Yamaha YZF-R6 User manual

EB000000

YZF-R6

SERVICE MANUAL

1998 by Yamaha Motor Co., Ltd.

First edition, August 1998

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EB001000 NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

andtheirqualifiedmechanics.itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-

al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-

hicle unsafe and unfit for use.

Yamaha Motor Company,Ltd.iscontinuallystrivingtoimproveallofitsmodels.Modificationsandsig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EB002000

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failuretofollow WARNINGinstructionscouldresultinsevereinjuryordeathto

themotorcycleoperator,abystander or apersoncheckingorrepairingthemo-

torcycle.

ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

126

EB003000 HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanationsof all installation,removal, disassembly, assembly, repair andcheck procedures arelaid

out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

exceptinChapter3(“PERIODICCHECKSANDADJUSTMENTS”),wherethesub-sectiontitle(-s)ap-

pears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

CARB

ELECCHAS

COOL

CHK

ADJ

TRBL

SHTG

EB004000

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Cooling system

6Carburetor(-s)

7Chassis

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 intheexplodeddiagramsindi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum disulfide oil

21 Wheel bearing grease

22 Lithium soap base grease

23 Molybdenum disulfide grease

Symbols 24 to 25 intheexplodeddiagramsindi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETORS

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO 1

SPEC 2

ENG 4

COOL 5

CARB 6

CHAS 7

ELEC 8

TRBL

SHTG 9

CHK

ADJ

INDEX

GEN

INFO

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . .

REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .

USING A DYNAMOMETER 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INTAKE SYSTEM 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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