Yamaha 2001 YZF-R6 User manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R62001.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementary
Service Manual together with the following manual.
YZF-R6 ’99 SERVICE MANUAL: 5EB1-AE1
YZF-R6 (L) 2000 SUPPLEMENTARY SERVICE MANUAL: 5EB1-AE2
YZF-R6 2001
SUPPLEMENTARY
SERVICE MANUAL
2000 by Yamaha Motor Co., Ltd.
First Edition, September 2000
All rights reserved.
Any reproduction or 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha
motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycles
repair.
Repairsattemptedbyanyonewithoutthisknowledgearelikelytorenderthemotorcyclesunfitfor use.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
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 Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
FailuretofollowWARNINGinstructionscouldresultinsevere injuryordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

7
2143
8
6
5
YP002000 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanationsofallinstallation,removal,disassembly,assembly,repairandinspectionproceduresare
laid 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” on the following page.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic Inspections 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.)
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 (see “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-
tial0ly.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
15
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELEC
CHK
ADJ
TRBL
SHTG
16 17
COOL
CHAS
EB003000
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustment
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 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
23 Apply molybdenum disulfide grease
Symbols 24 to 25 intheexplodeddiagramsindi-
cate the following:
24 Apply locking agent (LOCTITE)
25 Use new one

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 8. . . . . .
CHASSIS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 10. . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE TIRES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS
SWINGARM AND DRIVE CHAIN 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
YZF-R6 WIRING DIAGRAM

–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5MT1 (N) (D) (B) (GB) (GR) (DK) (NL) (S) (I) (E)
5MT2 (N) (D) (A) (SF)
5MT3 (F)
5MT4 (AUS) (NZ)




Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2025 mm (except for N, S, F, AUS, NZ)
2080 mm (for N, S, F, AUS, NZ)
690 mm
1105 mm
820 mm
1380 mm
135 mm
3400 mm








Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
186 kg
167 kg
375 kg




–2–
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap
clearance
Chain drive (right)
23.000 23.021 mm
22.967 22.980 mm
0.028 0.064 mm



0.08 mm
Carburetors
Model (manufacturer) quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Starter jet 1
Starter jet 2
Butterfly valve size
Fuel level (below the line on the
float chamber)
CVRD37 (KEIHIN) 4
6 8 mm
5EB00, 5EB200 (G), 5EB300 (F)
Carburetors 1 and 4: #152
Carburetors 2 and 3: #148
#110
Carburetors 1 and 4: N7RA
Carburetors 2 and 3: N7SA
2.6
#110
0.9
#38
0.8
0.8
0.8
1-1/2 2
1.2
#50
0.6
#110
17.5 18.5 mm
















–3–
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 189 kg
High-speed riding
Min. tire tread depth
Tubeless
120/60ZR17 (55W)
MICHELIN Pilot SPORT B
DUNLOP D207F.J
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)







1.6 mm
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 189 kg
High-speed riding
Min. tire tread depth
Tubeless
180/55 ZR17 (73 W)
MICHELIN Pilot SPORT B
DUNLOP D207.N
250 kPa (2.5 kg/cm2, 2.5 bar)
290 kPa (2.9 kg/cm2, 2.9 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)






1.6 mm
Drive chain
Model (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section
532ZLV KAI (DID)
116
40 50 mm
150.1 mm





