Yamaha YZFR6V 2006 Service Manual
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Yamaha YZFR6V 2006 Service Manual

Yamaha YZFR6V 2006 Service Manual

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YZFR6V(C)
SERVICE MANUAL
LIT-11616-19-78
2C0-28197-10

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Summary of Contents for Yamaha YZFR6V 2006

  • Page 1 YZFR6V(C) SERVICE MANUAL LIT-11616-19-78 2C0-28197-10...
  • Page 2 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 3: Table Of Contents

    MODEL LABEL ..................1-1 FEATURES ..................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM ....................1-3 YCC-T (Yamaha Chip Controlled Throttle)..........1-4 INSTRUMENT FUNCTIONS..............1-7 IMPORTANT INFORMATION ............... 1-11 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-11 REPLACEMENT PARTS ................ 1-11 GASKETS, OIL SEALS AND O-RINGS ..........

  • Page 4: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.

  • Page 5: Features

    FEATURES EAS20170 FEATURES ET2C01025 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 6: Fi System

    FEATURES ET2C01019 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 7: Ycc-T (Yamaha Chip Controlled Throttle)

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 8 FEATURES YCC-T system outline 1. Throttle position sensor (for throttle cable 18. Atmospheric pressure sensor pulley) 2. Throttle servo motor 3. Throttle position sensor (for throttle valves) 4. ECU (engine control unit) 5. ETV main CPU (32 bit) 6. ETV sub CPU (16 bit) 7.
  • Page 9 FEATURES YCC-T control outline 1. Throttle position sensor (for throttle cable 18. Idle speed control pulley) 19. Calculated throttle valve opening angle 2. Throttle position sensor (for throttle valves) 3. Crankshaft position sensor 4. Speed sensor 5. Coolant temperature sensor 6.

  • Page 10: Instrument Functions

    FEATURES ET2C01020 • To switch the speedometer and odometer/trip- INSTRUMENT FUNCTIONS meter displays between kilometers and miles, press the “SELECT” button for at least one Multi-function meter unit second. EW2C01003 WARNING Be sure to stop the vehicle before making Tachometer any setting changes to the multi-function meter unit.
  • Page 11 FEATURES To set the clock: “SELECT” button, and then push it again for a 1. Push the “SELECT” button and “RESET” but- few seconds until the stopwatch digits stop ton together for at least two seconds. flashing. 2. When the hour digits start flashing, push the “RESET”...
  • Page 12 FEATURES EC2C01021 Display brightness and shift timing indicator CAUTION: light control mode Do not operate the engine if it is overheated. Air intake temperature display 1. Display brightness 2. Shift timing indicator light activation/deactivation 3. Shift timing indicator light 1. Air intake temperature display This mode cycles through five control functions, The air intake temperature display indicates the allowing you to make the following settings in the...
  • Page 13 FEATURES To adjust the brightness of the multi-function To set the shift timing indicator light deactivation meter displays and tachometer: function: 1. Turn the key to “OFF”. NOTE: 2. Push and hold the “SELECT” button. • The shift timing indicator light deactivation 3.

  • Page 14: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 15: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 16: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...

  • Page 17: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 18 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-11 90890-01426 YU-38411 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter H 3-13 90890-03139 Steering nut wrench 3-27, 4-58 90890-01403 Spanner wrench YU-33975 Fork spring compressor 4-47, 4-52 90890-01441 YM-01441 Rod holder...
  • Page 19 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-51, 4-52 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-51, 4-52 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring nut wrench 4-58 90890-01268 Spanner wrench YU-01268...
  • Page 20 Valve guide reamer (4.5 mm) YM-04118 Valve spring compressor 5-24 90890-04109 Sheave holder 5-28, 5-29, 90890-01701 5-31 Primary clutch holder YS-01880-A Flywheel puller 5-28 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-29, 5-31, 90890-85505 5-57 ® (Three Bond No.1215 1-17...
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-41, 5-45 90890-04086 YM-91042 Thickness gauge 5-41 0.15 0.10 0.05 90890-03180 0.20 0.03 0.50 Feeler gauge set 0.25 0.30 YU-26900-9 0.35 0.40 Piston pin puller set 5-60 90890-01304 Piston pin puller YU-01304 YU-01304 Radiator cap tester...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 7-12 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 7-12 90890-03176 YM-03176 Digital circuit tester 7-13 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 8-92 90890-06754 Opama pet-4000 spark checker YM-34487 1-19...
  • Page 23 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................ 2-10 ELECTRICAL SPECIFICATIONS..............2-13 TIGHTENING TORQUES................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-25 ENGINE ....................2-25 CHASSIS ....................

