Yamaha 2006 YZFR6V User manual

2006
SERVICE MANUAL
YZF-R6(V)
2C0-28197-E0

EAS20040
YZF-R6(V) 2006
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
First edition, November 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
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.
NOTE:
Designs and specifications are subject to change without notice.
EAS20080
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!
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, a bystander or a person checking or repairing the ve-
hicle.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.

EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
GM
E
BLS M
91011
12 13 14
15 16
LT New
T
R
.
.
123
456
78
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10.Gear oil
11. Molybdenum disulfide oil
12.Wheel bearing grease
13. Lithium-soap-based grease
14. Molybdenum disulfide grease
15.Apply locking agent (LOCTITE®).
16. Replace the part with a new one.

EAS20110 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
OUTLINE OF THE FI SYSTEM................................................................. 1-2
FI SYSTEM................................................................................................1-3
YCC-T (Yamaha Chip Controlled Throttle)................................................1-4
INSTRUMENT FUNCTIONS .....................................................................1-7
IMPORTANT INFORMATION .......................................................................1-12
PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-12
REPLACEMENT PARTS.........................................................................1-12
GASKETS, OIL SEALS AND O-RINGS ..................................................1-12
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-12
BEARINGS AND OIL SEALS ..................................................................1-13
CIRCLIPS ................................................................................................1-13
CHECKING THE CONNECTIONS ................................................................1-14
SPECIAL TOOLS ..........................................................................................1-15

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1”is stamped
on the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1”is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1
1

FEATURES
1-2
EAS20170
FEATURES
ET2C01025
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1
10
13
22
21
20
26 7 83 45 9 11 12
141516171819
1. Air temperature sensor
2. Engine trouble warning light
3. Air induction system solenoid
4. Throttle servo motor
5. Atmospheric pressure sensor
6. Secondary injectors
7. Primary injectors
8. Intake air pressure sensor
9. Fuel pump
10.Relay unit (fuel pump relay)
11.Lean angle sensor
12.ECU (engine control unit)
13.EXUP servo motor
14.O2sensor
15.Speed sensor
16. Coolant temperature sensor
17.Crankshaft position sensor
18.Throttle position sensor (for throttle cable
pulley)
19. Throttle position sensor (for throttle valves)
20. Spark plug
21.Ignition coil
22.Cylinder identification sensor

FEATURES
1-3
ET2C01019
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor (for throttle cable pulley), throttle position sensor (for throttle valves), coolant
temperature sensor, atmospheric pressure sensor, cylinder identification sensor, lean angle sensor,
crankshaft position sensor, intake air pressure sensor, air temperature sensor, speed sensor and O2
sensor enable the ECU to determine the injection duration. The injection timing is determined through
the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the
engine can be supplied at all times in accordance with the driving conditions.
2
19
18
B
17
15
14
13
12
A
3
1
16 411
5
C8
67
9
#3#1 #2 #4
#3#1 #2 #4
10
1. Secondary injector
2. Fuel pump
3. Primary injector
4. Cylinder identification sensor
5. ECU (engine control unit)
6. Throttle position sensor (for throttle cable
pulley)
7. Throttle position sensor (for throttle valves)
8. Speed sensor
9. Air temperature sensor
10.Lean angle sensor
11.O2sensor
12. Catalytic converter
13. Coolant temperature sensor
14.Crankshaft position sensor
15. Intake air pressure sensor
16.Throttle servo motor
17. Throttle body
18.Atmospheric pressure sensor
19.Air filter case
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
ET2C01026
YCC-T (Yamaha Chip Controlled Throttle)
Mechanism characteristics
Yamaha developed the YCC-T system employing the most advanced electronic control technologies.
Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast-
er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that produces computations of running conditions every
1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instan-
taneously calculate the ideal throttle valve opening and generate signals to operate the motor-driven
throttle valves and thus actively control the intake air volume.
The ECU contains three CPUs with a capacity about five times that of conventional units, making it pos-
sible for the system to respond extremely quickly to the slightest adjustments made by the rider. In par-
ticular, optimized control of the throttle valve opening provides the optimum volume of intake air for
easy-to-use torque, even in a high-revving engine.
Aims and advantages of using YCC-T
•Increased engine power
By shortening the air intake path, higher engine speed is possible →Increased engine power.
•Improved driveability
Air intake volume is controlled according to the operating conditions →Improved throttle response to
meet engine requirement.
Driving force is controlled at the optimal level according to the transmission gear position and engine
speed →Improved throttle control.
•Engine braking control
Due to the throttle control, optimal engine braking is made possible.
•Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated →A simple mechanism is used to maintain
a steady idle speed.
•Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
3
4
2
1
A
5
1. Throttle position sensor (for throttle cable
pulley)
2. Throttle servo motor
3. Throttle position sensor (for throttle valves)
4. Throttle valves
5. Throttle cable pulley with linkage guard
A. To throttle grip

