Page 2 - FOREWORD
YZF-R6T / YZF-R6TC SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. First edition, September 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P / N LIT-11...
Page 3 - NOTICE; system. Please read this material carefully.; IMPORTANT MANUAL INFORMATION; WARNING
EAS00030 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamah...
Page 4 - HOW TO USE THIS MANUAL; each page indicate the current chapter.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divi...
Page 5 - SYMBOLS
EAS00008 SYMBOLS The following symbols are not relevant to every vehicle.Symbols to indicate the subject of each chapter. General informationSpecificationsPeriodic checks and adjustmentsChassisEngineCooling systemFuel injection systemElectrical systemTroubleshooting Symbols to indicate the following...
Page 6 - CONTENTS; GENERAL INFORMATION; ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER; COOLING SYSTEM
CONTENTS GENERAL INFORMATION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 7 - ELECTRICAL SYSTEM; ELECTRIC STARTING SYSTEM
ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 COOLING SYSTEM . ....
Page 8 - SPECIAL TOOLS
GEN INFO 1 EAS00027 GENERAL INFORMATION SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri-ate tools or improvised techniques. Special tools, p...
Page 9 - GENERAL SPECIFICATIONS; Model code; GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS
SPEC 2 SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Model code 5SLR (USA except for CAL) • • • 5SLS (CAL) Dimensions Overall length 2,045 mm (80.5 in) • • • Overall width 690 mm (27.2 in) • • • Overall height 1,105 mm (43.5 in) • • • Seat height 830 mm (32.7 in) • ...
Page 10 - SPEC; Frame; CHASSIS SPECIFICATIONS
SPEC 3 CHASSIS SPECIFICATIONS Item Standard Limit Frame Caster angle 24.5° • • • Trail 95 mm (3.74 in) • • • Front tire Size 120 / 70 ZR17 M / C (55W) • • • Model (manufacturer) Pilot POWER C (MICHELIN) • • • D218FM (DUNLOP) Rear tire Model (manufacturer) Pilot POWER (MICHELIN) • • • D218M (DUNLOP) ...
Page 11 - ELECTRICAL SPECIFICATIONS; Front suspension; CHASSIS SPECIFICATIONS /
SPEC 4 ELECTRICAL SPECIFICATIONS Item Standard Limit Front suspension Spring Free length 248.8 mm (9.80 in) 243.8 mm (9.60 in) Installed length 244.3 mm (9.62 in) • • • Spring rate (K1) 8.8 N / mm (0.90 kg / mm, 50.22 lb / in) • • • Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.7244 in) • • • Inner tube oute...
Page 12 - ENGINE TIGHTENING TORQUES; TIGHTENING TORQUES
SPEC 5 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES NOTE: NOTE: 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm (9.1 m•kg, 66 ft•lb). 2. In the order from the pinch bolt → pinch bolt → pinch bolt , tighten ...
Page 13 - CABLE ROUTING
SPEC 6 CABLE ROUTING Right handlebar switch leadClutch cableMain switch leadLeft handlebar switch leadThrottle cable (return side)Throttle cable (pull side)Horn leadSteering coverFront brake hoseThrottle cablesJoint Pass the right handlebar switch lead inside the front brake hoses and over the throt...
Page 28 - h. Tighten the bleed screw and then release; Bleed screw; BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK ADJ 21 f. Fully pull the brake lever or fully press down the brake pedal and hold it in posi-tion. g. Loosen the bleed screw. NOTE: NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the ...
Page 29 - • spring preload; ADJUSTING THE FRONT FORK LEGS
CHK ADJ 22 EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han-dling and loss of stability. • Securely support the motorcycle so that there is no danger of...
Page 31 - FRONT WHEEL AND BRAKE DISCS
CHAS 24 EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job / Part Q’ty Remarks Removing the front wheel and brake discs Remove the parts in the order listed. NOTE: NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 1 Brake hose holder (left and right) 2 2 Front b...
Page 32 - CHAS; FRONT BRAKE PADS; FRONT AND REAR BRAKES
CHAS 25 EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job / Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. NOTE: NOTE: The following procedure applies to both of the front brake calipers. 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 ...
Page 33 - FRONT BRAKE MASTER CYLINDER
CHAS 26 EAS00584 FRONT BRAKE MASTER CYLINDER Order Job / Part Q’ty Remarks Removing the front brake master cylinder Remove the parts in the order listed.Drain.Refer to “CHANGING THE BRAKE FLUID” in chapter 3. Brake fluid 1 Stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm hol...
Page 35 - Disassembling the front brake
CHAS 28 EAS00585 Order Job / Part Q’ty Remarks Disassembling the front brake master cylinder Disassemble the parts in the order listed. Brake master cylinder kit 1 Bleed screw 1 Brake master cylinder body 1 For assembly, reverse the disassembly procedure. 6 Nm (0.6 m•kg, 4.3 ft•lb) FRONT AND REAR BR...
Page 36 - FRONT BRAKE CALIPERS
CHAS 29 EAS00613 FRONT BRAKE CALIPERS Order Job / Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. NOTE: NOTE: The following procedure applies to both of the front brake calipers. Brake fluid Drain.Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. 1 Union bolt ...
