Yamaha YZFR6V Manuals

Yamaha YZFR6V Manuals

Manuals and User Guides for Yamaha YZFR6V. We have 2 Yamaha YZFR6V manuals available for free PDF download: Service Manual

Yamaha YZFR6V Service Manual

Yamaha YZFR6V Service Manual (419 pages)

Brand: Yamaha | Category: Motorcycle | Size: 19.88 MB

Table of Contents

Table of Contents

6
- How to Use this Manual
  4
- Symbols
  5
- General Information
  7
- Identification
  8
  - Vehicle Identification Number
    8
  - Model Label
    8
- Features
  9
  - Outline of the Fi System
    9
  - Fi System
    10
  - YCC-T (Yamaha Chip Controlled Throttle)
    11
  - 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
    19
  - Circlips
    19
- Checking the Connections
  20
- Special Tools
  21
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  37
- Electrical Specifications
  40
- Tightening Torques
  43
- Lubrication Points and Lubricant Types
  52
  - Engine
    52
  - Chassis
    54
- Lubrication System Chart and Diagrams
  55
  - Engine Oil Lubrication Chart
    55
  - Lubrication Diagrams
    57
- Cooling System Diagrams
  69
- Cable Routing
  73
Periodic Checks and Adjustments

87
- Periodic Maintenance
  
  89
- Engine
  
  92
  - Adjusting the Valve Clearance
    92
  - Synchronizing the Throttle Bodies
    94
  - Adjusting the Throttle Cable Free Play
    96
  - Checking the Spark Plugs
    96
  - Measuring the Compression Pressure
    97
  - Checking the Engine Oil Level
    98
  - Changing the Engine Oil
    99
  - Measuring the Engine Oil Pressure
    100
  - Adjusting the Clutch Lever Free Play
    101
  - Replacing the Air Filter Element
    102
  - Checking the Throttle Body Joints
    103
  - Checking the Fuel Line
    103
  - Checking the Crankcase Breather Hose
    103
  - Checking the Exhaust System
    104
  - CHECKING the CANISTER (for California Only)
    104
  - Adjusting the Exup Cables
    104
  - Checking the Coolant Level
    106
  - Checking the Cooling System
    106
  - Changing the Coolant
    107
- Chassis
  
  109
  - Adjusting the Front Disc Brake
    109
    
    Adjusting the Rear Disc Brake
    109
    
    Checking the Brake Fluid Level
    110
    
    Checking the Front Brake Pads
    110
    
    Checking the Rear Brake Pads
    110
    
    Checking the Front Brake Hoses
    111
    
    Checking the Rear Brake Hoses
    111
    
    Adjusting the Rear Brake Light Switch
    111
    
    Bleeding the Hydraulic Brake System
    112
    
    Adjusting the Shift Pedal
    113
    
    Adjusting the Drive Chain Slack
    113
    
    Lubricating the Drive Chain
    114
    
    Checking and Adjusting the Steering Head
    114
    
    Checking the Front Fork
    116
    
    Adjusting the Front Fork Legs
    116
    
    Adjusting the Rear Shock Absorber Assembly
    118
    
    Checking the Tires
    120
    
    Checking the Wheels
    121
    
    Checking and Lubricating the Cables
    122
    
    Lubricating the Levers
    122
    
    Electrical System
    123
Chassis

125
- General Chassis
  
  129
- Front Wheel
  
  134
  - Removing the Front Wheel
    134
  - Disassembling the Front Wheel
    134
  - Checking the Front Wheel
    134
  - Assembling the Front Wheel
    135
  - Adjusting the Front Wheel Static Balance
    135
  - Checking the Front Brake Discs
    136
  - Installing the Front Wheel (Front Brake Discs)
    136
- Rear Wheel
  
  138
  - Removing the Rear Wheel
    141
  - Disassembling the Rear Wheel
    141
  - Checking the Rear Wheel
    141
  - Checking the Rear Brake Caliper Bracket
    141
  - Checking the Rear Wheel Drive Hub
    141
  - Checking and Replacing the Rear Wheel Sprocket
    141
  - Assembling the Rear Wheel
    142
  - Adjusting the Rear Wheel Static Balance
    142
  - Checking the Rear Brake Disc
    142
  - Installing the Rear Wheel (Rear Brake Disc)
    142
- Front Brake
  
