YZF-R6 2001-2002 Suplementario
YZF-R6 2001-2002 Suplementario
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R6N/YZF-R6NC. For complete service information procedures it is necessary to use this Supple-
mentary Service Manual together with the following manual.
EAS00001
YZF-R6N/YZF-R6NC
SUPPLEMENTARY SERVICE MANUAL
2000 by Yamaha Motor Corporation,
U.S.A.
First edition, September 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Corpora-
tion, U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-14-39
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha
motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycles
repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycles unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
5 8
7
EB003000
1 2 SYMBOLS
The following symbols are not relevant to every
GEN
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
chapter.
3 4 1 General information
INSP 2 Specifications
ADJ ENG 3 Periodic checks and adjustment
4 Engine
5 6 5 Cooling system
6 Carburetor(-s)
7 Chassis
COOL CARB 8 Electrical system
9 Troubleshooting
7 8
CHAS ELEC
10
Symbols 10 to 17 indicate the following.
9
10 Serviceable with engine mounted
TRBL 11 Filling fluid
12 Lubricant
SHTG 13 Special tool
11 12 14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
13 14
15 16 17
24 25
Symbols 24 to 25 in the exploded diagrams indi-
cate the following:
24 Apply locking agent (LOCTITE)
25 Use new one
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 8
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 9
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CHASSIS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code YZF-R6N: 5MT5, 5MT8 (U.S.A.)
YZF-R6NC:5MT6, 5MT9 (California)
YZF-R6N: 5MT7, 5MTA (Canada)
Weight
Wet (with oil and a full fuel tank) 186 kg (410 lb)
187 kg (412 lb) (California)
Dry (without oil and fuel) 167 kg (368 lb)
168 kg (370 lb) (California)
Maximum load (total of cargo, rider, 375 kg (827 lb)
passenger, and accessories)
–1–
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Camshafts
Drive system Chain drive (right)
Camshaft cap inside diameter 23.000 23.021 mm (0.9055 0.9063 in)
Camshaft journal diameter 22.967 22.980 mm (0.9042 0.9047 in)
Camshaft-journal-to-camshaftcap 0.028 0.062 mm (0.0011 0.0025 in) 0.08 mm
clearance (0.0031 in)
Carburetors
Model (manufacturer) quantity CVRD37 (KEIHIN) 4
Throttle cable free play (at the 6 8 mm (0.24 0.31 in)
flange of the throttle grip)
ID mark 5GV101, 5GV210 (California)
Main jet Carburetors 1 and 4: #152, #148 (California)
Carburetors 2 and 3: #148
Main air jet #110
Jet needle Carburetors 1 and 4: N7SB
Carburetors 1 and 4: N7SD (California)
Carburetors 2 and 3: N7SA
Carburetors 2 and 3: N7SE (California)
Needle jet 2.6
Pilot air jet Carburetors 1 and 4: #105
Carburetors 2 and 3: #110
Pilot outlet 0.9
Pilot jet #38, #35 (California)
Bypass 1 0.8
Bypass 2 0.8
Bypass 3 0.8
Valve seat size 1.2
–2–
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Tire type Tubeless
Size 120/60ZR17 (55W)
Model (manufacturer) MICHELIN Pilot SPORT B
DUNLOP D207F.J
–3–
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
Ignition system type C.D.I. SSS
Ignition timing 10_ BTDC at 1300 r/min SSS
5_ BTDC at 1300 r/min (California) SSS
Advanced timing 55_ BTDC at 5250 r/min SSS
Advancer type Throttle position sensor and electrical SSS
Pickup coil resistance/color 248 372 Ω/Gy-B SSS
Transistorized coil ignition unit model F8T383 (MITSUBISHI) SSS
(manufacturer)
Battery
Battery type GT9B-4 SSS
Battery voltage/capacity 12 V/8 AH SSS
Bulbs (voltage/wattage quantity)
Headlight 12 V 60 W/55 W 2 SSS
Tail/brake light 13.5 V 6.1 W/0.6 W 20 (LED) SSS
Turn signal/position light 12 V 27 W/8 W 2 (front) SSS
12 V 27 W 2 (rear) SSS
Licence plate light 12 V 5 W 1 SSS
Meter light 12 V 1.4 W 2 SSS
Sidestand relay
Model G8R-30Y-M SSS
Coil resistance 162 198 Ω SSS
Fuel pump relay model (manufacturer) G8R-30Y-M (OMRON) SSS
Resistance 162 198 Ω
Fuses (amperage quantity)