Page 38 - • Before installation, all internal brake com-; Recommended brake fluid
CHAS 31 EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. 1. Install: • brake master cylinder kit• circ...
Page 39 - • Use only the designated brake fluid. Other
CHAS 32 4. Fill: • brake fluid reservoir (with the specified amount of the recom-mended brake fluid) 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 tha...
Page 40 - FRONT FORK LEGS; FRONT FORK
CHAS 33 EAS00647 FRONT FORK FRONT FORK LEGS Order Job / Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. Front brake calipers Refer to “FRONT AND REAR BRAKES”. Front cowling inner panels Refer to “COWLINGS” in ch...
Page 41 - Disassembling the front fork legs
CHAS 34 EAS00648 Order Job / Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed. NOTE: NOTE: The following the procedure applies to both of the front fork legs. Cap bolt 1 O-ring 1 Damper adjusting rod 1 Nut 1 Washer 1 Spacer 1 Fork spring 1 Dust seal 1 Oil...
Page 43 - DISASSEMBLING THE FRONT FORK LEGS; The fork spring is compressed.
CHAS 36 EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.1. Remove: • cap bolt (from the damper adjusting rod) • spacer • nut a. Press down on the spacer with the fork spring compressor . b. Install the rod holder between the nut and the space...
Page 44 - CHECKING THE FRONT FORK LEGS; Damper rod holder
CHAS 37 4. Remove: • damper rod assembly bolt• damper rod assembly NOTE: NOTE: While holding the damper rod assembly with the damper rod holder , loosen the damper rod assembly bolt. EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.1. Check: • inne...
Page 45 - • When assembling the front fork leg, be sure
CHAS 38 CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu-larly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check...
Page 46 - Always use new copper washer.; • inner tube’s outer surface; , tighten the damper; Recommended lubricant
CHAS 39 WARNING Always use new copper washer. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface 3. Tighten: • damper rod assembly bolt ...
Page 47 - Fork seal driver
CHAS 40 CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg...
Page 48 - (onto the damper rod
CHAS 41 8. Install: • rod puller • rod puller attachment (onto the damper rod ) 9. Fill: • front fork leg (with the specified amount of the recom-mended fork oil) NOTE: NOTE: • While filling the front fork leg, keep it upright.• After filling, slowly pump the front fork leg up and down to distribute...
Page 49 - Fork spring compressor
CHAS 42 e. Press down on the spacer with the fork spring compressor . f. Pull up the rod puller and install the rod holder between the nut and the spacer . NOTE: NOTE: Use the side of the rod holder that is marked “B”. g. Remove the rod puller and adapter.h. Install the nut and position it as speci-...
Page 50 - CHECKING THE DRIVE CHAIN; SWINGARM AND DRIVE CHAIN
CHAS 43 EAS00709 SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension ) / 2 • 15-link...
Page 51 - between the drive
CHAS 44 CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol-vents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure meth-ods could force dirt or water int...
Page 52 - Removing the radiator; RADIATOR
COOL 45 EAS00454 COOLING SYSTEM RADIATOR Order Job / Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat Refer to “SEATS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter 3. Side cowlings and bottom ...
Page 53 - COOL; Order
COOL 46 Order Job / Part Q’ty Remarks 9 Radiator cap 1 For installation, reverse the removal procedure. 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) RADIATOR
Page 54 - CIRCUIT DIAGRAM
ELEC 47 EAS00755 ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switchBatteryFuse (main)Star ter relayStar ter motorFuse (ignition)Star ting circuit cut-off relaySidestand switchNeutral switchEngine stop switchStar t switchClutch switch ELECTRIC STARTING SYSTEM
Page 55 - ELEC
ELEC 48 EAS00757 TROUBLESHOOTING Check: 1. main and ignition fuses2. battery3. starter motor4. starting circuit cut-off relay5. starter relay6. main switch7. engine stop switch8. neutral switch9. sidestand switch 10. clutch switch11. start switch12. wiring connections (of the entire starting system)...
Page 59 - TROUBLESHOOTING
ELEC 52 EAS00808 TROUBLESHOOTING Check: 1. main, ignition, and radiator fan motor fuses2. battery3. main switch4. radiator fan motor5. radiator fan motor relay6. coolant temperature sensor7. wiring connections (the entire cooling system) NOTE: NOTE: • Before troubleshooting, remove the following par...
Page 61 - Coolant temperature sensor; • Handle the coolant temperature sensor
ELEC 54 EAS00812 EAS00813 6. Coolant temperature sensor • Remove the coolant temperature sensor.• Connect the pocket tester ( Ω × 1k) to the coolant temperature sensor as shown. • Immerse the coolant temperature sensor in a container filled with coolant . NOTE: NOTE: Make sure the coolant temperatur...
Page 63 - COLOR CODE
YZF-R6T / YZF-R6TC WIRING DIAGRAM Main switchA.C. magnetoRectifier / regulatorFuse (backup)BatteryFuse (main)Starter relayStarter motorFuse (fuel injection)Fuse (ignition)Starting circuit cut-off relaySidestand switchFuel pumpECUIgnition coilSpark plugFuel injectorAir induction system solenoidNeutra...
