Yamaha YZFR6V User manual

SERVICE MANUAL
YZFR6V(C)
LIT-11616-19-78 2C0-28197-10

EAS20050
YZFR6V(C)
SERVICE MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First edition, December 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-19-78

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.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
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:
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• 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 ....................................................................... 1-11
PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-11
REPLACEMENT PARTS ........................................................................ 1-11
GASKETS, OIL SEALS AND O-RINGS.................................................. 1-11
LOCK WASHERS/PLATES AND COTTER PINS................................... 1-11
BEARINGS AND OIL SEALS.................................................................. 1-12
CIRCLIPS................................................................................................ 1-12
CHECKING THE CONNECTIONS................................................................ 1-13
SPECIAL TOOLS.......................................................................................... 1-14

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