–4–
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
C.D.I.
10_BTDC at 1300 r/min
55_BTDC at 5250 r/min
Throttle position sensor and electrical
248 372 Ω/Gy-B
F8T383 (MITSUBISHI)
SSS
SSS
SSS
SSS
SSS
SSS
Battery
Battery type
Battery voltage/capacity GT9B-4
12 V/8 AH
SSS
SSS
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
License plate light
Meter light
12 V 60 W/55 W 2
12 V 5 W 2
13.5 V 6.1 W/1 W 20 (LED)
12 V 21 W 4
12 V 5 W 1
12 V 1.4 W 2
SSS
SSS
SSS
SSS
Sidestand relay
Model
Coil resistance G8R-30Y-M
162 198 Ω
SSS
SSS
Fuel pump relay model (manufacturer)
Resistance G8R-30Y-M (OMRON) 162 198 Ω
SSS
Fuses (amperage quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Backup fuse (odometer)
Reserve
30 A 1
20 A 1
20 A 1
15 A 1
7.5 A 1
7.5 A 1
30 A 1
20 A 1
15 A 1
7.5 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–5–
TIGHTENING TORQUES SPEC
ENGINE TIGHTENING TORQUES
Item Fastener Thread
size
Q’ty Tightening
torque Remarks
s
i
ze
Qy
Nm mkg
Cap bolt (timing chain tensioner)
Neutral switch Bolt Screw M6 M6 1 27 20 0.7 2.0

–6–
CABLE ROUTING SPEC
A Fasten the battery box and starter motor lead with a plastic clamp.
B Fasten thewire positiveleadand startermotor leadwithclamp atthe
end of the cover of the battery positive terminal.
The end of the clamp is facing frontward.
C Route the under of the CDI unit coupler.
D Clamp the lead at the rear of the two holes.
E Route the leads into the hole.
F Route the lead along the inside of the two ribs.
G Routethelicenseplatelightleadandtaillightleadalongtheoutsideof
the battery box so that the leads do not get caught between the rib of
the battery box and the fender.
1 Reservoir tank
2 Fuse box
3 Tool kit
4 Wire minus lead
5 Wire harness
6 Battery box
7 Frame
EB206000
CABLE ROUTING

–7–
O Fasten the main harness, ground lead and battery
box with a plastic clamp.
P The end of the clamp is facing upward.
Q The end of the clamp is facing upward.
R Licence and flasher light sub harness on the
taillight unit.
S Licence and flasher light sub harness on the
taillight unit.
T Clamp the leads.
U Store the ends of all leads at the inside of the rib.
V Fasten the licence light lead. And bend the licence
light lead.
W Fasten the flasher light lead. And bend the flasher
light lead.
CABLE ROUTING SPEC
H Routetheseatlockcableintotheholeoftheframe.
Mount the cable so that the side covered with a
cable protector up the end is positioned at rear.
I Fasten the seat lock cable with a steel clamp.
J Do not fasten the seat lock cable.
K Routethewirenegativeleadunderthestarterrelay
lead.
L Fasten the main harness, starter relay lead and
wire negative lead with a plastic clamp.
M Route the wire negative lead under the main
harness.
N Position the wire negative lead coupler under the
main harness.

–8–
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS CHK
ADJ
NOTE:
EB300000 PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
The annual checks must beperformed every year, except if a kilometer-based maintenance is
performed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
ANNUAL
CHECK
1 * Fuel line Check fuel hoses for cracks or damage. √ √ √ √ √
2 * Fuel filter Check condition. √ √
3Spark plu
g
s
Check condition.
Clean and regap. √ √
3
Spark
pl
u
gs
Replace. √ √
4 * Valves Check valve clearance.
Adjust. Every 40,000 km
5
Air filter element
Clean. √ √
5Air filter element Replace. √ √
6 Clutch Check operation.
Adjust. √ √ √ √ √
7 * Front brake
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE) √ √ √ √ √ √
7
Front
brake
Replace brake pads. Whenever worn to the limit
8 * Rear brake
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE) √ √ √ √ √ √
8
Rear
brake
Replace brake pads. Whenever worn to the limit
9
*
Brake hoses
Check for cracks or damage. √ √ √ √ √
9 * Brake hoses Replace (See NOTE) Every 4 years
10 * Wheels Check runout and for damage. √ √ √ √
11 * Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√ √ √ √
12 * Wheel bearings Check bearing for looseness or damage. √ √ √ √
13
*
Swingarm
Check operation and for excessive play. √ √ √ √
13 * Swingarm Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chain
Check chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.
Every 1,000 km and after washing
the motorcycle or riding in the rain.
15 *Steering bearings Check bearing play and steering for roughness. √ √ √ √ √
Lubricate with lithium-soap-based grease. Every 20,000 km
16 *Chassis fasteners Make sure that all nuts, bolts and screws are properly
tightened. √ √ √ √ √

