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R6 2014 Series
Yamaha R6 2014 Series Manuals
Manuals and User Guides for Yamaha R6 2014 Series. We have
1
Yamaha R6 2014 Series manual available for free PDF download: Service Manual
Yamaha R6 2014 Series Service Manual (430 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 19 MB
Table of Contents
Important Manual Information
3
How to Use this Manual
4
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
YCC-T (Yamaha Chip Controlled Throttle)/Ycc-I (Yamaha Chip Controlled Intake)
11
Instrument Functions
15
Important Information
19
Preparation for Removal and Disassembly
19
Replacement Parts
19
Gaskets, Oil Seals and O-Rings
19
Lock Washers/Plates and Cotter Pins
19
Bearings and Oil Seals
20
Circlips
20
Rubber Parts
20
Basic Service Information
21
Quick Fasteners
21
Electrical System
22
Special Tools
27
Specifications
33
General Specifications
34
Engine Specifications
35
Chassis Specifications
40
Electrical Specifications
43
Tightening Torques
45
General Tightening Torque Specifications
45
Engine Tightening Torques
46
Chassis Tightening Torques
50
Lubrication Points and Lubricant Types
54
Engine
54
Chassis
55
Lubrication System Chart and Diagrams
56
Engine Oil Lubrication Chart
56
Lubrication Diagrams
58
Cooling System Diagrams
70
Cable Routing
74
Periodic Checks and Adjustments
93
Periodic Maintenance
96
Introduction
96
Periodic Maintenance Chart for the Emission Control System
96
General Maintenance and Lubrication Chart
96
Checking the Fuel Line
99
Checking the Spark Plugs
99
Adjusting the Valve Clearance
100
Checking the Crankcase Breather Hose
103
Synchronizing the Throttle Bodies
103
Checking the Exhaust System
104
CHECKING the CANISTER (for California Only)
105
Checking the Air Induction System
105
Replacing the Air Filter Element
105
Adjusting the Clutch Lever Free Play
106
Checking the Brake Operation
107
Checking the Brake Fluid Level
107
Adjusting the Front Disc Brake
108
Checking the Front Brake Pads
108
Adjusting the Rear Disc Brake
108
Checking the Rear Brake Pads
109
Checking the Front Brake Hoses
109
Checking the Rear Brake Hoses
109
Bleeding the Hydraulic Brake System
110
Checking the Wheels
111
Checking the Tires
111
Checking the Wheel Bearings
113
Checking the Swingarm Operation
113
Lubricating the Swingarm Pivot
113
Adjusting the Drive Chain Slack
113
Lubricating the Drive Chain
114
Checking and Adjusting the Steering Head
114
Lubricating the Steering Head
115
Checking the Chassis Fasteners
115
Lubricating the Levers
115
Lubricating the Pedals
115
Checking the Sidestand
115
Lubricating the Sidestand
115
Checking the Sidestand Switch
115
Checking the Front Fork
115
Adjusting the Front Fork Legs
116
Checking the Rear Shock Absorber Assembly
118
Adjusting the Rear Shock Absorber Assembly
118
Checking the Connecting Arm and Relay Arm
120
Checking the Engine Oil Level
120
Changing the Engine Oil
120
Measuring the Engine Oil Pressure
122
Checking the Coolant Level
123
Checking the Cooling System
123
Changing the Coolant
124
Checking the Brake Light Switches
125
Adjusting the Rear Brake Light Switch
125
Checking and Lubricating the Cables
126
Adjusting the Throttle Cable Free Play
126
Checking the Switches, Lights and Signals
126
Checking and Charging the Battery
127
Checking the Fuses
127
Replacing the Headlight Bulbs
127
Adjusting the Headlight Beams
127
Chassis
129
General Chassis
132
Front Wheel
137
Removing the Front Wheel
139
Disassembling the Front Wheel
139
Checking the Front Wheel
139
Assembling the Front Wheel
140
Adjusting the Front Wheel Static Balance
140
Checking the Front Brake Discs
141
Installing the Front Wheel (Front Brake Discs)
141
Rear Wheel
143
Removing the Rear Wheel
146
Disassembling the Rear Wheel
146
Checking the Rear Wheel
146
Checking the Rear Brake Caliper Bracket
146
Checking the Rear Wheel Drive Hub
