Yamaha R6 2009 Manuals

Manuals and User Guides for Yamaha R6 2009. We have 1 Yamaha R6 2009 manual available for free PDF download: Service Manual

Yamaha R6 2009 Service Manual

Yamaha R6 2009 Service Manual (434 pages)

Brand: Yamaha | Category: Motorcycle | Size: 24.53 MB

Table of Contents

Table of Contents

7
- 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
- Gaskets, Oil Seals and O-Rings
  21
- Lock Washers/Plates and Cotter Pins
  21
- Preparation for Removal and Disassembly
  21
- Replacement Parts
  21
- Important Information
  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
- General Tightening Torque Specifications
  46
- Tightening Torques
  46
- Engine Tightening Torques
  47
- Chassis Tightening Torques
  51
- Engine
  55
- Lubrication Points and Lubricant Types
  55
- Chassis
  57
- Engine Oil Lubrication Chart
  58
- Lubrication System Chart and Diagrams
  58
- Lubrication Diagrams
  60
- Cooling System Diagrams
  72
- Cable Routing
  76
Periodic Checks and Adjustments

93
- General Maintenance and Lubrication Chart
  96
- Introduction
  96
- Periodic Maintenance
  96
- Periodic Maintenance Chart for the Emission Control System
  96
- Adjusting the Valve Clearance
  99
- Engine
  99
- Synchronizing the Throttle Bodies
  102
- Adjusting the Throttle Cable Free Play
  103
- Checking the Spark Plugs
  104
- Measuring the Compression Pressure
  105
- Checking the Engine Oil Level
  106
- Changing the Engine Oil
  107
- Measuring the Engine Oil Pressure
  108
- Adjusting the Clutch Lever Free Play
  109
- Replacing the Air Filter Element
  110
- Checking the Crankcase Breather Hose
  111
- Checking the Fuel Line
  111
- Checking the Throttle Body Joints
  111
- Adjusting the Exup Cables
  112
- Checking the Exhaust System
  112
- Checking the Coolant Level
  114
- Checking the Cooling System
  114
- Changing the Coolant
  115
- Adjusting the Front Disc Brake
  117
- Adjusting the Rear Disc Brake
  117
- Chassis
  117
- Checking the Brake Fluid Level
  118
- Checking the Front Brake Pads
  118
- Checking the Rear Brake Pads
  118
- Adjusting the Rear Brake Light Switch
  119
- Checking the Front Brake Hoses
  119
- Checking the Rear Brake Hoses
  119
- Bleeding the Hydraulic Brake System
  120
- Adjusting the Drive Chain Slack
  121
- Adjusting the Shift Pedal
  121
- Checking and Adjusting the Steering Head
  122
- Lubricating the Drive Chain
  122
- Adjusting the Front Fork Legs
  124
- Checking the Front Fork
  124
- Adjusting the Rear Shock Absorber Assembly
  126
- Checking the Tires
  128
- Checking and Lubricating the Cables
  130
- Checking the Wheels
  130
- Lubricating the Levers
  130
- Lubricating the Pedals
  130
- Lubricating the Sidestand
  130
Chassis

133
- General Chassis
  137
- Checking the Front Wheel
  143
- Disassembling the Front Wheel
  143
- Front Wheel
  143
- Removing the Front Wheel
  143
- Adjusting the Front Wheel Static Balance
  144
- Assembling the Front Wheel
  144
- Checking the Front Brake Discs
  145
- Installing the Front Wheel (Front Brake Discs)
  145
- Rear Wheel
  147
- Checking and Replacing the Rear Wheel Sprocket
  150
- Checking the Rear Brake Caliper Bracket
  150
- Checking the Rear Wheel
  150
- Checking the Rear Wheel Drive Hub
  150
- Disassembling the Rear Wheel
  150
- Removing the Rear Wheel
  150
- Adjusting the Rear Wheel Static Balance
  151
- Assembling the Rear Wheel
  151
- Checking the Rear Brake Disc
  151
- Installing the Rear Wheel (Rear Brake Disc)
  151
- Front Brake
  153
- Checking the Front Brake Discs
  158
- Introduction
  158
- Replacing the Front Brake Pads
  159
- Disassembling the Front Brake Calipers
  160
- Removing the Front Brake Calipers
  160
- Assembling the Front Brake Calipers
  161
- Checking the Front Brake Calipers
  161
- Installing the Front Brake Calipers
  161
- Removing the Front Brake Master Cylinder
  162
- Assembling the Front Brake Master Cylinder
  163
- Checking the Front Brake Master Cylinder
  163
- Installing the Front Brake Master Cylinder
  163
- Rear Brake
  165
- Checking the Rear Brake Disc
  170
- Introduction
  170
- Replacing the Rear Brake Pads
  170
- Removing the Rear Brake Caliper
  171
- Checking the Rear Brake Caliper
  172
- Disassembling the Rear Brake Caliper
  172
- Assembling the Rear Brake Caliper
  173
- Installing the Rear Brake Caliper
  173
- Assembling the Rear Brake Master Cylinder
  174
- Checking the Rear Brake Master Cylinder
  174
- Installing the Rear Brake Master Cylinder
  174
- Removing the Rear Brake Master Cylinder
  174
- Handlebars
  176
- Checking the Handlebars
  178
- Installing the Handlebars
  178
- Removing the Handlebars
  178
- Front Fork
  180
- Disassembling the Front Fork Legs
  182
- Removing 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
- Checking the Steering Head
  192
- Installing the Steering Head
  192
- Removing the Lower Bracket
  192
- Rear Shock Absorber Assembly
  194
- Disposing of a Rear Shock Absorber
  195
- Handling the Rear Shock Absorber
  195
- Removing the Rear Shock Absorber Assembly
  195
- Checking the Connecting Arm and Relay Arm
  196
- Checking the Rear Shock Absorber Assembly
  196
- Installing the Rear Shock Absorber Assembly
  196
- Installing the Relay Arm
  196
- Swingarm
  198
- Checking the Swingarm
  200
- Removing the Swingarm
  200
- Installing the Swingarm
  201
- Chain Drive
  203
- Checking the Drive Chain
  204
- Removing the Drive Chain
  204
- Checking the Drive Sprocket
  205
- Checking the Rear Wheel Drive Hub
  205
- Checking the Rear Wheel Sprocket
  205
- Installing the Drive Chain
  205
Engine

