Yamaha YZF-R6R Service Manual
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Also See for YZF-R6R:
- Owner's manual (140 pages) ,
- Supplementary service manual (538 pages)
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Summary of Contents for Yamaha YZF-R6R
- Page 2 EAS00010 YZF-R6R/YZF-R6SR YZF-R6RC/YZF-R6SRC SERVICE MANUAL 2002 by Yamaha Motor Corporation, U.S.A. First edition, December 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-16-45...
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Page 3: Important Manual Information
If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. -
Page 4: How To Use This Manual
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. - Page 5 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...
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Page 6: Table Of Contents
EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG... -
Page 7: General Information
CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......VEHICLE IDENTIFICATION NUMBER ......MODEL LABEL . -
Page 8: Periodic Checks And Adjustments
ENGINE OIL LUBRICATION CHART ......2-30 LUBRICATION DIAGRAMS ........2-31 CABLE ROUTING . -
Page 9: Chassis
CHASSIS ........... . 3-39 ADJUSTING THE FRONT BRAKE . - Page 10 FRONT AND REAR BRAKES ........4-16 FRONT BRAKE PADS .
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Page 11: Engine
REAR SHOCK ABSORBER ASSEMBLY ......4-68 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER ..........4-70 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER... - Page 12 VALVES AND VALVE SPRINGS ....... . 5-21 REMOVING THE VALVES .
- Page 13 OIL PAN AND OIL PUMP ........5-54 REMOVING THE OIL PAN .
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Page 14: Cooling System
CHAPTER 6 COOLING SYSTEM RADIATOR ........... CHECKING THE RADIATOR . - Page 15 CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ........CHECKING SWITCH CONTINUITY .
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Page 16: Troubleshooting
FUEL PUMP SYSTEM ......... 8-46 CIRCUIT DIAGRAM . - Page 17 UNSTABLE HANDLING ........FAULTY LIGHTING OR SIGNALING SYSTEM .
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Page 18: Gen Info
MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. - Page 19 FEATURES INFO EAS00896 FEATURES OUTLINE OF 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 chamber.
- Page 20 FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 284 kPa (2.84 kg/cm ) higher than the intake manifold pressure.
- Page 21 FEATURES INFO INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: S a speedometer (which shows the riding speed) S an odometer (which shows the total distance traveled) S two tripmeters (which show the distance traveled since they were last set to zero) S a fuel reserve tripmeter (which shows the 1 Multi-function display distance traveled since the fuel level warning...
- Page 22 FEATURES INFO Display brightness and shift timing indica- tor light control mode This mode cycles through five control functions, allowing you to make the following settings in the order listed below. 1. Display brightness: This function allows you to adjust the brightness of the multi-function display to suit the outside lighting conditions.
- Page 23 FEATURES INFO To set the shift timing indicator light activation function NOTE: S The indicator light activation function can be set between 10,000 and 16,000 r/min. S From 10,000 r/min to 12,000 r/min, the indicatar light can be set in increments of 500 r/min. S From 12,000 r/min to 16,000 r/min, the indicatar light can be set in increments of 200 r/min.
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Page 24: Important Information
5. Keep all parts away from any source of fire. EAS00021 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 25 IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the...
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Page 26: Checking The Connections
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times. -
Page 27: Special Tools
SPECIAL TOOLS INFO EAS00027 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 28 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Rod puller Rod puller 90890-01437 Rod puller attachment YM-01437 Rod puller These tools are used to pull up the front fork attachment damper rod.
- Page 29 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Piston ring compressor 90890-04044 YM-04044 This tool is used to compress piston rings when installing the cylinder. Carburetor angle driver 90890-03158 This tool is used to turn the pilot screw when adjusting the engine idling speed. Valve spring Valve spring compressor compressor...
- Page 30 Tool No. Tool name/Function Illustration Vacuum/pressure pump gauge set 90890-06756 YB-35956 This tool used to measure the vacuum pres- sure. Yamaha bond No. 1215 90890-85505 ACC-11001- 05-01 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1-13...