Yamaha YZF-R6 2000 Service Manual Download | Manualshive

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–13–

Order

Job / Part

Q’ty

Remarks

1
2
3
4
5
6
7

Removing the drive sprocket
Reserve tank
Locknut
Shift rod
Shift arm
Drive sprocket cover
Nut
Lock washer
Drive sprocket

2
1
1
1
1
1
1

Remove the parts in the order listed.
Refer to “CHANGING THE COOLANT”

For installation reverse the remove
procedure.

10 Nm (1.0 m

kg)

70 Nm (7.0 m

kg)

ENGINE

ENG

EAS00190

OVERHAULING THE ENGINE

ENGINE

DRIVE SPROCKET

«
...
19
20
21
22
23
...
»

Summary of Contents for YZF-R6 2000

Page 1: ......

Page 2: ......

Page 3: ... procedures it is necessary to use this Supplemen tary Service Manual together with the following manual YZF R6 99 SERVICE MANUAL 5EB1 AE1 YZF R6 L 2000 SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co Ltd First Edition August 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...prove 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 Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Sym...

Page 5: ...pections and Adjustments where the sub section title s appear In Chapter 3 Periodic Inspections and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 N...

Page 6: ...ooting 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 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearin...

Page 7: ...AND ADJUSTMENT 12 CHASSIS 12 ADJUSTING THE CLUTCH CABLE FREE PLAY 12 OVERHAULING THE ENGINE 13 ENGINE 13 DRIVE SPROCKET 13 ENGINE 14 INSTALLING THE ENGINE 15 PICKUP COIL AND PICKUP ROTOR 16 INSTALLING THE PICKUP COIL ROTOR 16 CHASSIS 18 REAR SHOCK ABSORBER ASSEMBLY 18 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 19 SWINGARM AND DRIVE CHAIN 20 INSTALLING THE SWINGARM 22 YZF R6 L 2000 WIRING DIAGRAM ...

Page 8: ......

Page 9: ...this will help prevent damage caused by the use of inappropri ate tools or improvised techniques When placing an order refer to the list provided below to avoid any mistakes Tool No Tool name Function Illustration Pivot shaft wrench 90890 01471 Adapter 90890 01476 Pivot shaft wrench Adapter This tool is used to loosen or tighten the pivot adjust bolt and engine mount adjust bolt ...

Page 10: ... bearing clearance 0 028 0 052 mm Carburetors ID mark Jet needle Pilot screw turns out 5EB1 1 4 N7RA 2 3 N7SA 1 1 2 2 ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system Ignition timing 10 BTDC at 1300 r min Ignition coils Primary coil resistance Secondary coil resistance 0 204 0 276 Ω 8 5 11 5 Ω Oil level switch model manufacturer 5EB DENSO Fuel pump relay model manufacturer Resistance ...

Page 11: ...HTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Thread size Tightening torque Remarks Nm m kg Engine mounting adjusting bolts Rear shock absorber and frame Pivot shaft adjust bolt M10 7 40 5 0 7 4 0 0 5 ...

Page 12: ...ect relay D Don t kink E Put coupler into stay F Make sure the connector is out off the bottom end of front cowling G Route the right handlebar switch lead in front of the front fork inner tube H Route the throttle cables between the brake hose and right handlebar switch lead I Route the wire harness through under the left handlebar switch lead and starter cable J Fasten the left handlebar switch ...

Page 13: ... of band to for ward Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie Cut the end of locking tie And then route the horn lead under the brake hose and clamp it to the under cover ...

Page 14: ...ROUTING SPEC 1 Fuel pump lead 2 Pickup coil lead 3 Thermo switch 4 Clutch cable 5 Rear brake switch lead A Route the ignition coil lead and thermo switch lead over the heat protector plate B Route the clutch cable through the guide on the frame C Position the face of steel clip up ward D Route the coolant hoses 3 hoses under the heat protector plate E Fasten the clutch cable to the coolant hose pr...

Page 15: ...r lead connector be tween radiator hose and wireharness CABLE ROUTING SPEC C Don t touch the wireharness with the throttle cable pully Route the wire harness under the radiator hose D Route the fuel tank breather hose and fuel tank drain hose between reservor tank breather hose and wireharness E Route the wireharness through the slite of rear fender F Route the seat lock cable outside of the wire ...

Page 16: ...gh the holder of the hook and the side stand Don t kink K When the sidestand is used L The bottom end of the drain hose comes here M Fasten the sidestand switch lead and oil level sen sor lead with a band N Route the reservoir tank breather hose oil level switch lead and sidestand switch lead through the holder O Route the starter cable between wireharness and left handlebar switch lead CABLE ROUT...

Page 17: ... and handlebar switch leads left and right over the heat protector D Route the radiator hoses under the heat protector 1 Throttle cable 2 Right handlebar switch lead 3 Thermo unit lead 4 Reservoir tank breather hose 5 Carburetor idle adjusting cable 6 Pickup coil connector 7 Neutral switch connector 8 Rear brake switch connector 9 Right handlebar switch connectors 10 Throttle position sensor conne...

Page 18: ...r motor lead to the rear fender with a band K Fasten the battery positive lead and starter mo tor lead with a band CABLE ROUTING SPEC L Position the rear turn signal light connectors left and right and taillight connector between the rear fender and taillight bracket M Install the seatlock cable to the frame bracket with protector side N Fasten the lead through under the wireharness and oil relay ...

