Yamaha R6 2008 Sport Motorcycle Manuals

Yamaha R6 2008 Sport Motorcycle Manuals

Manuals and User Guides for Yamaha R6 2008 Sport Motorcycle. We have 2 Yamaha R6 2008 Sport Motorcycle manuals available for free PDF download: Service Manual

Yamaha R6 2008 Service Manual

Yamaha R6 2008 Service Manual (434 pages)

Yamaha Motorcycle

Brand: Yamaha | Category: Motorcycle | Size: 23 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
    13
    
    Instrument Functions
    17
  - Important Information
    21
    
    Preparation for Removal and Disassembly
    21
    
    Replacement Parts
    21
    
    Gaskets, Oil Seals and O-Rings
    21
    
    Lock Washers/Plates and Cotter Pins
    21
    
    Bearings and Oil Seals
    22
    
    Circlips
    22
  - Checking the Connections
    23
  - Special Tools
    24
Specifications

31
- General Specifications
  32
- Engine Specifications
  33
- Chassis Specifications
  40
- Electrical Specifications
  43
- Tightening Torques
  46
- Lubrication Points and Lubricant Types
  55
  - Engine
    55
  - Chassis
    56
- Lubrication System Chart and Diagrams
  58
  - Engine Oil Lubrication Chart
    58
  - Lubrication Diagrams
    60
- Cooling System Diagrams
  72
- Cable Routing
  76
Periodic Checks and Adjustments

93
- Periodic Maintenance
  
  96
- Engine
  
  99
  - Adjusting the Valve Clearance
    99
  - Synchronizing the Throttle Bodies
    102
  - Adjusting the Throttle Cable Free Play
    103
  - Checking the Spark Plugs
    104
  - Measuring the Compression Pressure
    104
  - Checking the Engine Oil Level
    106
  - Changing the Engine Oil
    106
  - Measuring the Engine Oil Pressure
    108
  - Adjusting the Clutch Lever Free Play
    109
  - Replacing the Air Filter Element
    109
  - Checking the Throttle Body Joints
    110
  - Checking the Fuel Line
    111
  - Checking the Crankcase Breather Hose
    111
  - Checking the Exhaust System
    111
  - Adjusting the Exup Cables
    112
  - Checking the Coolant Level
    113
  - Checking the Cooling System
    114
  - Changing the Coolant
    114
- Chassis
  
  117
  - Adjusting the Front Disc Brake
    117
    
    Adjusting the Rear Disc Brake
    117
    
    Checking the Brake Fluid Level
    118
    
    Checking the Front Brake Pads
    118
    
    Checking the Rear Brake Pads
    118
    
    Checking the Front Brake Hoses
    119
    
    Checking the Rear Brake Hoses
    119
    
    Adjusting the Rear Brake Light Switch
    119
    
    Bleeding the Hydraulic Brake System
    120
    
    Adjusting the Shift Pedal
    121
    
    Adjusting the Drive Chain Slack
    121
    
    Lubricating the Drive Chain
    122
    
    Checking and Adjusting the Steering Head
    122
    
    Checking the Front Fork
    124
    
    Adjusting the Front Fork Legs
    124
    
    Adjusting the Rear Shock Absorber Assembly
    126
    
    Checking the Tires
    128
    
    Checking the Wheels
    130
    
    Checking and Lubricating the Cables
    130
    
    Lubricating the Levers
    130
    
    Lubricating the Pedals
    130
    
    Lubricating the Sidestand
    130
    
    Electrical System
    131
Chassis

133
- General Chassis
  
  137
- Front Wheel
  
  143
  - Removing the Front Wheel
    143
  - Disassembling the Front Wheel
    143
  - Checking the Front Wheel
    143
  - Assembling the Front Wheel
    144
  - Adjusting the Front Wheel Static Balance
    144
  - Checking the Front Brake Discs
    145
  - Installing the Front Wheel (Front Brake Discs)
    145
- Rear Wheel
  
  147
  - Removing the Rear Wheel
    150
  - Disassembling the Rear Wheel
    150
  - Checking the Rear Wheel
    150
  - Checking the Rear Brake Caliper Bracket
    150
  - Checking the Rear Wheel Drive Hub
    150
  - Checking and Replacing the Rear Wheel Sprocket
    150
  - Assembling the Rear Wheel
    151
  - Adjusting the Rear Wheel Static Balance
    151
  - Checking the Rear Brake Disc
    151
  - Installing the Rear Wheel (Rear Brake Disc)
    151
- Front Brake
  