207
- Engine Removal
  210
- Installing the Engine
  215
- Camshafts
  216
- Checking the Camshafts
  218
- Removing the Camshafts
  218
- Checking the Timing Chain Tensioner
  220
- Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
  220
- Installing the Camshafts
  221
- Cylinder Head
  224
- Checking the Cylinder Head
  225
- Installing the Cylinder Head
  225
- Removing the Cylinder Head
  225
- Checking the Valves and Valve Guides
  228
- Removing the Valves
  228
- Valves and Valve Springs
  228
- Checking the Valve Seats
  230
- Checking the Valve Springs
  232
- Checking the Valve Lifters
  233
- Installing the Valves
  233
- Checking the Starter Clutch
  236
- Generator and Starter Clutch
  236
- Installing the Starter Clutch
  236
- Removing the Generator
  236
- Installing the Generator
  237
- Pickup Rotor
  238
- Installing the Pickup Rotor
  239
- Removing the Pickup Rotor
  239
- Electric Starter
  241
- Checking the Starter Motor
  243
- Assembling the Starter Motor
  244
- Clutch
  245
- Checking the Clutch Plates
  249
- Checking the Friction Plates
  249
- Removing the Clutch
  249
- Checking the Clutch Boss
  251
- Checking the Clutch Housing
  251
- Checking the Clutch Springs
  251
- Checking the Pressure Plate
  251
- Checking the Primary Drive Gear
  251
- Checking the Primary Driven Gear
  251
- Checking the Oil Pump Drive Sprocket and Oil Pump Drive Chain
  252
- Checking the Pull Lever Shaft and Pull Rod
  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
- Checking the Oil Pump
  260
- Checking the Relief Valve
  260
- Removing the Oil Pan
  260
- Assembling the Oil Pump
  261
- Checking the Oil Pipes
  261
- Checking the Oil Strainer
  261
- Installing the Oil Pan
  261
- Crankcase
  262
- Assembling the Crankcase
  264
- Checking the Crankcase
  264
- Checking the Oil Pipe
  264
- Checking the Timing Chain
  264
- Disassembling the Crankcase
  264
- Checking the Cylinders and Pistons
  267
- Connecting Rods and Pistons
  267
- Removing the Connecting Rods and Pistons
  267
- Checking the Piston Rings
  268
- Checking the Piston Pins
  269
- Checking the Connecting Rods
  270
- Installing the Connecting Rods and Pistons
  271
- Crankshaft
  274
- Checking the Crankshaft and Connecting Rods
  275
- Checking the Oil Nozzles
  275
- Removing the Crankshaft Journal Bearings
  275
- Installing the Crankshaft
  277
- Transmission
  278
- Checking the Shift Drum Assembly
  282
- Checking the Shift Forks
  282
- Removing the Transmission
  282
- Assembling the Main Axle and Drive Axle
  283
- Checking the Transmission
  283
- Installing the Transmission
  284
Cooling System

287
- 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
- Checking the Water Pump
  297
- Disassembling the Water Pump
  297
- Assembling the Water Pump
  298
- Installing the Water Pump
  299
Fuel System

301
Electrical System

321
- Circuit Diagram
  324
- Ignition System
  324
- Engine Stopping Due to Sidestand Operation
  326
- Troubleshooting
  328
- Circuit Diagram
  330
- Electric Starting System
  330
- Starting Circuit Cut-Off System Operation
  332
- Troubleshooting
  334
- Charging System
  336
- Circuit Diagram
  336
- Troubleshooting
  338
- Circuit Diagram
  340
- Lighting System
  340
- Troubleshooting
  342
- Circuit Diagram
  344
- Signaling System
  344
- Troubleshooting
  346
- Circuit Diagram
  352
- Cooling System
  352
- Troubleshooting
  354
- Circuit Diagram
  356
- Fuel Injection System
  356
- Ecu Self-Diagnostic Function
  358
- Self-Diagnostic Function Table
  359
- Troubleshooting Method
  362
- Diagnostic Mode
  363
- Troubleshooting Details
  372
- Circuit Diagram
  396
- Fuel Pump System
  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 Rectifier/Regulator
  417
- Checking the Stator Coil
  417
- Checking the Horn
  418
- Checking the Oil Level Switch
  418
- Checking the Fuel Sender
  419
- Checking the Speed Sensor
  419
- (For Throttle Valves)
  420
- Checking the Coolant Temperature Sensor
  420
- Checking the Radiator Fan Motors
  420
- Checking the Throttle Position Sensor
  420
- Checking the Fuel Pump
  421
- Checking the Throttle Position Sensor
  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

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