Main fuse 30 A 1 SSS
Headlight fuse 20 A 1 SSS
Signaling system fuse 20 A 1 SSS
Ignition fuse 15 A 1 SSS
Radiator fan fuse 7.5 A 1 SSS
Backup fuse (odometer) 7.5 A 1 SSS
Reserve 30 A 1 SSS
20 A 1 SSS
15 A 1 SSS
7.5 A 1 SSS
–4–
TIGHTENING TORQUES SPEC
ENGINE TIGHTENING TORQUES
Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mkg ftlb
Cap bolt (timing chain tensioner) Bolt M6 1 7 0.7 5.1
Neutral switch Screw M6 2 20 2.0 14
–5–
CABLE ROUTING SPEC
EB206000
CABLE ROUTING
1 Reservoir tank A Fasten the battery box and starter motor lead with a plastic clamp.
2 Fuse box B Fasten the wire positive lead and starter motor lead with clamp at the
3 Tool kit end of the cover of the battery positive terminal.
4 Wire minus lead The end of the clamp is facing frontward.
5 Wire harness C Route the under of the CDI unit coupler.
6 Battery box D Clamp the lead at the rear of the two holes.
7 Frame E Route the leads into the hole.
F Route the lead along the inside of the two ribs.
G Route the license plate light lead and taillight lead along the outside of
the battery box so that the leads do not get caught between the rib of
the battery box and the fender.
–6–
CABLE ROUTING SPEC
H Route the seat lock cable into the hole of the frame. O Fasten the main harness, ground lead and battery
Mount the cable so that the side covered with a box with a plastic clamp.
cable protector up the end is positioned at rear. P The end of the clamp is facing upward.
I Fasten the seat lock cable with a steel clamp. Q The end of the clamp is facing upward.
J Do not fasten the seat lock cable. R Licence and flasher light sub harness on the
K Route the wire negative lead under the starter relay taillight unit.
lead. S Licence and flasher light sub harness on the
L Fasten the main harness, starter relay lead and taillight unit.
wire negative lead with a plastic clamp. T Clamp the leads.
M Route the wire negative lead under the main U Store the ends of all leads at the inside of the rib.
harness. V Fasten the licence light lead. And bend the licence
N Position the wire negative lead coupler under the light lead.
main harness. W Fasten the flasher light lead. And bend the flasher
light lead.
–7–
CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
EB304020
A 2. Check:
brake fluid level
Below the minimum level mark a Add the
recommended brake fluid to the proper level.
A Front brake
B Rear brake
B WARNING
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal.
–8–
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
EB304153
Spring preload
CAUTION:
Grooves are provided to indicate the ad-
justment position.
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
spring preload
Spring preload is
Direction a increased (suspension is
harder).
Spring preload is
Direction b decreased (suspension is
softer).
Standard
Minimum
Maximum (hard) (soft)
Adjusting
position 1 2 3 4 5 6 7 8
–9–
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjusting positions.
1. Adjust:
rebound damping
Rebound damping is
Direction a increased (suspension is
harder).
Rebound damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 10 clicks out*
Standard: 6 clicks out*
Maximum: 1 click out*
* From the fully turned-in position
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjusting positions.
1. Adjust:
compression damping
a. Turn the adjusting screw 1 in direction a or
b.
Compression damping is
Direction a increased (suspension is
harder).
Compression damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 9 clicks out*
Standard: 6 clicks out*
Maximum: 1 click out*
* From the fully turned-in position
–10–
CHK
CHECKING THE TIRES ADJ
EB304170
Basic weight
(with oil 186 kg (U.S.A.)
and a full 187 kg (California)
fuel tank)
Maximum 189 kg (U.S.A.)
load* 188 kg (California)
Cold tire
Front Rear
pressure
Up to 90 kg 250 kPa 250 kPa
(198 lb) (2.5 kg/cm2, (2.5 kg/cm2,
load* 36.3 psi) 36.3 psi)
90 kg (198 lb) 250 kPa 290 kPa
maximum (2.5 kg/cm2, (2.9 kg/cm2,
load* 36.3 psi) 42.1 psi)
250 kPa 250 kPa
High-speed
(2.5 kg/cm2, (2.5 kg/cm2,
riding
36.3 psi) 36.3 psi)
* total of cargo, rider, passenger and accesso-
ries
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
–11–
CHK
CHECKING THE TIRES ADJ
2. Check:
tire surfaces
Damage/wear Replace the tire.
