Yamaha YZF-R6 Service & Repair Manual 1999-2004
The Online Manual is not a printed product, not a PDF and not a download. Valid for 36 months
Yamaha YZF-R6 manual.
Includes Color Wiring Diagrams.
Clymer Yamaha YZF-R6 1999-2004 repair manual is written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul of your Yamaha YZF-R6 1999-2004, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today.
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage
CHAPTER TWO / TROUBLESHOOTING
Engine operating requirements / Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system / Fuel pump / Electrical testing / Electrical troubleshooting / Cooling system circuit / Steering and suspension / Brake system
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Cylinder numbering and firing order / Maintenance intervals / Tune-up / Ignition timing inspection(carbureted models) / Valve clearance / Spark plugs / Engine oil / Engine oil pressure / Carburetor synchronization / Idle speed adjustment / Fuel line inspection / Fuel filter / Emission control systems / Exhaust gas volume adjustment (Europe and Australia fuel injected models) / Exhaust system inspection / Control cable lubrication / Throttle cables / Choke cable inspection (carbureted models) / Clutch cable free play / Shift pedal height / Battery / Cooling system / Tires and wheels / Front suspension / Front fork adjustments / Steering head bearings / Rear suspension inspection / Shock absorber adjustments / Drive chain / Brake system / General lubrication / Fastener inspection / Specifications
CHAPTER FOUR / ENGINE TOP END
Servicing engine in the frame / Cylinder head cover / Camshaft / Cam sprocket / Cam chain tensioner / Cam chain guides / Cam chain / Cylinder head / Valve lifters and shims / Valve components / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine removal and installation / Timing rotor cover / Timing rotor / Alternator cover / Flywheel and starter gears / Starter clutch / Oil pan / Oil pump / Crankcase / Crankshaft / Connecting rods / Piston and piston rings / Engine break-in / Specifications
CHAPTER SIX / CLUTCH
Clutch cover / Clutch release mechanism / Clutch cable
CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM
Shift rod and shift lever / Engine sprocket cover / Engine sprocket / Shift pedal footrest / External internal shift mechanism
CHAPTER EIGHT / AIR/FUEL, EMISSIONS AND EXHAUST SYSTEMS – CARBURETED MODELS
Fuel tank / Fuel valve / Fuel sender / Fuel filter / Fuel pump / Fuel sender and fuel level indicator light / Air filter / Carburetor overhaul adjustments / Throttle position sensor / Throttle cable / Choke cable / Air induction system AIS / Evaporative emission control system / Exhaust system
CHAPTER NINE / AIR/FUEL, EMISSIONS AND EXHAUST SYSTEMS – FUEL INJECTED MODELS
Depressurizing the fuel system / Fuel tank / Fuel pump / Fuel injection relay / Fuel sender and fuel level indicator light / Air filter / Throttle body assembly / Piston valve / Fuel injector / Throttle position sensor / Pressure regulator / Cylinder identification sensor / Intake air pressure sensor / Intake air temperature sensor / Atmospheric pressure sensor / Lean angle cutoff switch / Crankshaft position sensor / Throttle cable replacement / Air induction system / Evaporative emission control system / Exhaust system / Fuel injection diagnostic system
CHAPTER TEN / ELECTRICAL SYSTEM
Charging system / Stator / Voltage regulator rectifier / Ignition system / Spark plug / Direct ignition coil / Pickup coil Crankshaft position sensor / Ignition control unit / Engine control unit / Starting system / Starting circuit cutoff relay / Starter / Lights / Meter assembly / Oil level warning light / Oil level switch / Oil level relay / Fuel level indicator / Fuel sender / Horn / Clock / Speedometer / Speed sensor / Diagnostic system / Switches
CHAPTER ELEVEN / COOLING SYSTEM
Inspection / Coolant reservoir / Radiator / Radiator fan / Thermo switch / Radiator fan relay / Temperature sensor thermostat / Water pump / Oil cooler / Carburetor heater system / Fast idle plunger
CHAPTER TWELVE / WHEELS AND TIRES
Motorcycle stand / Brake rotor protection / Wheel inspection / Front wheel / Front hub / Front wheel bearings / Rear wheel / Rear hub / Rear wheel bearing replacement / Wheel sprocket / Wheel balance / Tires / Specifications
CHAPTER THIRTEEN / FRONT SUSPENSION AND STEERING
Fork / Handlebar / Steering head / Steering head bearing races / Steering stem bearing
CHAPTER FOURTEEN / REAR SUSPENSION AND DRIVE CHAIN
Shock absorber / Rear suspension linkage / Swing arm / Drive chain
CHAPTER FIFTEEN / BRAKES
Brake service / Preventing brake fluid damage / Brake bleeding / Brake fluid draining / Brake pad inspection / Front brake caliper / Front master cylinder / Rear brake caliper / Rear brake master cylinder / Brake disc / Brake hose replacement / Brake pedal/footrest assembly / Specifications >br>
CHAPTER SIXTEEN / FRAME AND BODY>/b>
Rider¿s seat / Passenger seat / Body panel fasteners / Fairing service / Lower fairing / Console panel / Side fairing / Side cover / Windshield / Mirror / Front fairing / Tail cover / Rear fender / Front fender / Passenger footpeg / Sidestand / Specifications
INDEX
COLOR WIRING DIAGRAMS
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Key features:
- All colour step-by-step guides for over 200 jobs with 700+ photos
- Image zoom feature for close-up view of jobs
- Brand-new “how to” video tutorials covering key repair tasks
- Print complete sections to take with you into the workshop
- Troubleshooting section – quickly find the cause of a problem
- Colour wiring diagrams help track problems quickly and easily
- Easy search feature – find your job fast
- Dictionary of automotive terms
- Quick links to popular DIY tasks and other jobs linked to your task
- Conversion calculator – imperial and metric units