FEATURES
1-5
YCC-T system outline
1
1
4
5
8
10
11
12
9
6
7
13
14
15
16
17
18
2
23
1. Throttle position sensor (for throttle cable
pulley)
2. Throttle servo motor
3. Throttle position sensor (for throttle valves)
4. ECU (engine control unit)
5. ETV main CPU (32 bit)
6. ETV sub CPU (16 bit)
7. FI CPU (32 bit)
8. Throttle servo motor driver
9. Throttle servo motor driver operation
sensing/shut off circuit
10.Throttle servo motor driver operation sensing
feedback/emergency stop
11.Emergency stop
12.Engine revolution (pulse signal)
13.Sensor input
14.Neutral switch
15.Crankshaft position sensor
16.Speed sensor
17.Coolant temperature sensor
18.Atmospheric pressure sensor

FEATURES
1-6
YCC-T control outline
15 M
18
17
16
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1. Throttle position sensor (for throttle cable
pulley)
2. Throttle position sensor (for throttle valves)
3. Crankshaft position sensor
4. Speed sensor
5. Coolant temperature sensor
6. Neutral switch
7. Atmospheric pressure sensor
8. Throttle position (for throttle cable pulley) (two
signals)
9. Throttle position (for throttle valves) (two
signals)
10.Engine revolution
11.Vehicle speed
12.Coolant temperature
13.Neutral/In gear
14.Atmospheric pressure
15.Throttle servo motor
16.ECU (engine control unit)
17.Base map
18.Idle speed control
19.Calculated throttle valve opening angle

FEATURES
1-7
ET2C01020
INSTRUMENT FUNCTIONS
Multi-function meter unit
WARNING
EW2C01003
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
The multi-function meter unit is equipped with
the following:
•a speedometer (which shows the riding speed)
•a tachometer (which shows engine speed)
•an odometer (which shows the total distance
traveled)
•two tripmeters (which show the distance trav-
eled since they were last set to zero)
•a fuel reserve tripmeter (which shows the dis-
tance traveled since the fuel level warning light
came on)
•a stopwatch
•a clock
•a coolant temperature display
•an air intake temperature display
•a self-diagnosis device
•a display brightness and shift timing indicator
light control mode
NOTE:
•Be sure to turn the key to “ON”before using the
“SELECT”and “RESET”buttons.
•For the U.K. only: To switch the speedometer
and odometer/tripmeter displays between kilo-
meters and miles, press the “SELECT”button
for at least one second.
Tachometer
The electric tachometer allows the rider to mon-
itor the engine speed and keep it within the ideal
power range.
When the key is turned to “ON”, the tachometer
needle will sweep once across the r/min range
and then return to zero r/min in order to test the
electrical circuit.
CAUTION:
EC2C01020
Do not operate the engine in the tachometer
red zone.
Red zone: 17500 r/min and above
Clock mode
Turn the key to “ON”.
1. Clock
2. Speedometer
3. “SELECT”button
4. “RESET”button
5. Tachometer
6. Coolant temperature display/air intake
temperature display
7. Odometer/tripmeters/fuel reserve
tripmeter/stopwatch
8. Shift timing indicator light
8
5162
3
4
7
1. Tachometer
2. Tachometer red zone
1. Clock
1
2
1