  144
- Rear Brake
  
  161
  - Introduction
    161
  - Checking the Rear Brake Disc
    161
  - Replacing the Rear Brake Pads
    161
  - Removing the Rear Brake Caliper
    162
  - Disassembling the Rear Brake Caliper
    162
  - Checking the Rear Brake Caliper
    163
  - Assembling the Rear Brake Caliper
    163
  - Installing the Rear Brake Caliper
    164
  - Removing the Rear Brake Master Cylinder
    165
  - Checking the Rear Brake Master Cylinder
    165
  - Assembling the Rear Brake Master Cylinder
    165
  - Installing the Rear Brake Master Cylinder
    165
- Handlebars
  
  167
  - Removing the Handlebars
    169
  - Checking the Handlebars
    169
  - Installing the Handlebars
    169
- Front Fork
  
  171
  - Removing the Front Fork Legs
    174
  - Disassembling the Front Fork Legs
    174
  - Checking the Front Fork Legs
    175
  - Assembling the Front Fork Legs
    176
  - Installing the Front Fork Legs
    180
- Steering Head
  
  182
  - Removing the Lower Bracket
    185
  - Checking the Steering Head
    185
  - Installing the Steering Head
    185
- Rear Shock Absorber Assembly
  
  187
- Swingarm
  
  192
  - Removing the Swingarm
    194
  - Checking the Swingarm
    194
  - Installing the Swingarm
    195
Engine

201
- Engine Removal
  
  204
  - Installing the Engine
    209
- Camshafts
  
  210
- Cylinder Head
  
  218
  - Removing the Cylinder Head
    219
  - Checking the Cylinder Head
    219
  - Installing the Cylinder Head
    219
- Valves and Valve Springs
  
  222
  - Removing the Valves
    222
  - Checking the Valves and Valve Guides
    222
  - Checking the Valve Seats
    224
  - Checking the Valve Springs
    225
  - Checking the Valve Lifters
    226
  - Installing the Valves
    226
- Generator and Starter Clutch
  
  229
  - Removing the Generator
    231
  - Checking the Starter Clutch
    231
  - Installing the Starter Clutch
    231
  - Generator and Starter Clutch
    231
  - Installing the Generator
    232
- Pickup Rotor
  
  233
  - Removing the Pickup Rotor
    234
  - Installing the Pickup Rotor
    234
- Electric Starter
  
  236
  - Checking the Starter Motor
    238
  - Assembling the Starter Motor
    239
- Clutch
  
  240
  - Removing the Clutch
    244
  - Checking the Friction Plates
    244
  - Checking the Clutch Plates
    244
  - Checking the Clutch Springs
    245
  - Checking the Clutch Housing
    246
  - Checking the Clutch Boss
    246
  - Checking the Pressure Plate
    246
  - Checking the Primary Drive Gear
    246
  - Checking the Primary Driven Gear
    246
  - Checking the Pull Lever Shaft and Pull Rod
    246
  - Checking the Oil Pump Drive Sprocket and Oil Pump Drive Chain
    247
  - Installing the Clutch
    247
- Shift Shaft
  
  250
  - Checking the Shift Shaft
    252
  - Checking the Stopper Lever
    252
  - Installing the Shift Shaft
    252
- Oil Pump
  
  253
  - Removing the Oil Pan
    256
  - Checking the Oil Pump
    256
  - Checking the Relief Valve
    256
  - Checking the Oil Pipes
    257
  - Checking the Oil Strainer
    257
  - Assembling the Oil Pump
    257
  - Installing the Oil Pan
    257
- Crankcase
  
  258
  - Disassembling the Crankcase
    260
  - Checking the Crankcase
    260
  - Checking the Oil Pipe
    260
  - Checking the Timing Chain
    260
  - Assembling the Crankcase
    260
- Connecting Rods and Pistons
  
  263
- Crankshaft
  
  270
- Transmission
  
  279
  - Removing the Transmission
    279
  - Checking the Shift Forks
    279
  - Checking the Shift Drum Assembly
    279
  - Checking the Transmission
    280
  - Assembling the Main Axle and Drive Axle
    280
  - Installing the Transmission
    281
Cooling System

