front Wheel
    280
  - Checking the Front Wheel
    280
  - Checking the Brake Discs
    282
  - Installing the Front Wheel
    283
  - Adjusting the Front Wheel Static Balance
    283
- Rear Wheel, Brake Disc, and Rear Wheel Sprocket
  285
  - Rear Wheel
    285
  - Brake Disc and Rear Wheel Sprocket
    286
  - Removing the Rear Wheel
    288
  - Checking the Rear Wheel
    288
  - Checking the Rear Wheel Drive Hub
    289
  - Checking and Replacing the Rear Wheel Sprocket
    289
  - Installing the Rear Wheel
    290
  - Adjusting the Rear Wheel Static Balance
    290
- Front and Rear Brakes
  291
- Front Fork
  319
  - Removing the Front Fork Legs
    319
  - Disassembling the Front Fork Legs
    320
  - Checking the Front Fork Legs
    324
  - Assembling the Front Fork Legs
    325
  - Installing the Front Fork Legs
    330
- Handlebars
  331
  - Removing the Handlebars
    333
  - Checking the Handlebars
    333
  - Installing the Handlebars
    334
- Steering Head
  336
  - Lower Bracket
    336
  - Removing the Lower Bracket
    338
  - Checking the Steering Head
    338
  - Installing the Steering Head
    339
- Rear Shock Absorber Assembly
  341
- Swingarm and Drive Chain
  345
  - Removing the Drive Chain
    347
  - Removing the Swingarm
    347
  - Checking the Drive Chain
    350
  - Installing the Swingarm
    352
  - Installing the Drive Chain
    352
8 Elec

355
- Chapter 8. Electrical
  357
- Electrical Components
  357
- Instrument Functions
  358
  - Indicator Lights
    358
  - Oil Level/Coolant Temperature Warning Light
    358
  - Combination Meter
    359
- Switches
  361
  - Checking Switch Continuity
    361
- Checking the Switches
  362
- Checking the Bulbs and Bulb Sockets
  364
  - Types of Bulbs
    364
  - Checking the Condition of the Bulbs
    364
  - Checking the Condition of the Bulb Sockets
    366
  - CHECKING the Leds
    366
- Ignition System
  367
  - Circuit Diagram
    367
  - Troubleshooting
    368
- Electric Starting System
  372
  - Circuit Diagram
    372
  - Starting Circuit Cutoff System Operation
    373
  - Troubleshooting
    374
- Starter Motor
  378
  - Checking the Starter Motor
    380
  - Assembling the Starter Motor
    381
- Charging System
  382
  - Circuit Diagram
    382
  - Troubleshooting
    383
- Lighting System
  385
  - Circuit Diagram
    385
  - Troubleshooting
    386
  - Checking the Lighting System
    387
- Signaling System
  391
  - Circuit Diagram
    391
  - Troubleshooting
    393
  - Checking the Signaling System
    394
- Cooling System
  401
  - Circuit Diagram
    401
  - Troubleshooting
    402
- Fuel Pump System
  405
  - Circuit Diagram
    405
  - Fuel Pump Circuit Operation
    406
  - Troubleshooting
    407
  - Checking the Fuel Pump
    409
- Self-Diagnosis
  410
  - Troubleshooting
    411
Trbl Shtg

416
- Chapter 9
  418
- Starting Problems
  418
  - Engine
    418
  - Fuel System
    418
  - Electrical Systems
    418
- Troubleshooting
  418
- Faulty Gear Shifting
  419
  - Shifting Is Difficult
    419
  - Shift Pedal Does Not Move
    419
  - Jumps out of Gear
    419
- Incorrect Engine Idling Speed
  419
  - Engine
    419
  - Fuel System
    419
  - Electrical Systems
    419
- Poor Medium-And-High-Speed Performance
  419
- Faulty Clutch
  420
  - Clutch Slips
    420
  - Clutch Drags
    420
- Overcooling Cooling System
  420
- Overheating
  420
  - Engine
    420
  - Cooling System
    420
  - Fuel System
    420
  - Chassis
    420
  - Electrical Systems
    420
- Faulty Front Fork Legs
  421
  - Leaking Oil
    421
  - Malfunction
    421
  - Unstable Handling
    421
- Poor Braking Performance
  421

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YAMAHA 1999 YZF-R6 Service Manual

YAMAHA 1999 YZF-R6 Service Manual (400 pages)

