YAMAHA YZF-R6 99 Manuals

Manuals and User Guides for YAMAHA YZF-R6 99. We have 1 YAMAHA YZF-R6 99 manual available for free PDF download: Service Manual

YAMAHA YZF-R6 99 Service Manual

YAMAHA YZF-R6 99 Service Manual (400 pages)

Motorcycle YZF-R6 99 5EB-AE1

Brand: YAMAHA | Category: Motorcycle | Size: 9.43 MB

Table of Contents

Gen Info

7
- Important Manual Information
  3
- How to Use this Manual
  4
- Table of Contents
  7
- Chapter 1
  8
- General Information
  8
- Motorcycle Identification
  8
  - Vehicle Identification Number
    8
  - Model Code
    8
- Important Information
  9
  - Preparation for Removal and Disassembly
    9
  - Replacement Parts
    9
  - Gaskets, Oil Seals and O-Rings
    9
  - Using a Dynamometer
    10
  - Lock Washers/Plates and Cotter Pins
    10
  - Bearings and Oil Seals
    10
  - Circlips
    10
- Checking the Connections
  11
- Features
  12
  - Air Intake System
    12
  - Thermostat
    12
  - Ignition System
    13
- Special Tools
  15
Table of Contents

19
- Chapter 2. Specifications
  20
- General Specifications
  20
- Engine Specifications
  21
- Chassis Specifications
  30
- Electrical Specifications
  36
- Conversion Table
  37
- Tightening Torques
  37
- Lubrication Points and Lubricant Types
  42
  - Engine Lubrication Points and Lubricant Types
    42
  - Chassis Lubrication Points and Lubricant Types
    43
- Oil Flow Diagrams
  44
- Coolant Flow Diagrams
  48
- Cable Routing
  52
Table of Contents

59
- Chapter 3
  61
- Introduction
  61
- Periodic Checks and Adjustments
  61
- Periodic Maintenance and Lubrication Intervals
  61
- Rider and Passenger Seats
  63
- Fuel Tank
  64
- Cowlings
  66
  - Removal
    67
  - Installation
    67
- Air Filter Case and Ignition Coils
  68
  - Removal
    70
  - Installation
    70
- Engine
  71
- Chassis
  99
  - Adjusting the Front Brake
    99
  - Adjusting the Rear Brake
    99
  - Checking the Brake Fluid Level
    101
  - Checking the Brake Pads
    102
  - Adjusting the Rear Brake Light Switch
    102
  - Checking the Brake Hoses
    103
  - Bleeding the Hydraulic Brake System
    103
  - Adjusting the Shift Pedal
    105
  - Adjusting the Drive Chain Slack
    105
  - Lubricating the Drive Chain
    107
  - Checking and Adjusting the Steering Head
    107
  - Checking the Front Fork
    110
  - Adjusting the Front Fork Legs
    111
  - Adjusting the Rear Shock Absorber Assembly
    113
  - Checking the Tires
    115
  - Checking the Wheels
    117
  - Checking and Lubricating the Cables
    118
  - Lubricating the Levers and Pedals
    118
  - Lubricating the Sidestand
    118
  - Lubricating the Rear Suspension
    118
- Electrical System
  119
  - Checking and Charging the Battery
    119
  - Checking the Fuses
    124
  - Replacing the Headlight Bulbs
    126
  - Adjusting the Headlight Beams
    127
Table of Contents

128
- Cylinder Head
  145
- Valves and Valve Springs
  148
- Starter Clutch and Generator
  163
- Shift Shaft
  168
- Clutch
  171
- Checking the Friction Plates
  176
- Removing the Clutch
  176
- Checking the Clutch Housing
  177
- Checking the Clutch Plates
  177
- Checking the Clutch Springs
  177
- Checking the Clutch Boss
  178
- Checking the Pressure Plate
  178
- Checking the Pull Lever Shaft and Pull Rod
  178
- Installing the Clutch
  179
- Oil Pan and Oil Pump
  181
  - Removing the Oil Pan
    184
  - Checking the Oil Pump
    184
  - Checking the Relief Valve
    185
  - Checking the Oil Delivery Pipe and Oil Pipe
    185
  - Checking the Oil Strainer
    185
  - Checking the Oil Nozzles
    185
  - Assembling the Oil Pump
    186
  - Installing the Oil Pump
    186
  - Installing the Oil Strainer
    186
  - Installing the Oil Pan
    186
- Crankcase
  187
  - Oil Baffle Plates and Oil Filter Bolt
    189
  - Disassembling the Crankcase
    190
  - Checking the Crankcase
    191
  - Checking the Bearings and Oil Seals
    191
  - Checking the Sprockets and Chains
    191
  - Assembling the Crankcase
    192
- Connecting Rods and Pistons
  194
- Crankshaft
  206
  - Removing the Crankshaft
    207
  - Checking the Crankshaft
    207
  - Checking the Crankshaft Journal Bearings
    207
  - Installing the Crankshaft
    210
- Transmission
  211
  - Removing the Transmission
    217
  - Checking the Shift Forks
    217
  - Checking the Shift Drum Assembly
    218
  - Checking the Transmission
    218
  - Installing the Transmission
    219
Table of Contents