283
- Radiator
  
  284
  - Checking the Radiator
    286
  - Installing the Radiator
    286
- Oil Cooler
  
  287
  - Checking the Oil Cooler
    289
  - Installing the Oil Cooler
    289
- Thermostat
  
  290
  - Checking the Thermostat
    291
  - Installing the Thermostat
    291
- Water Pump
  
  292
  - Checking the Water Pump
    293
  - Installing the Water Pump
    293
Fuel System

294
- Fuel Tank
  295
- Fuel Tank
  
  297
  - Checking the Fuel Pump Body
    297
  - Checking the Fuel Pump Operation
    297
  - Installing the Fuel Pump
    297
  - Removing the Fuel Pump
    297
  - Removing the Fuel Tank
    297
  - Installing the Fuel Tank
    298
- Air Filter Case
  
  299
- Throttle Bodies
  
  303
- Air Induction System
  
  309
  - Checking the Air Induction System
    313
Electrical System

314
- Ignition System
  
  316
  - Circuit Diagram
    316
  - Engine Stopping Due to Sidestand Operation
    318
  - Troubleshooting
    319
- Electric Starting System
  
  321
  - Circuit Diagram
    321
  - Starting Circuit Cut-Off System Operation
    323
  - Troubleshooting
    325
- Charging System
  
  327
  - Circuit Diagram
    327
  - Troubleshooting
    329
- Lighting System
  
  330
  - Circuit Diagram
    330
  - Troubleshooting
    332
- Signaling System
  
  334
  - Circuit Diagram
    334
  - Troubleshooting
    336
- Cooling System
  
  341
  - Circuit Diagram
    341
  - Troubleshooting
    343
- Fuel Injection System
  
  344
  - Circuit Diagram
    344
  - Ecu Self-Diagnostic Function
    346
  - Self-Diagnostic Function Table
    347
  - Troubleshooting Method
    350
  - Diagnostic Mode
    351
  - Troubleshooting Details
    359
- Fuel Pump System
  
  383
  - Circuit Diagram
    383
  - Troubleshooting
    385
- Electrical Components
  
  386
  - Checking the Switches
    390
  - Checking the Bulbs and Bulb Sockets
    393
  - Checking the Fuses
    394
  - Checking and Charging the Battery
    395
  - Checking the Relays
    398
  - Checking the Turn Signal Relay
    399
  - Checking the Relay Unit (Diode)
    400
  - Checking the Ignition Coils
    401
  - Checking the Crankshaft Position Sensor
    402
  - Checking the Lean Angle Sensor
    402
  - Checking the Stator Coil
    403
  - Checking the Rectifier/Regulator
    403
  - Checking the Horn
    404
  - Checking the Oil Level Switch
    404
  - Checking the Fuel Sender
    404
  - Checking the Speed Sensor
    405
  - Checking the Radiator Fan Motors
    405
  - Checking the Coolant Temperature Sensor
    406
  - Checking the Throttle Position Sensor
    406
  - (For Throttle Valves)
    406
  - Checking the Throttle Position Sensor
    407
  - (For Throttle Cable Pulley)
    407
  - Checking the Fuel Pump
    407
  - Checking the Air Induction System Solenoid
    408
  - Checking the Cylinder Identification Sensor
    409
  - Checking the Intake Air Pressure Sensor
    409
  - Checking the Air Temperature Sensor
    409
Troubleshooting

411
- General Information
  412
- Incorrect Engine Idling Speed
  412
- Starting Failures
  412
- Troubleshooting
  412
- Faulty Clutch
  413
- Faulty Gear Shifting
  413
- Jumps out of Gear
  413
- Overheating
  413
- Poor Medium-And-High-Speed Performance
  413
- Shift Pedal Does Not Move
  413
- Faulty Front Fork Legs
  414
- Overcooling
  414
- Poor Braking Performance
  414
- Unstable Handling
  414
- Faulty Lighting or Signaling System
  415
  - Wiring Diagram
    418

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Yamaha YZFR6V Service Manual

Yamaha YZFR6V Service Manual (11 pages)

Brand: Yamaha | Category: Motorcycle | Size: 0.21 MB

Table of Contents

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