  153
  - Introduction
    158
    
    Checking the Front Brake Discs
    158
    
    Replacing the Front Brake Pads
    159
    
    Removing the Front Brake Calipers
    160
    
    Disassembling the Front Brake Calipers
    160
    
    Checking the Front Brake Calipers
    161
    
    Assembling the Front Brake Calipers
    161
    
    Installing the Front Brake Calipers
    161
    
    Removing the Front Brake Master Cylinder
    162
    
    Checking the Front Brake Master Cylinder
    163
    
    Assembling the Front Brake Master Cylinder
    163
    
    Installing the Front Brake Master Cylinder
    163
- Rear Brake
  
  165
  - Introduction
    170
  - Checking the Rear Brake Disc
    170
  - Replacing the Rear Brake Pads
    170
  - Removing the Rear Brake Caliper
    171
  - Disassembling the Rear Brake Caliper
    171
  - Checking the Rear Brake Caliper
    172
  - Assembling the Rear Brake Caliper
    172
  - Installing the Rear Brake Caliper
    173
  - Removing the Rear Brake Master Cylinder
    174
  - Checking the Rear Brake Master Cylinder
    174
  - Assembling the Rear Brake Master Cylinder
    174
  - Installing the Rear Brake Master Cylinder
    174
- Handlebars
  
  176
  - Removing the Handlebars
    178
  - Checking the Handlebars
    178
  - Installing the Handlebars
    178
- Front Fork
  
  180
  - Removing the Front Fork Legs
    182
  - Disassembling the Front Fork Legs
    182
  - Checking the Front Fork Legs
    183
  - Assembling the Front Fork Legs
    184
  - Installing the Front Fork Legs
    188
- Steering Head
  
  190
  - Removing the Lower Bracket
    192
  - Checking the Steering Head
    192
  - Installing the Steering Head
    192
- Rear Shock Absorber Assembly
  
  194
- Swingarm
  
  198
  - Removing the Swingarm
    200
  - Checking the Swingarm
    200
  - Installing the Swingarm
    201
- Chain Drive
  
  203
  - Removing the Drive Chain
    204
  - Checking the Drive Chain
    204
  - Checking the Drive Sprocket
    205
  - Checking the Rear Wheel Sprocket
    205
  - Checking the Rear Wheel Drive Hub
    205
  - Installing the Drive Chain
    205
Engine

207
- Engine Removal
  
  210
  - Installing the Engine
    215
- Camshafts
  
  216
- Cylinder Head
  
  224
  - Removing the Cylinder Head
    225
  - Checking the Cylinder Head
    225
  - Installing the Cylinder Head
    225
- Valves and Valve Springs
  
  228
  - Removing the Valves
    228
  - Checking the Valves and Valve Guides
    228
  - Checking the Valve Seats
    230
  - Checking the Valve Springs
    232
  - Checking the Valve Lifters
    233
  - Installing the Valves
    233
  - Generator and Starter Clutch
    235
- Generator and Starter Clutch
  
  236
  - Removing the Generator
    236
  - Checking the Starter Clutch
    236
  - Installing the Starter Clutch
    236
  - Installing the Generator
    237
- Pickup Rotor
  
  238
  - Removing the Pickup Rotor
    239
  - Installing the Pickup Rotor
    239
- Electric Starter
  
  241
  - Checking the Starter Motor
    243
  - Assembling the Starter Motor
    244
- Clutch
  
  245
  - Removing the Clutch
    249
  - Checking the Friction Plates
    249
  - Checking the Clutch Plates
    249
  - Checking the Clutch Springs
    250
  - Checking the Clutch Housing
    251
  - Checking the Clutch Boss
    251
  - Checking the Pressure Plate
    251
  - Checking the Primary Drive Gear
    251
  - Checking the Primary Driven Gear
    251
  - Checking the Pull Lever Shaft and Pull Rod
    252
  - Checking the Oil Pump Drive Sprocket and Oil Pump Drive Chain
    252
  - Installing the Clutch
    252
- Shift Shaft
  
  255
  - Checking the Shift Shaft
    256
  - Checking the Stopper Lever
    256
  - Installing the Shift Shaft
    256
- Oil Pump
  
  257
  - Removing the Oil Pan
    260
  - Checking the Oil Pump
    260
  - Checking the Relief Valve
    260
  - Checking the Oil Pipes
    261
  - Checking the Oil Strainer
    261
  - Assembling the Oil Pump
    261
  - Installing the Oil Pan
    261
- Crankcase
  
  262
  - Disassembling the Crankcase
    264
  - Checking the Crankcase
    264
  - Checking the Oil Pipe
    264
  - Checking the Timing Chain
    264
  - Assembling the Crankcase
    264
- Connecting Rods and Pistons
  
  267
- Crankshaft
  
  274
- Transmission
  
  278
  - Removing the Transmission
    282
  - Checking the Shift Forks
    282
  - Checking the Shift Drum Assembly
    282
  - Checking the Transmission
    283
  - Assembling the Main Axle and Drive Axle
    283
  - Installing the Transmission
    284
Cooling System