–9–
INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS CHK
ADJ
NOTE:
NO
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
ANNUAL
CHECK
17 Sidestand SCheck operation.
SLubricate. √ √ √ √ √
18 * Sidestand switch SCheck operation. √ √ √ √ √ √
19 * Front fork SCheck operation and for oil leakage. √ √ √ √
20 * Rear shock absorber
assembly SCheck operation and shock absorber for oil leakage. √ √ √ √
21
*
Rear suspension
relay arm and SCheck operation. √ √ √ √
21 *
relay
arm
and
connecting arm
pivoting points SLubricate with lithium-soap-based grease. √ √
22 * Carburetors SCheck starter (choke) operation.
SAdjust engine idling speed and synchronization. √ √ √ √ √ √
23 Engine oil SChange. √ √ √ √ √ √
24 Engine oil filter
cartridge SReplace. √√√
25
*
Cooling system
SCheck coolant level and vehicle for coolant leakage. √ √ √ √ √
25 * Cooling system SChange. Every 3 years
26 Moving parts and
cables SLubricate. √ √ √ √ √
27 * Lights, signals and
switches
SCheck operation.
SAdjustheadlight beam. √ √ √ √ √ √
EAU03541
DThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.
DHydraulic brake service
SRegularly check and, if necessary, correct the brake fluid level.
SEvery two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
SReplace the brake hoses every four years and if cracked or damaged.

–10–
CHECKING THE BRAKE FLUID LEVEL CHK
ADJ
A
B
NOTE:
WARNING
CAUTION:
NOTE:
CHASSIS
EB304020
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
Make sure that the motorcycle is upright.
2. Check:
brake fluid level
Below theminimum levelmark aAdd the
recommended brake fluid to the proper lev-
el.
Recommended brake fluid
DOT 4
AFront brake
BRear brake
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
In order toensure a correctreading of thebrake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal.

–11–
CHECKING THE TIRES CHK
ADJ
WARNING
WARNING
EB304170
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Measure:
tire pressure
Out of specification Regulate.
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil
and a full
fuel tank)
186 kg
Maximum
load* 189 kg
Cold tire
pressure Front Rear
Up to 90 kg
load*
250 kPa
(2.5 kg/cm2,
2.5 bar)
250 kPa
(2.5 kg/cm2,
2.5 bar)
90 kg
maximum
load*
250 kPa
(2.5 kg/cm2,
2.5 bar)
290 kPa
(2.9 kg/cm2,
2.9 bar)
High-speed
riding
250 kPa
(2.5 kg/cm2,
2.5 bar)
250 kPa
(2.5 kg/cm2,
2.5 bar)
* total of cargo, rider, passenger and accesso-
ries
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.

–12–
CHECKING THE TIRES CHK
ADJ
A B
WARNING
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth
1.6 mm
1Tire tread depth
2Side wall
Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire failure
and personal injury from sudden deflation.
When using a tube tire, be sure to install the
correct tube.
Alwaysreplaceanewtubetireandanewtube
as a set.
To avoid pinching the tube, make sure that
the wheel rim band and tube are centered in
the wheel groove.
Patching a punctured tube is not recom-
mended.Ifitisabsolutelynecessarytodoso,
use great care and replace the tube as soon
as possible with a good quality replacement.
ATire BWheel
Tube wheel Tube tire only
Tubeless wheel Tube or tubeless
tire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one ap-
proved by Yamaha is used on this
motorcycle.
Front tire
Manufacturer Size Model
MICHELIN 120/60 ZR17
(55W) Pilot SPORT B
DUNLOP 120/60 ZR17
(55W) D207FJ