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Yamaha YZF-R6 Repair Manual 1999-2004
 This repair and service manual covers Yamaha YZF-R6 sportbikes, 1999-2004.
Table of Contents
QUICK REFERENCE DATA
CHAPTER 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 replacement
CHAPTER 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 DIAGRAMS
Clymer 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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PRODUCT DETAILS:- Publisher: Clymer Manuals — 2004
- Author: Clymer Staff
- Binding: Paperback — 7 x 10¾ inches
- Pages: 545 — Over 1000 b&w photos and diagrams
- ISBN: 9780892879069
Yamaha YZF-R6 Repair Manual 1999-2004 |
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