146
Checking and Replacing the Rear Wheel Sprocket
146
Assembling the Rear Wheel
147
Adjusting the Rear Wheel Static Balance
147
Checking the Rear Brake Disc
147
Installing the Rear Wheel (Rear Brake Disc)
147
Front Brake
149
Introduction
154
Checking the Front Brake Discs
154
Replacing the Front Brake Pads
155
Removing the Front Brake Calipers
156
Disassembling the Front Brake Calipers
156
Checking the Front Brake Calipers
156
Assembling the Front Brake Calipers
157
Installing the Front Brake Calipers
157
Removing the Front Brake Master Cylinder
158
Checking the Front Brake Master Cylinder
158
Assembling the Front Brake Master Cylinder
158
Installing the Front Brake Master Cylinder
159
Rear Brake
161
Introduction
166
Checking the Rear Brake Disc
166
Replacing the Rear Brake Pads
166
Removing the Rear Brake Caliper
167
Disassembling the Rear Brake Caliper
167
Checking the Rear Brake Caliper
168
Assembling the Rear Brake Caliper
168
Installing the Rear Brake Caliper
169
Removing the Rear Brake Master Cylinder
170
Checking the Rear Brake Master Cylinder
170
Assembling the Rear Brake Master Cylinder
170
Installing the Rear Brake Master Cylinder
170
Handlebars
172
Removing the Handlebars
174
Checking the Handlebars
174
Installing the Handlebars
174
Front Fork
176
Removing the Front Fork Legs
178
Disassembling the Front Fork Legs
178
Checking the Front Fork Legs
179
Assembling the Front Fork Legs
180
Installing the Front Fork Legs
184
Steering Head
185
Removing the Lower Bracket
187
Checking the Steering Head
187
Installing the Steering Head
187
Rear Shock Absorber Assembly
189
Handling the Rear Shock Absorber
190
Disposing of a Rear Shock Absorber
190
Removing the Rear Shock Absorber Assembly
190
Checking the Rear Shock Absorber Assembly
190
Checking the Connecting Arm and Relay Arm
191
Installing the Relay Arm
191
Installing the Rear Shock Absorber Assembly
191
Swingarm
193
Removing the Swingarm
195
Checking the Swingarm
195
Installing the Swingarm
196
Chain Drive
198
Removing the Drive Chain
199
Checking the Drive Chain
199
Engine
203
Engine Inspection
206
Measure the Compression Pressure
206
Engine Removal
208
Installing the Engine
213
Adjusting the Shift Pedal
213
Adjusting the Exup Cables
214
Camshafts
216
Removing the Camshafts
218
Checking the Camshafts
218
Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
219
Checking the Timing Chain Tensioner
220
Installing the Camshafts
221
Cylinder Head
224
Removing the Cylinder Head
225
Checking the Cylinder Head
225
Installing the Cylinder Head
225
Valves and Valve Springs
227
Removing the Valves
228
Checking the Valves and Valve Guides
228
Checking the Valve Seats
230
Checking the Valve Springs
231
Checking the Valve Lifters
232
Installing the Valves
232
Generator and Starter Clutch
234
Removing the Generator
235
Checking the Starter Clutch
235
Installing the Starter Clutch
235
Installing the Generator
236
Pickup Rotor
237
Removing the Pickup Rotor
238
Installing the Pickup Rotor
238
Electric Starter
240
Checking the Starter Motor
242
Assembling the Starter Motor
243
Clutch
244
Removing the Clutch
248
Checking the Friction Plates
248
Checking the Clutch Plates
248
Checking the Clutch Springs
249
Checking the Clutch Housing
250
Checking the Clutch Boss
250
Checking the Pressure Plate
250
Checking the Primary Drive Gear
250
Checking the Primary Driven Gear
250
Checking the Pull Lever Shaft and Pull Rod
251
Checking the Oil Pump Drive Sprocket and Oil Pump Drive Chain
251
Installing the Clutch
251
Shift Shaft
254
Checking the Shift Shaft
255
Checking the Stopper Lever
255
Installing the Shift Shaft
255
Oil Pump
256
Removing the Oil Pan
259
Checking the Oil Pump
259
Checking the Relief Valve
259
Checking the Oil Pipes
259
Checking the Oil Strainer
259
Assembling the Oil Pump
259
Installing the Oil Pan
260
Crankcase
261
Disassembling the Crankcase