  • Page 24: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2C05/2C08 (USA) 2C06 (California) Dimensions Overall length 2040 mm (80.3 in) Overall width 700 mm (27.6 in) Overall height 1100 mm (43.3 in) Seat height 850 mm (33.5 in) Wheelbase 1380 mm (54.3 in) Ground clearance 130 mm (5.12 in) Minimum turning radius...

  • Page 25: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid-cooled 4-stroke, DOHC Displacement 599 cm³ (36.55 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 67.0 × 42.5 mm (2.64 × 1.67 in) Compression ratio 12.8 :1 Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min) Minimum–maximum...
  • Page 26 ENGINE SPECIFICATIONS Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) Thermostat Valve opening temperature 71 °C (159.8 °F) Valve full open temperature 85 °C (185 °F) Valve lift (full open) More than 8 mm (0.31 in)
  • Page 27 ENGINE SPECIFICATIONS Exhaust B 25.082–25.182 mm (0.9875–0.9914 in) Limit 25.032 mm (0.9855 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links 98XRH2015/118 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.12–0.19 mm (0.0047–0.0075 in) Exhaust 0.16–0.23 mm (0.0063–0.0091 in) Valve dimensions...
  • Page 28 ENGINE SPECIFICATIONS Valve margin thickness D (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 0.8 mm (0.03 in) Valve margin thickness D (exhaust) 1.10–1.30 mm (0.0433–0.0512 in) Limit 1.0 mm (0.04 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.460 mm (0.1756 in) Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in) Limit...
  • Page 29 ENGINE SPECIFICATIONS Spring tilt (intake) 2.5°/1.6 mm Spring tilt (exhaust) 2.5°/1.6 mm Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 67.000–67.010 mm (2.6378–2.6382 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
  • Page 30 ENGINE SPECIFICATIONS 2nd ring Ring type Taper Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.70–0.80 mm (0.0276–0.0315 in) Limit 1.00 mm (0.0394 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Oil ring Dimensions (B ×...
  • Page 31 ENGINE SPECIFICATIONS Plate quantity 8 pcs Warpage limit 0.10 mm (0.0039 in) Clutch spring free length 55.00 mm (2.17 in) Minimum length 54.00 mm (2.13 in) Spring quantity 6 pcs Transmission Transmission type Constant mesh 6-speed Primary reduction system Spur gear Primary reduction ratio 85/41 (2.073) Secondary reduction system...
  • Page 32 ENGINE SPECIFICATIONS Fuel injection sensor 248–372 Ω at 20 °C (68 °F) Crankshaft position sensor resistance Cylinder identification sensor output voltage (ON) Less than 0.8 V Cylinder identification sensor output voltage (OFF) More than 4.8 V Intake air pressure sensor output voltage 3.15–4.15 V Atmospheric pressure sensor output voltage 3.15–4.15 V...

