Yamaha YZFR6X(C) 2008 Service Manual

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Yamaha YZFR6X(C) 2008 Service Manual - PDF DOWNLOAD

FILE DETAILS:

Language : English
Pages : 434
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

2008 YZFR6X(C) R6 Service Manual 1
Important Manual Information 3
How To Use This Manual 4
Symbols 5
Table Of Contents 7
General Information 9
Identification 10
Vehicle Identification Number 10
Model Label 10
Features 11
Outline Of The FI System 11
FI System 12
YCC-T (Yamaha Chip Controlled Throttle) 13
YCC-I (Yamaha Chip Controlled Intake) 13
Instrument Functions 17
Important Information 21
Preparation For Removal And Disassembly 21
Replacement Parts 21
Gaskets, Oil Seals And O-Rings 21
Lock Washers/Plates And Cotter Pins 21
Bearings And Oil Seals 22
Circlips 22
Checking The Connections 23
Special Tools 24
Specifications 31
General Specifications 32
Engine Specifications 33
Chassis Specifications 40
Electrical Specifications 43
Tightening Torques 46
General Tightening Torque Specifications 46
Engine Tightening Torques 47
Chassis Tightening Torques 51
Lubrication Points And Lubricant Types 55
Engine 55
Chassis 56
Lubrication System Chart And Diagrams 58
Engine Oil Lubrication Chart 58
Lubrication Diagrams 60
Cooling System Diagrams 72
Cable Routing 76
Periodic Checks And Adjustments 93
Periodic Maintenance 96
Introduction 96
Periodic Maintenance Chart For The Emission Control System 96
General Maintenance And Lubrication Chart 96
Engine 99
Adjusting The Valve Clearance 99
Synchronizing The Throttle Bodies102
Adjusting The Throttle Cable Free Play103
Checking The Spark Plugs104
Measuring The Compression Pressure104
Checking The Engine Oil Level106
Changing The Engine Oil106
Measuring The Engine Oil Pressure108
Adjusting The Clutch Lever Free Play109
Replacing The Air Filter Element109
Checking The Throttle Body Joints110
Checking The Fuel Line111
Checking The Crankcase Breather Hose111
Checking The Exhaust System111
Adjusting The Exup Cables112
Checking The Coolant Level113
Checking The Cooling System114
Changing The Coolant114
Chassis117
Adjusting The Front Disc Brake117
Adjusting The Rear Disc Brake117
Checking The Brake Fluid Level118
Checking The Front Brake Pads118
Checking The Rear Brake Pads118
Checking The Front Brake Hoses119
Checking The Rear Brake Hoses119
Adjusting The Rear Brake Light Switch119
Bleeding The Hydraulic Brake System120
Adjusting The Shift Pedal121
Adjusting The Drive Chain Slack121
Lubricating The Drive Chain122
Checking And Adjusting The Steering Head122
Checking The Front Fork124
Adjusting The Front Fork Legs124
Adjusting The Rear Shock Absorber Assembly126
Checking The Tires128
Checking The Wheels130
Checking And Lubricating The Cables130
Lubricating The Levers130
Lubricating The Pedals130
Lubricating The Sidestand130
Lubricating The Rear Suspension130
Electrical System131
Checking And Charging The Battery131
Checking The Fuses131
Replacing The Headlight Bulbs131
Adjusting The Headlight Beams131
Chassis133
General Chassis136
Front Wheel141
Removing The Front Wheel143
Disassembling The Front Wheel143
Checking The Front Wheel143
Assembling The Front Wheel144
Adjusting The Front Wheel Static Balance144
Checking The Front Brake Discs145
Installing The Front Wheel (Front Brake Discs)145
Rear Wheel147
Removing The Rear Wheel150
Disassembling The Rear Wheel150
Checking The Rear Wheel150
Checking The Rear Brake Caliper Bracket150
Checking The Rear Wheel Drive Hub150
Checking And Replacing The Rear Wheel Sprocket150
Assembling The Rear Wheel151
Adjusting The Rear Wheel Static Balance151
Checking The Rear Brake Disc151
Installing The Rear Wheel (Rear Brake Disc)151
Front Brake153
Introduction158
Checking The Front Brake Discs158
Replacing The Front Brake Pads159
Removing The Front Brake Calipers160
Disassembling The Front Brake Calipers160
Checking The Front Brake Calipers161
Assembling The Front Brake Calipers161
Installing The Front Brake Calipers161
Removing The Front Brake Master Cylinder162
Checking The Front Brake Master Cylinder163
Assembling The Front Brake Master Cylinder163
Installing The Front Brake Master Cylinder163
Rear Brake165
Introduction170
Checking The Rear Brake Disc170
Replacing The Rear Brake Pads170
Removing The Rear Brake Caliper171
Disassembling The Rear Brake Caliper171