FEATURES
1-8
To set the clock:
1. Push the “SELECT”button and “RESET”but-
ton together for at least two seconds.
2. When the hour digits start flashing, push the
“RESET”button to set the hours.
3. Push the “SELECT”button, and the minute
digits will start flashing.
4. Push the “RESET”button to set the minutes.
5. Push the “SELECT”button and then release
it to start the clock.
Odometer, tripmeter, and stopwatch modes
Push the “SELECT”button to switch the display
between the odometer mode “ODO”, the tripme-
ter modes “TRIP A”and “TRIP B”and the stop-
watch mode in the following order:
TRIP A →TRIP B →ODO →Stopwatch →
TRIP A
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode “F-TRIP”and
start counting the distance traveled from that
point. In that case, push the “SELECT”button to
switch the display between the various tripme-
ter, odometer, and stopwatch modes in the fol-
lowing order:
F-TRIP →Stopwatch →TRIP A →TRIP B →
ODO →F-TRIP
To reset a tripmeter, select it by pushing the “SE-
LECT”button, and then push the “RESET”but-
ton for at least one second. If you do not reset
the fuel reserve tripmeter manually, it will reset
itself automatically and the display will return to
the prior mode after refueling and traveling 5 km
(3 mi).
Stopwatch mode
To change the display to the stopwatch mode,
select it by pushing the “SELECT”button. (The
stopwatch digits will start flashing.) Release the
“SELECT”button, and then push it again for a
few seconds until the stopwatch digits stop
flashing.
Standard measurement:
1. Push the “RESET”button to start the stop-
watch.
2. Push the “SELECT”button to stop the stop-
watch.
3. Push the “SELECT”button again to reset the
stopwatch.
Split-time measurement:
1. Push the “RESET”button to start the stop-
watch.
2. Push the “RESET”button or start switch “”
to measure split-times. (The colon “:”will start
flashing.)
3. Push the “RESET”button or start switch “”
to display the final split-time or push the “SE-
LECT”button to stop the stopwatch and dis-
play total elapsed time.
4. Push the “SELECT”button to reset the stop-
watch.
NOTE:
To change the display back to the prior mode,
push the “SELECT”button for a few seconds.
Coolant temperature display
The coolant temperature display indicates the
temperature of the coolant. Push the “RESET”
button to switch the coolant temperature display
to the air intake temperature display.
NOTE:
When the coolant temperature display is select-
ed, “C”is displayed for one second, and then the
coolant temperature is displayed.
1. Odometer/tripmeters/fuel reserve
tripmeter/stopwatch
1
1. Coolant temperature display
1

FEATURES
1-9
CAUTION:
EC2C01021
Do not operate the engine if it is overheated.
Air intake temperature display
The air intake temperature display indicates the
temperature of the air drawn into the air filter
case. Push the “RESET”button to switch the
coolant temperature display to the air intake
temperature display.
NOTE:
•Even if the air intake temperature is set to be
displayed, the coolant temperature warning
light comes on when the engine overheats.
•When the key is turned to “ON”, the coolant
temperature is automatically displayed, even if
the air intake temperature was displayed prior
to turning the key to “OFF”.
•When the air intake temperature display is se-
lected, “A”is displayed before the temperature.
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
odometer/trip meter/fuel reserve trip meter/stop-
watch display will indicate a two-digit error code
(e.g., 11, 12, 13).
If the display indicates an error code, note the
code number, and then check the vehicle. Refer
to “FUEL INJECTION SYSTEM”on page 8-33.
CAUTION:
EC2C01022
If the display indicates an error code, the ve-
hicle should be checked as soon as possible
in order to avoid engine damage.
This model is also equipped with a self-diagno-
sis device for the immobilizer system.
If any of the immobilizer system circuits are de-
fective, the immobilizer system indicator light will
flash, and then the odometer/trip meter/fuel re-
serve trip meter/stopwatch display will indicate a
two-digit error code (e.g., 51, 52, 53).
NOTE:
If the display indicates error code 52, this could
be caused by transponder interference. If this er-
ror code appears, try the following.
1. Use the code re-registering key to start the
engine.
NOTE:
Make sure there are no other immobilizer keys
close to the main switch, and do not keep more
than one immobilizer key on the same key ring!
Immobilizer system keys may cause signal inter-
ference, which may prevent the engine from
starting.
2. If the engine starts, turn it off and try starting
the engine with the standard keys.
3. If one or both of the standard keys do not start
the engine, re-register the standard keys.
If the display indicates an error code, note the
code number, and then check the vehicle. Refer
to “IMMOBILIZER SYSTEM”on page 8-77.
CAUTION:
EC2C01022
If the display indicates an error code, the ve-
hicle should be checked as soon as possible
in order to avoid engine damage.
Display brightness and shift timing indicator
light control mode
This mode cycles through five control functions,
allowing you to make the following settings in the
order listed below.
1. Air intake temperature display
1
1. Display brightness
2. Shift timing indicator light
activation/deactivation
3. Shift timing indicator light
1
3
2
1