263
Checking the Crankcase
263
Checking the Oil Pipe
263
Checking the Timing Chain
263
Assembling the Crankcase
263
Connecting Rods and Pistons
265
Removing the Connecting Rods and Pistons
266
Checking the Cylinders and Pistons
266
Checking the Piston Rings
267
Checking the Piston Pins
268
Checking the Connecting Rods
269
Installing the Connecting Rods and Pistons
270
Crankshaft
273
Removing the Crankshaft Journal Bearings
274
Checking the Oil Nozzles
274
Checking the Crankshaft and Connecting Rods
274
Installing the Crankshaft
276
Transmission
282
Removing the Transmission
282
Checking the Shift Forks
282
Checking the Shift Drum Assembly
283
Checking the Transmission
283
Assembling the Main Axle and Drive Axle
283
Installing the Transmission
284
Cooling System
287
Radiator
288
Checking the Radiator
290
Installing the Radiator
290
Oil Cooler
292
Checking the Oil Cooler
293
Installing the Oil Cooler
293
Thermostat
294
Checking the Thermostat
295
Installing the Thermostat
295
Water Pump
296
Disassembling the Water Pump
298
Checking the Water Pump
298
Assembling the Water Pump
298
Installing the Water Pump
299
Fuel System
301
Fuel Tank
303
Removing the Fuel Tank
303
Removing the Fuel Pump
303
Checking the Fuel Pump Body
303
Checking the Fuel Pump Operation
303
Installing the Fuel Pump
303
Installing the Fuel Tank
304
Air Filter Case
305
Removing the Fuel Hose (Primary Injector Fuel Rail Side and Secondary Injector Fuel Rail Side)
307
Removing the Air Filter Case
307
Checking the Secondary Injectors
307
Removing the Intake Funnel
307
Checking the Intake Funnel
307
Installing the Intake Funnel
308
Checking the Intake Funnel Operation
308
Installing the Air Filter Case
308
Installing the Fuel Hose (Primary Injector Fuel Rail Side and Secondary Injector Fuel Rail Side)
308
Throttle Bodies
310
Checking the Throttle Body Joints
313
Checking the Primary Injectors
313
Checking the Throttle Bodies
313
CHECKING the ROLLOVER VALVE (for California Only)
313
Checking the Fuel Pressure
313
Adjusting the Throttle Position Sensor (for Throttle Valves)
314
Adjusting the Throttle Position Sensor (for Throttle Cable Pulley)
314
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
327
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
350
Circuit Diagram
350
Troubleshooting
352
Fuel Injection System
354
Circuit Diagram
354
Ecu Self-Diagnostic Function
356
Troubleshooting Method
357
Diagnostic Mode
358
Troubleshooting Details
359
Fuel Pump System
390
Electrical Components
394
Checking the Switches
398
Checking the Relays
404
Checking the Turn Signal Relay
406
Checking the Relay Unit (Diode)
406
Checking the Ignition Coils
407
Checking the Crankshaft Position Sensor
408
Checking the Lean Angle Sensor
408
Checking the Stator Coil
409
Checking the Starter Motor Operation
409
Checking the Rectifier/Regulator
410
Checking the Oil Level Switch
410
Checking the Fuel Sender
411
Checking the Coolant Temperature Sensor
411
Checking the Radiator Fan Motors
411
Checking the Fuel Pump
412
Checking the Air Induction System Solenoid
412
Checking the Cylinder Identification Sensor
413
Checking the Intake Air Temperature Sensor
413
Troubleshooting
415
Troubleshooting
416
General Information
416
Starting Failures
416
Incorrect Engine Idling Speed
416
Poor Medium-And-High-Speed Performance
417
Faulty Gear Shifting
417
Shift Pedal Does Not Move
417
Jumps out of Gear
417
Faulty Clutch
417
Overheating
417
Overcooling
418
Poor Braking Performance
418
Faulty Front Fork Legs
418
Unstable Handling
418
Faulty Lighting or Signaling System
419
Self-Diagnostic Function and Diagnostic Code Table
420
Self-Diagnostic Function Table
420
Communication Error with the Meter
421
Diagnostic Code: Sensor Operation Table
421
Diagnostic Code: Actuator Operation Table
423
Wiring Diagram
426
Color Code
426
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