Front tire
Manufacturer Size Model
120/60 ZR17 Pilot
MICHELIN
(55W) SPORT B
120/60 ZR17
DUNLOP D207FJ
(55W)
–12–
CHK
CHECKING THE TIRES/CHECKING THE WHEELS ADJ
Rear tire
Manufacturer Size Model
180/55 ZR17 Pilot
MICHELIN
(73W) SPORT B
180/55 ZR17
DUNLOP D207N
(73W)
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
sould be traveled at normal speed before
any highspeed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
–13–
SWINGARM AND DRIVE CHAIN CHAS
EAS00700
CHASSIS
SWINGARM AND DRIVE CHAIN
6 Nm (0.6 mkg,
4.3 ftlb)
–14–
SWINGARM AND DRIVE CHAIN CHAS
6 Nm (0.6 mkg,
4.3 ftlb)
–15–
SWINGARM AND DRIVE CHAIN CHAS
EAS00709
NOTE:
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three dif-
ferent places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
–16–
YZF-R6N/YZF-R6NC WIRING DIAGRAM
1 Main switch
2 Fuse (back up)
3 Rectifier / Regulator
4 A.C. magneto
5 Battery
6 Fuse (main)
7 Starter relay
8 Starter motor
9 Starting circuit cut-off relay
10 Sidestand switch
11 Fuel pump
12 Throttle position sensor
13 Pickup coil
14 CDI unit
15 Ignition coil #1
16 Ignition coil #2
17 Ignition coil #3
18 Ignition coil #4
19 Spark plug
20 Meter assembly
21 Fuel level indicator light
22 Oil level / coolant temperature warning light
23 Neutral indicator light
24 Tachometer
25 Combination meter
26 Hi beam indicator light
27 Turn signal indicator light
28 Meter lights
29 Speed sensor
30 Neutral switch
31 Thermo unit
32 Fuel sender
33 Right handlebar switch
34 Front brake light switch
35 Engine stop switch
36 Start switch
37 Left handlebar switch
38 Dimmer switch
39 Horn switch
40 Clutch switch
41 Turn signal switch
42 Horn
43 Flasher relay
44 Frotn turn signal light (left)
45 Front turn signal light (right)
46 Rear turn signal light (left)
47 Rear turn signal light (right)
48 Oil level switch
49 Headlight
50 Rear brake light switch
51 Tail / brake light
52 Licence light
53 Fuse (ignition)
54 Fuse (signal)
55 Fuse (headlight)
56 Fuse (radiator fan motor)
57 Thermo switch
58 Radiator fan motor
59 Headlight relay
COLOR CODE
B ...... Black R...... Red Br / W . . Brown / White R/B . . . Red / Black
Br . . . . . Brown Sb . . . . . Sky blue G/R . . . Green / Red R/L . . . Red / Blue
Ch . . . . Chocolate W ..... White G/W . . . Green / White R/W . . . Red / White
Dg . . . . Dark green Y ...... Yellow G/Y . . . Green / Yellow R/Y . . . Red / Yellow
G ..... Green B/L . . . . Black / Blue Gy / B . . Gray / Black Sb / W . . Sky blue / White
Gy . . . . Gray B/R . . . Black / Red L/B . . . . Blue / Black W/G . . . White / Green
L ...... Blue B/W . . . Black / White L/R . . . Blue / Red W/R . . . White / Red
Lg . . . . . Blue green B/Y . . . Black / Yellow L/W . . . Blue / White W/Y . . . White / Yellow
O ..... Orange Br / B . . . Brown / Black L/Y . . . . Blue / Yellow Y/B . . . Yellow / Black
P ...... Pink Br / L . . . Brown / Blue O/B . . . Orange / Black
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.