Checking The Rear Brake Caliper172
Assembling The Rear Brake Caliper172
Installing The Rear Brake Caliper173
Removing The Rear Brake Master Cylinder174
Checking The Rear Brake Master Cylinder174
Assembling The Rear Brake Master Cylinder174
Installing The Rear Brake Master Cylinder174
Handlebars176
Removing The Handlebars178
Checking The Handlebars178
Installing The Handlebars178
Front Fork180
Removing The Front Fork Legs182
Disassembling The Front Fork Legs182
Checking The Front Fork Legs183
Assembling The Front Fork Legs184
Installing The Front Fork Legs188
Steering Head190
Removing The Lower Bracket192
Checking The Steering Head192
Installing The Steering Head192
Rear Shock Absorber Assembly194
Handling The Rear Shock Absorber195
Disposing Of A Rear Shock Absorber195
Removing The Rear Shock Absorber Assembly195
Checking The Rear Shock Absorber Assembly196
Checking The Connecting Arm And Relay Arm196
Installing The Relay Arm196
Installing The Rear Shock Absorber Assembly196
Swingarm198
Removing The Swingarm200
Checking The Swingarm200
Installing The Swingarm201
Chain Drive203
Removing The Drive Chain204
Checking The Drive Chain204
Checking The Drive Sprocket205
Checking The Rear Wheel Sprocket205
Checking The Rear Wheel Drive Hub205
Installing The Drive Chain205
Engine207
Engine Removal210
Installing The Engine215
Camshafts216
Removing The Camshafts218
Checking The Camshafts218
Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides220
Checking The Timing Chain Tensioner220
Installing The Camshafts221
Cylinder Head224
Removing The Cylinder Head225
Checking The Cylinder Head225
Installing The Cylinder Head225
Valves And Valve Springs227
Removing The Valves228
Checking The Valves And Valve Guides228
Checking The Valve Seats230
Checking The Valve Springs232
Checking The Valve Lifters233
Installing The Valves233
Generator And Starter Clutch235
Removing The Generator236
Checking The Starter Clutch236
Installing The Starter Clutch236
Installing The Generator237
Pickup Rotor238
Removing The Pickup Rotor239
Installing The Pickup Rotor239
Electric Starter241
Checking The Starter Motor243
Assembling The Starter Motor244
Clutch245
Removing The Clutch249
Checking The Friction Plates249
Checking The Clutch Plates249
Checking The Clutch Springs250
Checking The Clutch Housing251
Checking The Clutch Boss251
Checking The Pressure Plate251
Checking The Primary Drive Gear251
Checking The Primary Driven Gear251
Checking The Pull Lever Shaft And Pull Rod252
Checking The Oil Pump Drive Sprocket And Oil Pump Drive Chain252
Installing The Clutch252
Shift Shaft255
Checking The Shift Shaft256
Checking The Stopper Lever256
Installing The Shift Shaft256
Oil Pump257
Removing The Oil Pan260
Checking The Oil Pump260
Checking The Relief Valve260
Checking The Oil Pipes261
Checking The Oil Strainer261
Assembling The Oil Pump261
Installing The Oil Pan261
Crankcase262
Disassembling The Crankcase264
Checking The Crankcase264
Checking The Oil Pipe264
Checking The Timing Chain264
Assembling The Crankcase264
Connecting Rods And Pistons266
Removing The Connecting Rods And Pistons267
Checking The Cylinders And Pistons267
Checking The Piston Rings268
Checking The Piston Pins269
Checking The Connecting Rods270
Installing The Connecting Rods And Pistons271
Crankshaft274
Removing The Crankshaft Journal Bearings275
Checking The Oil Nozzles275
Checking The Crankshaft And Connecting Rods275
Installing The Crankshaft277
Transmission278
Removing The Transmission282
Checking The Shift Forks282
Checking The Shift Drum Assembly282
Checking The Transmission283
Assembling The Main Axle And Drive Axle283
Installing The Transmission284
Cooling System287
Radiator288
Checking The Radiator289
Installing The Radiator289
Oil Cooler291
Checking The Oil Cooler292
Installing The Oil Cooler292
Thermostat293
Checking The Thermostat294
Installing The Thermostat294
Water Pump295
Disassembling The Water Pump297
Checking The Water Pump297
Assembling The Water Pump298
Installing The Water Pump299
Fuel System301
Fuel Tank302
Removing The Fuel Tank303
Removing The Fuel Pump303
Checking The Fuel Pump Body303
Checking The Fuel Pump Operation303
Installing The Fuel Pump303
Installing The Fuel Tank304
Air Filter Case305
Removing The Fuel Hose (Primary Injector Fuel Rail Side And Secondary Injector Fuel Rail Side)307