Motorcycle YZF-R6 99 5EB-AE1

Brand: YAMAHA | Category: Motorcycle | Size: 9.43 MB

Table of Contents

Gen Info

7
- Important Manual Information
  3
- How to Use this Manual
  4
- Table of Contents
  7
- Chapter 1
  8
- General Information
  8
- Motorcycle Identification
  8
  - Vehicle Identification Number
    8
  - Model Code
    8
- Important Information
  9
  - Preparation for Removal and Disassembly
    9
  - Replacement Parts
    9
  - Gaskets, Oil Seals and O-Rings
    9
  - Using a Dynamometer
    10
  - Lock Washers/Plates and Cotter Pins
    10
  - Bearings and Oil Seals
    10
  - Circlips
    10
- Checking the Connections
  11
- Features
  12
  - Air Intake System
    12
  - Thermostat
    12
  - Ignition System
    13
- Special Tools
  15
Table of Contents

19
- Chapter 2. Specifications
  20
- General Specifications
  20
- Engine Specifications
  21
- Chassis Specifications
  30
- Electrical Specifications
  36
- Conversion Table
  37
- Tightening Torques
  37
- Lubrication Points and Lubricant Types
  42
  - Engine Lubrication Points and Lubricant Types
    42
  - Chassis Lubrication Points and Lubricant Types
    43
- Oil Flow Diagrams
  44
- Coolant Flow Diagrams
  48
- Cable Routing
  52
Table of Contents

59
- Chapter 3
  61
- Introduction
  61
- Periodic Checks and Adjustments
  61
- Periodic Maintenance and Lubrication Intervals
  61
- Rider and Passenger Seats
  63
- Fuel Tank
  64
- Cowlings
  66
  - Removal
    67
  - Installation
    67
- Air Filter Case and Ignition Coils
  68
  - Removal
    70
  - Installation
    70
- Engine
  71
- Chassis
  99
  - Adjusting the Front Brake
    99
  - Adjusting the Rear Brake
    99
  - Checking the Brake Fluid Level
    101
  - Checking the Brake Pads
    102
  - Adjusting the Rear Brake Light Switch
    102
  - Checking the Brake Hoses
    103
  - Bleeding the Hydraulic Brake System
    103
  - Adjusting the Shift Pedal
    105
  - Adjusting the Drive Chain Slack
    105
  - Lubricating the Drive Chain
    107
  - Checking and Adjusting the Steering Head
    107
  - Checking the Front Fork
    110
  - Adjusting the Front Fork Legs
    111
  - Adjusting the Rear Shock Absorber Assembly
    113
  - Checking the Tires
    115
  - Checking the Wheels
    117
  - Checking and Lubricating the Cables
    118
  - Lubricating the Levers and Pedals
    118
  - Lubricating the Sidestand
    118
  - Lubricating the Rear Suspension
    118
- Electrical System
  119
  - Checking and Charging the Battery
    119
  - Checking the Fuses
    124
  - Replacing the Headlight Bulbs
    126
  - Adjusting the Headlight Beams
    127
Table of Contents

128
- Cylinder Head
  145
- Valves and Valve Springs
  148
- Starter Clutch and Generator
  163
- Shift Shaft
  168
- Clutch
  171
- Checking the Friction Plates
  176
- Removing the Clutch
  176
- Checking the Clutch Housing
  177
- Checking the Clutch Plates
  177
- Checking the Clutch Springs
  177
- Checking the Clutch Boss
  178
- Checking the Pressure Plate
  178
- Checking the Pull Lever Shaft and Pull Rod
  178
- Installing the Clutch
  179
- Oil Pan and Oil Pump
  181
  - Removing the Oil Pan
    184
  - Checking the Oil Pump
    184
  - Checking the Relief Valve
    185
  - Checking the Oil Delivery Pipe and Oil Pipe
    185
  - Checking the Oil Strainer
    185
  - Checking the Oil Nozzles
    185
  - Assembling the Oil Pump
    186
  - Installing the Oil Pump
    186
  - Installing the Oil Strainer
    186
  - Installing the Oil Pan
    186
- Crankcase
  187
  - Oil Baffle Plates and Oil Filter Bolt
    189
  - Disassembling the Crankcase
    190
  - Checking the Crankcase
    191
  - Checking the Bearings and Oil Seals
    191
  - Checking the Sprockets and Chains
    191
  - Assembling the Crankcase
    192
- Connecting Rods and Pistons
  194
- Crankshaft
  206
  - Removing the Crankshaft
    207
  - Checking the Crankshaft
    207
  - Checking the Crankshaft Journal Bearings
    207
  - Installing the Crankshaft
    210
- Transmission
  211
  - Removing the Transmission
    217
  - Checking the Shift Forks
    217
  - Checking the Shift Drum Assembly
    218
  - Checking the Transmission
    218
  - Installing the Transmission
    219
Table of Contents

220
- Chapter 5. Cooling System
  221
- Radiator
  221
  - Checking the Radiator
    223
  - Installing the Radiator
    224
- Oil Cooler
  225
  - Checking the Oil Cooler
    227
  - Installing the Oil Cooler
    227
- Thermostat
  229
  - Checking the Thermostat
    231
  - Installing the Thermostat
    231
- Water Pump
  233
  - Disassembling the Water Pump
    234
  - Assembling the Water Pump
    234
Carburetors

