Yamaha YZF-R6 99 Bedienungsanleitung

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

MOTORCYCLE IDENTIFICATION GEN

INFO

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER

Thevehicleidentificationnumber 1isstamped

into the right side of the steering head pipe.

EB100020

MODEL CODE

The model code label 1is affixed to the frame.

This information will be needed to order spare

parts.

1-2

IMPORTANT INFORMATION GEN

INFO

EB102000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DIS-

ASSEMBLY

1. Beforeremovalanddisassembly, removeall

dirt, mud, dust, and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to “SPECIAL TOOLS”.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have been

“mated” through normal wear. Mated parts

mustalwaysbe reused orreplacedasan as-

sembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of disas-

sembly. This will speed up assembly and al-

low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB102010

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs.

Otherbrandsmay be similar infunctionandap-

pearance, but inferior in quality.

EB102020

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals, and O-rings. All gasket sur-

faces, oil seal lips, and O-rings must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

1-3

IMPORTANT INFORMATION GEN

INFO

CAUTION:

USING A DYNAMOMETER

The YZF-R6 has a carbon muffler that may

change color when exposed to high tempera-

tures. Therefore, when using a dynamometer

always use a fan to cool the muffler.

EB102030

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

1andcotterpins.Afterthe boltornuthasbeen

tightenedto specification,bendthelockwasher

tabs and the cotter pin ends along a flat of the

bolt or nut.

EB102040

BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-

ible. When installing oil seals, lubricate the

oil seal lips with a light coat of lithium soap

base grease. Oil bearings liberally when

installing, if appropriate.

1Oil seal

Donot spinthebearing withcompressedair

because this will damage the bearing sur-

faces.

1Bearing

EB102050

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips. Al-

ways replace piston pin clips after one use.

When installing a circlip 1, make sure that the

sharp-edged corner 2is positioned opposite

the thrust 3that the circlip receives.

4Shaft

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