FEATURES
1-10
•Display brightness:
This function allows you to adjust the bright-
ness of the displays and tachometer to suit the
outside lighting conditions.
•Shift timing indicator light activity:
This function allows you to choose whether or
not the indicator light should be activated and
whether it should flash or stay on when activat-
ed.
•Shift timing indicator light activation:
This function allows you to select the engine
speed at which the indicator light will be acti-
vated.
•Shift timing indicator light deactivation:
This function allows you to select the engine
speed at which the indicator light will be deac-
tivated.
•Shift timing indicator light brightness:
This function allows you to adjust the bright-
ness of the indicator light to suit your prefer-
ence.
NOTE:
In this mode, the odometer/trip meter/fuel re-
serve trip meter/stopwatch display shows the
current setting for each function (except the shift
timing indicator light activity function).
To adjust the brightness of the multi-function
meter displays and tachometer:
1. Turn the key to “OFF”.
2. Push and hold the “SELECT”button.
3. Turn the key to “ON”, and then release the
“SELECT”button after five seconds.
4. Push the “RESET”button to select the de-
sired brightness level.
5. Push the “SELECT”button to confirm the se-
lected brightness level. The control mode
changes to the shift timing indicator light ac-
tivity function.
To set the shift timing indicator light activity func-
tion:
1. Push the “RESET”button to select one of the
following indicator light activity settings:
•The indicator light will stay on when activated.
(This setting is selected when the indicator
light stays on.)
•The indicator light will flash when activated.
(This setting is selected when the indicator
light flashes four times per second.)
•The indicator light is deactivated; in other
words, it will not come on or flash. (This set-
ting is selected when the indicator light flash-
es once every two seconds.)
2. Push the “SELECT”button to confirm the se-
lected indicator light activity. The control
mode changes to the shift timing indicator
light activation function.
To set the shift timing indicator light activation
function:
NOTE:
The shift timing indicator light activation function
can be set between 10000 r/min and 18000
r/min. From 10000 r/min to 13000 r/min, the indi-
cator light can be set in increments of 500 r/min.
From 13000 r/min to 18000 r/min, the indicator
light can be set in increments of 200 r/min.
1. Push the “RESET”button to select the de-
sired engine speed for activating the indicator
light.
2. Push the “SELECT”button to confirm the se-
lected engine speed. The control mode
changes to the shift timing indicator light de-
activation function.
To set the shift timing indicator light deactivation
function:
NOTE:
•The shift timing indicator light deactivation
function can be set between 10000 r/min and
18000 r/min. From 10000 r/min to 13000 r/min,
the indicator light can be set in increments of
500 r/min. From 13000 r/min to 18000 r/min,
the indicator light can be set in increments of
200 r/min.
•Be sure to set the deactivation function to a
higher engine speed than for the activation
function, otherwise the shift timing indicator
light will remain deactivated.
1. Push the “RESET”button to select the de-
sired engine speed for deactivating the indi-
cator light.
2. Push the “SELECT”button to confirm the se-
lected engine speed. The control mode
changes to the shift timing indicator light
brightness function.

FEATURES
1-11
To adjust the shift timing indicator light bright-
ness:
1. Push the “RESET”button to select the de-
sired indicator light brightness level.
2. Push the “SELECT”button to confirm the se-
lected indicator light brightness level. The dis-
play will return to the odometer or tripmeter
mode.