287
- Radiator
  
  289
  - Checking the Radiator
    289
    
    Installing the Radiator
    289
- Oil Cooler
  
  291
  - Checking the Oil Cooler
    292
  - Installing the Oil Cooler
    292
- Thermostat
  
  293
  - Checking the Thermostat
    294
  - Installing the Thermostat
    294
- Water Pump
  
  295
  - Disassembling the Water Pump
    297
  - Checking the Water Pump
    297
  - Assembling the Water Pump
    298
  - Installing the Water Pump
    299
Fuel System

301
- Fuel Tank
  302
- Fuel Tank
  
  303
  - Checking the Fuel Pump Body
    303
  - Checking the Fuel Pump Operation
    303
  - Installing the Fuel Pump
    303
  - Removing the Fuel Pump
    303
  - Removing the Fuel Tank
    303
  - Installing the Fuel Tank
    304
- Air Filter Case
  
  306
- Throttle Bodies
  
  311
- Air Induction System
  
  316
  - Checking the Air Induction System
    320
Electrical System

321
- Ignition System
  
  324
  - Circuit Diagram
    324
  - Engine Stopping Due to Sidestand Operation
    326
  - Troubleshooting
    328
- Electric Starting System
  
  330
  - Circuit Diagram
    330
  - Starting Circuit Cut-Off System Operation
    332
  - Troubleshooting
    334
- Charging System
  
  336
  - Circuit Diagram
    336
  - Troubleshooting
    338
- Lighting System
  
  340
  - Circuit Diagram
    340
  - Troubleshooting
    342
- Signaling System
  
  344
  - Circuit Diagram
    344
  - Troubleshooting
    346
- Cooling System
  
  352
  - Circuit Diagram
    352
  - Troubleshooting
    354
- Fuel Injection System
  
  356
  - Circuit Diagram
    356
  - Ecu Self-Diagnostic Function
    358
  - Self-Diagnostic Function Table
    359
  - Troubleshooting Method
    362
  - Diagnostic Mode
    363
  - Troubleshooting Details
    372
- Fuel Pump System
  
  396
  - Circuit Diagram
    396
  - Troubleshooting
    398
- Electrical Components
  
  400
  - Checking the Switches
    404
  - Checking the Bulbs and Bulb Sockets
    407
  - Checking the Fuses
    408
  - Checking and Charging the Battery
    409
  - Checking the Relays
    412
  - Checking the Turn Signal/Hazard Relay
    413
  - Checking the Relay Unit (Diode)
    414
  - Checking the Ignition Coils
    415
  - Checking the Crankshaft Position Sensor
    416
  - Checking the Lean Angle Sensor
    416
  - Checking the Starter Motor Operation
    416
  - Checking the Stator Coil
    417
  - Checking the Rectifier/Regulator
    417
  - Checking the Horn
    418
  - Checking the Oil Level Switch
    418
  - Checking the Fuel Sender
    419
  - Checking the Speed Sensor
    419
  - Checking the Radiator Fan Motors
    420
  - Checking the Coolant Temperature Sensor
    420
  - Checking the Throttle Position Sensor
    420
  - Checking the Throttle Position Sensor
    421
  - Checking the Fuel Pump
    421
  - Checking the Air Induction System Solenoid
    422
  - Checking the Atmospheric Pressure Sensor
    422
  - Checking the Cylinder Identification Sensor
    423
  - Checking the Intake Air Pressure Sensor
    423
  - Checking the Air Temperature Sensor
    424
Troubleshooting

425
- General Information
  426
- Incorrect Engine Idling Speed
  426
- Starting Failures
  426
- Troubleshooting
  426
- Faulty Clutch
  427
- Faulty Gear Shifting
  427
- Jumps out of Gear
  427
- Overheating
  427
- Poor Medium-And-High-Speed Performance
  427
- Shift Pedal Does Not Move
  427
- Faulty Front Fork Legs
  428
- Overcooling
  428
- Poor Braking Performance
  428
- Unstable Handling
  428
- Faulty Lighting or Signaling System
  429
  - Wiring Diagram
    430

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Yamaha R6 2008 Service Manual

Yamaha R6 2008 Service Manual (22 pages)

Brand: Yamaha | Category: Motorcycle | Size: 2 MB

Table of Contents

Table of Contents
6
Identification
7
Vehicle Identification Number
7
Model Label
7
Features
8
Outline of the Fi System
8
Fi System
9
YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
10
Instrument Functions
14
Important Information
18
Preparation for Removal and Disassembly
18
Replacement Parts
18
Gaskets, Oil Seals and O-Rings
18
Lock Washers/Plates and Cotter Pins
18
Bearings and Oil Seals
20
Circlips
20
Checking the Connections
21
Special Tools
22

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