238
- Carburetors
  239
- Chapter 6. Carburetors
  239
- Checking the Carburetors
  245
- Assembling the Carburetors
  247
- Installing the Carburetors
  249
- Measuring and Adjusting the Fuel Level
  250
- Checking and Adjusting the Throttle Position Sensor
  251
- Checking the Fuel Pump
  254
- Checking the Fuel Cock
  255
- Checking the Fuel Cock Operation
  255
Table of Contents

256
- Chapter 7. Chassis
  258
- Front Wheel and Brake Discs
  258
  - Removing the Front Wheel
    260
  - Checking the Front Wheel
    260
  - Checking the Brake Discs
    262
  - Installing the Front Wheel
    263
  - Adjusting the Front Wheel Static Balance
    263
- Rear Wheel, Brake Disc, and Rear Wheel Sprocket
  265
  - Rear Wheel
    265
  - Brake Disc and Rear Wheel Sprocket
    266
  - Removing the Rear Wheel
    268
  - Checking the Rear Wheel
    268
  - Checking the Rear Wheel Drive Hub
    269
  - Checking and Replacing the Rear Wheel Sprocket
    269
  - Installing the Rear Wheel
    270
  - Adjusting the Rear Wheel Static Balance
    270
- Front and Rear Brakes
  271
- Front Fork
  299
  - Removing the Front Fork Legs
    299
  - Disassembling the Front Fork Legs
    300
  - Checking the Front Fork Legs
    304
  - Assembling the Front Fork Legs
    305
  - Installing the Front Fork Legs
    310
- Handlebars
  311
  - Removing the Handlebars
    313
  - Checking the Handlebars
    313
  - Installing the Handlebars
    314
- Steering Head
  316
  - Lower Bracket
    316
  - Removing the Lower Bracket
    318
  - Checking the Steering Head
    318
  - Installing the Steering Head
    319
- Rear Shock Absorber Assembly
  321
- Swingarm and Drive Chain
  325
  - Removing the Drive Chain
    327
  - Removing the Swingarm
    327
  - Checking the Drive Chain
    330
  - Installing the Swingarm
    332
  - Installing the Drive Chain
    332
Table of Contents

333
- Chapter 8. Electrical
  335
- Electrical Components
  335
- Instrument Functions
  336
  - Indicator Lights
    336
  - Oil Level/Coolant Temperature Warning Light
    336
  - Combination Meter
    337
- Switches
  339
  - Checking Switch Continuity
    339
- Checking the Switches
  340
- Checking the Bulbs and Bulb Sockets
  342
  - Types of Bulbs
    342
  - Checking the Condition of the Bulbs
    342
  - Checking the Condition of the Bulb Sockets
    344
  - CHECKING the Leds
    344
- Ignition System
  345
  - Circuit Diagram
    345
  - Troubleshooting
    346
- Electric Starting System
  350
  - Circuit Diagram
    350
  - Starting Circuit Cutoff System Operation
    351
  - Troubleshooting
    352
- Starter Motor
  356
  - Checking the Starter Motor
    358
  - Assembling the Starter Motor
    359
- Charging System
  360
  - Circuit Diagram
    360
  - Troubleshooting
    361
- Lighting System
  363
  - Circuit Diagram
    363
  - Troubleshooting
    364
  - Checking the Lighting System
    365
- Signaling System
  369
  - Circuit Diagram
    369
  - Troubleshooting
    371
  - Checking the Signaling System
    372
- Cooling System
  379
  - Circuit Diagram
    379
  - Troubleshooting
    380
- Fuel Pump System
  383
  - Circuit Diagram
    383
  - Fuel Pump Circuit Operation
    384
  - Troubleshooting
    385
  - Checking the Fuel Pump
    387
- Self-Diagnosis
  388
Trbl Shtg

392
- Chapter 9. Troubleshooting
  394
- Starting Problems
  394
  - Engine
    394
  - Fuel System
    394
  - Electrical Systems
    394
- Faulty Gear Shifting
  395
  - Shifting Is Difficult
    395
  - Shift Pedal Does Not Move
    395
  - Jumps out of Gear
    395
- Incorrect Engine Idling Speed
  395
  - Engine
    395
  - Fuel System
    395
  - Electrical Systems
    395
- Poor Medium-And-High-Speed Performance
  395
- Faulty Clutch
  396
  - Clutch Slips
    396
  - Clutch Drags
    396
- Overcooling Cooling System
  396
- Overheating
  396
  - Engine
    396
  - Cooling System
    396
  - Fuel System
    396
  - Chassis
    396
  - Electrical Systems
    396
- Faulty Front Fork Legs
  397
  - Leaking Oil
    397
  - Malfunction
    397
  - Unstable Handling
    397
- Poor Braking Performance
  397

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