Page 19: ...er hose must be located over the groove G Reservoir tank breather hose above the wire harness T Insert the projection of the band wireharness into the hole of the frame U 1 Speed sensor 2 AC magneto connector 3 Sidestand switch connector 4 Oil level switch connector 5 Meter ground lead V Fasten the leads above 1 5 and starter motor lead with a band W Route the fuel tank drain hose and fuel tank br...

Page 20: ...ained Direction Clutch cable free play is increased Direction Clutch cable free play is decreased If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side Engine side a Loosen the locknut 2 b Turn the adjusting nut 3 in direction c or d until the specified clutch cable free play is ob tained Direction Clutch cable free p...

Page 21: ...t Shift rod Shift arm Drive sprocket cover Nut Lock washer Drive sprocket 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to CHANGING THE COOLANT For installation reverse the remove procedure 10 Nm 1 0 m kg 70 Nm 7 0 m kg ENGINE ENG EAS00190 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET ...

Page 22: ...bolts 4 2 2 2 2 2 2 Remove the parts in the order listed For installation reverse the removal procedure NOTE Use the pivot shaft wrench to loosen the engine mounting adjust bolt NOTE Place a suitable stand under the frame and engine Refer to INSTALLING THE ENGINE 45 Nm 4 5 m kg 55 Nm 5 5 m kg 24 Nm 2 4 m kg 24 Nm 2 4 m kg 13 Nm 1 3 m kg 38 Nm 3 8 m kg 55 Nm 5 5 m kg 7 Nm 0 7 m kg ENGINE ...

Page 23: ...rear mounting bolt threads with lithium soap base grease Do not fully tighten the nuts and bolts 2 Tighten self locking nut front mounting bolts button head bolt pinch bolt M8 M6 engine mounting adjusting bolts Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mount ing adjust bolt Pivot shaft wrench 90890 01471 Pivot shaft wrench adapter 90890 01476 3 Install dri...

Page 24: ...il rotor 2 Tighten pickup coil rotor bolt 1 While holding the generator rotor 2 with the sheave holder 3 tighten the pickup coil rotor bolt Sheave holder 90890 01701 3 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 4 Install pickup coil cover When installing the pickup coil cover align the timing chain guide intake side pin 1 of the with the hole 2 in the pickup co...

Page 25: ... 17 PICKUP COIL AND PICKUP ROTOR ENG 5 Install Clutch cable holder Clutch cable Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 ...

Page 26: ...orber assembly Coller oil seal bearing Relay arm Coller oil seal bearing Connecting arm Coller oil seal bearing 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 2 1 Remove the parts in the order listed Refer to REMOVING THE REAR WHEEL Refer to REMOVING THE REAR SHOCK ABSORBER ASSEMBLY For installation reverse the removal procedure 40 Nm 4 0 m kg 40 Nm 4 0 m kg 40 Nm 4 0 m kg REAR SHOCK ABSORBER ASSEMBLY ...

Page 27: ...he motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove rear wheel rear shock absorber assembly lower bolt 1 relay arm to swingarm bolt 2 While removing the rear shock absorber as sembly lower bolt hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock ab...

Page 28: ... Adjusting bolt locknut Drive chain guard Rear fender Flap Pivot shaft nut washer Pivot shaft Swingarm 2 2 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE in chapter 4 Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Refer to REAR SHOCK ABSORBER ASSEMBLY 95 Nm 9 5 m kg 6 Nm 0 6 m kg 6 Nm 0 6 m kg 5 Nm 0 5 m kg EAS00700 SWINGARM AND DRIVE CHAIN ...

Page 29: ...6 17 Pivot shaft adjust bolt Drive chain Dust cover Oil seal Bush Shim Drive chain guide Bush Left bearing Right bearing 2 1 1 1 1 1 1 1 1 1 Refer to REMOVING INSTALLING THE SWINGARM For installation reverse the removal procedure 95 Nm 9 5 m kg 6 Nm 0 6 m kg 6 Nm 0 6 m kg 5 Nm 0 5 m kg ...

Page 30: ...aft washer pivot shaft adjust bolt 1 pivot shaft nut Use the pivot shaft wrench 2 and pivot shaft wrench adapter 3 to tighten the pivot adjust bolt Pivot shaft wrench 90890 01471 Pivot shaft wrench adapter 90890 01476 3 Install rear shock absorber assembly rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY and REAR WHEEL 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter...

Page 31: ... 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 Illumination light 29 Speed sensor 30 Neutral switch 31 Thermo unit 32 Fuel sender 33 Right handlebar switch 34 Front brake light switch 35 Light ...

Page 32: ... signal switch 44 Horn 45 Flasher relay 46 Headlight relay Hi 47 Headlight relay Lo 48 Headlight 50 Front turn signal light left 51 Front turn signal light right 52 Rear turn signal light left 53 Rear turn signal light right 54 Tail brake light 55 Oil level relay 56 Oil level switch 57 Rear brake light switch 58 Fuse ignition 60 Fuse signaling system 61 Fuse headlight 62 Fuse radiator fan motor 63...

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