  • Page 33: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.00° Trail 97.0 mm (3.82 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 34 CHASSIS SPECIFICATIONS Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter...
  • Page 35 CHASSIS SPECIFICATIONS Spring free length 163.5 mm (6.44 in) Installed length 152.5 mm (6.00 in) Spring rate K1 98.00 N/mm (559.58 lb/in) (9.99 kgf/mm) Spring stroke K1 0.0–60.0 mm (0.00–2.36 in) Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²) Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in)

  • Page 36: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 10.0°/1300 r/min Engine control unit Model/manufacturer TBDF24/DENSO Ignition coil Model/manufacturer F6T558/MITSUBISHI Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω...
  • Page 37 ELECTRICAL SPECIFICATIONS High beam indicator light Fuel level warning light Coolant temperature warning light Engine trouble warning light Shift timing indicator light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM14/MITSUBA Power output 0.60 kW 0.0012–0.0022 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 10.0 mm (0.39 in)
  • Page 38 ELECTRICAL SPECIFICATIONS Fuel pump relay Model/manufacturer G8R-30Y-V4/OMRON Fan motor relay Model/manufacturer ACM33211M05/MATSUSHITA Fuses Main fuse 50.0 A Headlight fuse 15.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A 15.0 A × 2 Radiator fan fuse Fuel injection system fuse 15.0 A Backup fuse 7.5 A...

  • Page 39: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 40: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap bolt (intake and 10 Nm (1.0 m·kg, 7.2 ft·lb) exhaust) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe assembly) Cylinder head nut (1st) 25 Nm (2.5 m·kg, 18 ft·lb) Cylinder head nut (final) 42 Nm (4.2 m·kg, 30 ft·lb)
  • Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper air filter case to lower air 2 Nm (0.2 m·kg, 1.4 ft·lb) filter case bolt Upper air filter case joint bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Secondary injector fuel rail 5 Nm (0.5 m·kg, 3.6 ft·lb) Locknut (throttle cable) 5 Nm (0.5 m·kg, 3.6 ft·lb)
  • Page 42 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Main gallery plug 8 Nm (0.8 m·kg, 5.8 ft·lb) Ventilation chamber cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pipe 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankshaft position sensor bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 43 TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 2-20...

  • Page 44: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front right 45 Nm (4.5 m·kg, 32 ft·lb) side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 32 ft·lb) side) Engine mounting nut (rear upper 68 Nm (6.8 m·kg, 49 ft·lb) side) Engine mounting nut (rear lower...
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) NOTE Horn and front brake hose joint 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Front brake hose guide bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Lower bracket and front brake 10 Nm (1.0 m·kg, 7.2 ft·lb) hose joint bracket bolt...
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel tank bracket and fuel tank 7 Nm (0.7 m·kg, 5.1 ft·lb) bolt Canister and canister bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) Canister bracket and ventilation 10 Nm (1.0 m·kg, 7.2 ft·lb) chamber cover Radiator bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 47 TIGHTENING TORQUES 4. In the order pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 Nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening. NOTE: Lower ring nut 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then loosen the lower ring nut completely.

  • Page 48: Lubrication Points And Lubricant Types

    Primary driven gear inner surface Clutch pull rod Transmission gears (wheel and pinion) and collars Main axle and drive axle Shift forks and shift fork guide bars Shift shaft Yamaha bond No.1215 Cylinder head cover mating surface (Three Bond ® No.1215...
  • Page 49 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond ® No.1215 Yamaha bond No.1215 Stator coil lead grommet (Three Bond ® No.1215 2-26...

  • Page 50: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Tube guide (throttle grip) inner surface and throttle cables Brake lever pivoting point and metal-to-metal moving parts Clutch cable end Clutch lever pivoting point and metal-to-metal moving parts Relay arm, connecting arm and rear shock absorber spacer Swingarm pivot shaft...
  • Page 51 LUBRICATION POINTS AND LUBRICANT TYPES 2-28...

  • Page 52: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-29...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main gallery 7. Oil nozzle 8. Timing chain tensioner 9. Intake camshaft 10. Exhaust camshaft 11. Oil pipe 12. Main axle 13.

  • Page 54: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-31...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Ventilation chamber cover 2. Relief valve 3. Ventilation chamber oil drain pipe 4. Oil cooler 2-32...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Oil check bolt 5. Oil strainer 6. Ventilation chamber oil drain pipe 7. Oil pipe 8. Oil pump 2-34...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter 3. Oil pipe 4. Oil pump 5. Oil strainer 2-36...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Oil pipe 4. Ventilation chamber oil drain pipe 5. Relief valve 2-38...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 63 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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