220
- Chapter 5. Cooling System
  221
- Radiator
  221
  - Checking the Radiator
    223
  - Installing the Radiator
    224
- Oil Cooler
  225
  - Checking the Oil Cooler
    227
  - Installing the Oil Cooler
    227
- Thermostat
  229
  - Checking the Thermostat
    231
  - Installing the Thermostat
    231
- Water Pump
  233
  - Disassembling the Water Pump
    234
  - Assembling the Water Pump
    234
Carburetors

238
- Carburetors
  239
- Chapter 6. Carburetors
  239
- Checking the Carburetors
  245
- Assembling the Carburetors
  247
- Installing the Carburetors
  249
- Measuring and Adjusting the Fuel Level
  250
- Checking and Adjusting the Throttle Position Sensor
  251
- Checking the Fuel Pump
  254
- Checking the Fuel Cock
  255
- Checking the Fuel Cock Operation
  255
Table of Contents

256
- Chapter 7. Chassis
  258
- Front Wheel and Brake Discs
  258
  - Removing the Front Wheel
    260
  - Checking the Front Wheel
    260
  - Checking the Brake Discs
    262
  - Installing the Front Wheel
    263
  - Adjusting the Front Wheel Static Balance
    263
- Rear Wheel, Brake Disc, and Rear Wheel Sprocket
  265
  - Rear Wheel
    265
  - Brake Disc and Rear Wheel Sprocket
    266
  - Removing the Rear Wheel
    268
  - Checking the Rear Wheel
    268
  - Checking the Rear Wheel Drive Hub
    269
  - Checking and Replacing the Rear Wheel Sprocket
    269
  - Installing the Rear Wheel
    270
  - Adjusting the Rear Wheel Static Balance
    270
- Front and Rear Brakes
  271
- Front Fork
  299
  - Removing the Front Fork Legs
    299
  - Disassembling the Front Fork Legs
    300
  - Checking the Front Fork Legs
    304
  - Assembling the Front Fork Legs
    305
  - Installing the Front Fork Legs
    310
- Handlebars
  311
  - Removing the Handlebars
    313
  - Checking the Handlebars
    313
  - Installing the Handlebars
    314
- Steering Head
  316
  - Lower Bracket
    316
  - Removing the Lower Bracket
    318
  - Checking the Steering Head
    318
  - Installing the Steering Head
    319
- Rear Shock Absorber Assembly
  321
- Swingarm and Drive Chain
  325
  - Removing the Drive Chain
    327
  - Removing the Swingarm
    327
  - Checking the Drive Chain
    330
  - Installing the Swingarm
    332
  - Installing the Drive Chain
    332
Table of Contents

333
- Chapter 8. Electrical
  335
- Electrical Components
  335
- Instrument Functions
  336
  - Indicator Lights
    336
  - Oil Level/Coolant Temperature Warning Light
    336
  - Combination Meter
    337
- Switches
  339
  - Checking Switch Continuity
    339
- Checking the Switches
  340
- Checking the Bulbs and Bulb Sockets
  342
  - Types of Bulbs
    342
  - Checking the Condition of the Bulbs
    342
  - Checking the Condition of the Bulb Sockets
    344
  - CHECKING the Leds
    344
- Ignition System
  345
  - Circuit Diagram
    345
  - Troubleshooting
    346
- Electric Starting System
  350
  - Circuit Diagram
    350
  - Starting Circuit Cutoff System Operation
    351
  - Troubleshooting
    352
- Starter Motor
  356
  - Checking the Starter Motor
    358
  - Assembling the Starter Motor
    359
- Charging System
  360
  - Circuit Diagram
    360
  - Troubleshooting
    361
- Lighting System
  363
  - Circuit Diagram
    363
  - Troubleshooting
    364
  - Checking the Lighting System
    365
- Signaling System
  369
  - Circuit Diagram
    369
  - Troubleshooting
    371
  - Checking the Signaling System
    372
- Cooling System
  379
  - Circuit Diagram
    379
  - Troubleshooting
    380
- Fuel Pump System
  383
  - Circuit Diagram
    383
  - Fuel Pump Circuit Operation
    384
  - Troubleshooting
    385
  - Checking the Fuel Pump
    387
- Self-Diagnosis
  388
Trbl Shtg

392
- Chapter 9. Troubleshooting
  394
- Starting Problems
  394
  - Engine
    394
  - Fuel System
    394
  - Electrical Systems
    394
- Faulty Gear Shifting
  395
  - Shifting Is Difficult
    395
  - Shift Pedal Does Not Move
    395
  - Jumps out of Gear
    395
- Incorrect Engine Idling Speed
  395
  - Engine
    395
  - Fuel System
    395
  - Electrical Systems
    395
- Poor Medium-And-High-Speed Performance
  395
- Faulty Clutch
  396
  - Clutch Slips
    396
  - Clutch Drags
    396
- Overcooling Cooling System
  396
- Overheating
  396
  - Engine
    396
  - Cooling System
    396
  - Fuel System
    396
  - Chassis
    396
  - Electrical Systems
    396
- Faulty Front Fork Legs
  397
  - Leaking Oil
    397
  - Malfunction
    397
  - Unstable Handling
    397
- Poor Braking Performance
  397

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