Removing The Air Filter Case307
Checking The Secondary Injectors307
Removing The Intake Funnel307
Checking The Intake Funnel307
Installing The Intake Funnel308
Checking The Intake Funnel Operation308
Installing The Air Filter Case308
Installing The Fuel Hose (Primary Injector Fuel Rail Side And Secondary Injector Fuel Rail Side)308
Throttle Bodies310
Checking The Primary Injectors313
Checking The Throttle Bodies313
Checking The Rollover Valve (For California Only)313
Checking The Fuel Pressure313
Adjusting The Throttle Position Sensor (For Throttle Valves)314
Adjusting The Throttle Position Sensor (For Throttle Cable Pulley)314
Installing The Throttle Body Joints315
Air Induction System316
Checking The Air Induction System320
Electrical System321
Ignition System324
Circuit Diagram324
Engine Stopping Due To Sidestand Operation326
Troubleshooting328
Electric Starting System330
Circuit Diagram330
Starting Circuit Cut-Off System Operation332
Troubleshooting334
Charging System336
Circuit Diagram336
Troubleshooting338
Lighting System340
Circuit Diagram340
Troubleshooting342
Signaling System344
Circuit Diagram344
Troubleshooting346
Cooling System352
Circuit Diagram352
Troubleshooting354
Fuel Injection System356
Circuit Diagram356
ECU Self-Diagnostic Function358
Self-Diagnostic Function Table359
Troubleshooting Method362
Diagnostic Mode363
Troubleshooting Details372
Fuel Pump System396
Circuit Diagram396
Troubleshooting398
Electrical Components400
Checking The Switches404
Checking The Bulbs And Bulb Sockets407
Checking The Fuses408
Checking And Charging The Battery409
Checking The Relays412
Checking The Turn Signal/hazard Relay413
Checking The Relay Unit (diode)414
Checking The Ignition Coils415
Checking The Crankshaft Position Sensor416
Checking The Lean Angle Sensor416
Checking The Starter Motor Operation416
Checking The Stator Coil417
Checking The Rectifier/regulator417
Checking The Horn418
Checking The Oil Level Switch418
Checking The Fuel Sender419
Checking The Speed Sensor419
Checking The Radiator Fan Motors420
Checking The Coolant Temperature Sensor420
Checking The Throttle Position Sensor (for Throttle Valves)420
Checking The Throttle Position Sensor (for Throttle Cable Pulley)421
Checking The Fuel Pump421
Checking The Air Induction System Solenoid422
Checking The Atmospheric Pressure Sensor422
Checking The Cylinder Identification Sensor423
Checking The Intake Air Pressure Sensor423
Checking The Air Temperature Sensor424
Troubleshooting425
Troubleshooting426
General Information426
Starting Failures426
Incorrect Engine Idling Speed426
Poor Medium-and-High-Speed Performance427
Poor Medium-and-High-Speed Performance427
Faulty Gear Shifting427
Shift Pedal Does Not Move427
Jumps Out Of Gear427
Faulty Clutch427
Overheating427
Overcooling428
Poor Braking Performance428
Faulty Front Fork Legs428
Unstable Handling428
Faulty Lighting Or Signaling System429
Wiring Diagram430
YZFR6X(C) 430
YZFR6X(C) Wiring Diagram433
YZFR6X(C) Wiring Diagram434

DESCRIPTION:

How to Use This Manual

This manual is designed to be a convenient and easy-to-read reference for mechanics. It provides comprehensive explanations of all installation, removal, disassembly, assembly, repair, and check procedures, with each step laid out in sequential order.

Manual Structure

Chapters and Sections:
- The manual is divided into chapters, and each chapter contains multiple sections.
- The current section title ("1") is displayed at the top of each page.
Sub-section Titles:
- Sub-section titles ("2") appear in smaller print than the section title.

Exploded Diagrams

Visual Assistance:
- To help identify parts and clarify procedure steps, exploded diagrams ("3") are included at the beginning of each removal and disassembly section.
Step Numbers:
- Numbers ("4") are provided in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
Symbols:
- Symbols ("5") are used to indicate parts that need lubrication or replacement. Please refer to the "SYMBOLS" section for more details.
Job Instruction Chart:
- A job instruction chart ("6") accompanies the exploded diagram. It includes the order of jobs, part names, and additional notes.
Supplemental Information:
- Jobs ("7") that require more information (such as special tools or technical data) are described sequentially within the manual.

G.B 13/03/25