Yamaha YZF-R6 Repair Manual 1999-2004
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This repair and service manual covers Yamaha YZF-R6 sportbikes, 1999-2004.Table of ContentsQUICK REFERENCE DATACHAPTER ONE: GENERAL INFORMATION Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage.CHAPTER TWO: TROUBLESHOOTING Engine operating requirements / Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system (carbureted models) / Fuel system (fuel injected models) / Fuel pump / Electrical testing / Electrical troubleshooting / Cooling system circuit / Steering and suspension / Brake system.CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP Cylinder numbering and firing order / Maintenance intervals / Tune-up / Ignition timing inspection (carbureted models) / Valve clearance / Spark plugs / Engine oil / Engine oil pressure / Throttle body synchronization / Idle speed adjustment / Fuel line inspection / Fuel filter / Emission control systems / Exhaust gas volume adjustment (Europe and Australia fuel injected models) / Exhaust system inspection / Control cable lubrication / Throttle cables / Choke cable inspection (carbureted models) / Clutch cable free play / Shift pedal height / Battery / Cooling system / Tires and wheels / Front suspension / Front suspension inspection / Front fork adjustments / Steering head bearings / Rear suspension inspection / Shock absorber adjustments / Drive chain / Brake system / General lubrication / Fastener inspection.CHAPTER FOUR: ENGINE TOP-END Servicing engine in the frame / Cylinder head cover / Camshaft / Cam sprocket / Cam chain tensioner / Cam chain guides / Cam chain / Cylinder head / Valve lifters and shims / Valve components.CHAPTER FIVE: ENGINE LOWER-END Engine / Timing rotor cover / Timing rotor / Alternator cover / Flywheel and starter gears / Starter clutch / Oil pan / Oil pump / Crankcase / Crankshaft / Connecting rods / Piston and piston rings / Engine break-in.CHAPTER SIX: CLUTCH Clutch cover / Clutch release mechanism / Clutch / Clutch cable replacement.CHAPTER SEVEN: TRANSMISSION and SHIFT MECHANISM Shift rod and shift lever / Engine sprocket cover / Engine sprocket / Shift pedal / footrest bracket / External shift mechanism / Internal shift mechanism / Transmission.CHAPTER EIGHT: AIR and FUEL, EMISSIONS and EXHAUST SYSTEMS—CARBURETED MODELS Fuel tank / Fuel valve / Fuel sender / Fuel filter / Fuel pump / Fuel sender and fuel level indicator light / Air filter housing / Carburetor / Carburetor overhaul / Carburetor adjustments / Throttle position sensor / Throttle cable replacement / Choke cable replacement / Heat shield / Radiator cover / Air induction system (AIS) / Evaporative emission control system (California models) / Exhaust system.CHAPTER NINE: AIR and FUEL, EMISSIONS and EXHAUST SYSTEMS—FUEL INJECTED MODELS Fuel injection system precautions / Hose and wiring harness identification / Depressurizing the fuel system / Fuel tank / Fuel pump / Fuel injection relay / Fuel sender and fuel level indicator light / Air filter housing / Heat shield / Radiator cover / Throttle body assembly / Piston valve / Fuel injector / Throttle position sensor / Pressure regulator / Cylinder identification sensor / Intake air pressure sensor / Intake air temperature sensor / Atmospheric pressure sensor / Lean angle cutoff switch / Crankshaft position sensor / Throttle cable replacement / Air induction system (AIS) / Evaporative emission control system (California models) / Exhaust system / Fuel injection diagnostic system.CHAPTER TEN: ELECTRICAL SYSTEM Electrical component replacement / Electrical connectors / Negative battery cable / Charging system / Stator / Voltage regulator / rectifier / Ignition system / Spark plug / Direct ignition coil / Pickup coil Crankshaft position sensor / Ignition control unit / engine control unit / Starting system / Starting circuit cutoff relay / Starter / Starter relay / Light bulbs / Headlight / Auxiliary light (Europe models) / Headlight relay / Meter assembly / Taillight assembly / License plate light (2001-on models) / Position light / Turn signals / Neutral indicator light / Oil level warning light / Oil level switch / Oil level relay (1999-2000 models) / Fuel level indicator light / Fuel sender / Horn / Clock / Speedometer / Speed sensor / Diagnostic system / Switches / Fuses.CHAPTER ELEVEN: COOLING SYSTEM Cooling system inspection / Hoses and hose clamps / Coolant reservoir / Radiator / Radiator fan / Thermo switch (carbureted models) / Radiator fan relay (fuel injected models) / Temperature sensor thermostat / Water pump / Oil cooler / Carburetor heater system / Fast idle plunger (fuel injected models).CHAPTER TWELVE: WHEELS and TIRES Motorcycle stand / Brake rotor protection / Wheel inspection / Front wheel / Front hub / Front wheel bearings / Rear wheel / Rear hub / Rear wheel bearing replacement / Wheel sprocket / Wheel balance / Tires.CHAPTER THIRTEEN: FRONT SUSPENSION and STEERING Front fork / Handlebar / Steering head / Steering head bearing races / Steering stem bearing replacementCHAPTER FOURTEEN: REAR SUSPENSION and DRIVE CHAIN Shock absorber / Rear suspension linkage / Swing arm / Bearing replacement / Drive chain.CHAPTER FIFTEEN: BRAKES Brake service / Preventing brake fluid damage / Brake bleeding / Brake fluid draining / Brake pad inspection / Front brake caliper / Front master cylinder / Rear brake caliper / Rear brake master cylinder / Brake disc / Brake hose replacement / Brake pedal / footrest assembly.CHAPTER SIXTEEN: FRAME andD BODY Rider's seat / Passenger seat / Body panel fasteners / Fairing service / Lower fairing / Console panel / Side fairing / Side cover / Windshield / Mirror / Front fairing / Tail cover / Rear fender (2001-on models) / Front fender / Passenger footpeg / Sidestand.INDEX / COLOR WIRING DIAGRAMSClymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and illustrations guide you through every job, from basic maintenance and troubleshooting, to complete teardown and rebuild.
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