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YZFR6V
Yamaha YZFR6V User Manual
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EAS20050
YZFR6V(C)
SER
VICE MA
NU
AL
©2005 by
Y
amaha Motor Corporation, U
.S.A.
First edition, Dece
mber 2005
All rights reserved.
Any re
produ
ction or unauthorized use
without the written permission of
Y
amaha Motor Corporation, U
.S.A.
is expressl
y pr
ohibited.
Printed in U
.S.A.
P/N LIT
-11616-19-78
1
3
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
General Tightening Torque Specifications
43
Engine Tightening Torques
44
Chassis Tightening Torques
48
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
General Maintenance and Lubrication Chart
89
Introduction
89
Periodic Maintenance Chart for the Emission Control System
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
Introduction
149
Checking the Front Brake Discs
149
Replacing the Front Brake Pads
150
Removing the Front Brake Calipers
151
Disassembling the Front Brake Calipers
151
Checking the Front Brake Calipers
151
Assembling the Front Brake Calipers
152
Installing the Front Brake Calipers
152
Removing the Front Brake Master Cylinder
153
Checking the Front Brake Master Cylinder
153
Assembling the Front Brake Master Cylinder
153
Installing the Front Brake Master Cylinder
154
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
Handling the Rear Shock Absorber
189
Disposing of a Rear Shock Absorber
189
Removing the Rear Shock Absorber Assembly
189
Checking the Rear Shock Absorber Assembly
189
Checking the Connecting Arm and Relay Arm
190
Installing the Relay Arm
190
Installing the Rear Shock Absorber Assembly
190
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
Removing the Camshafts
212
Checking the Camshafts
212
Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
214
Checking the Timing Chain Tensioner
214
Installing the Camshafts
215
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
Removing the Connecting Rods and Pistons
263
Checking the Cylinders and Pistons
263
Checking the Piston Rings
264
Checking the Piston Pins
265
Checking the Connecting Rods
266
Installing the Connecting Rods and Pistons
267
Crankshaft
270
Removing the Crankshaft Journal Bearings
271
Checking the Oil Nozzles
271
Checking the Crankshaft and Connecting Rods
271
Installing the Crankshaft
273
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
Default Chapter
295
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
Removing the Fuel Hose (Primary Injector Fuel Rail to Secondary Injector Fuel Rail)
301
Checking the Secondary Injectors
301
Installing the Fuel Hose (Primary Injector Fuel Rail to Secondary Injector Fuel Rail)
301
Throttle Bodies
303
Checking the Primary Injectors
306
Checking the Throttle Bodies
306
CHECKING the ROLLOVER VALVE (for California Only)
306
Checking the Fuel Pressure
306
Adjusting the Throttle Position Sensor (for Throttle Valves)
307
Adjusting the Throttle Position Sensor (for Throttle Cable Pulley)
307
Installing the Throttle Body Joints
308
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
5
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Yamaha YZFR6V Specifications
General
Brand
Yamaha
Model
YZFR6V
Category
Motorcycle
Language
English
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