Yamaha YZF-R6 L 2000 User manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R6(L)2000.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplemen-
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.

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.
Repairsattemptedby anyone without thisknowledgeare likely to renderthemotorcycles unfit for 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 injury or deathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicates special precautions thatmust be taken toavoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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5
YP002000 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanationsofall installation, removal, disassembly, assembly, repairand inspection procedures are
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
GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUE 3. . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS 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

–1–
SPECIAL TOOLS GEN
INFO
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Useonlytheappropriatespecialtoolsasthiswillhelppreventdamagecausedbytheuseofinappropri-
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.

–2–
ENGINE SPECIFICATIONS/ELECTRICAL SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Pistons
Oil ring
Dimensions (B T)
End gap (installed) 1.5 2.0 mm 0.10 0.35 mm


Crankshaft
Crankshaft-journal-to-crankshaft-
journal-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 G8R-30Y-M (OMRON) 162 198 Ω
