Yamaha YZF-R6 L 2000 Service Manual
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Yamaha YZF-R6 L 2000 Service Manual

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Summary of Contents for Yamaha YZF-R6 L 2000

  • Page 3 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...

  • Page 4: Important Information

    It is not possible to include all the knowledge of a mechanic in one manu- 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.

  • Page 5: How To Use This Manual

    YP002000 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 inspection procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 6: General Information

    EB003000 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustment 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis COOL CARB...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION ........SPECIAL TOOLS .

  • Page 9: Special Tools

    SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 10: Specifications

    SPEC ENGINE SPECIFICATIONS/ELECTRICAL SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Pistons Oil ring Dimensions (B 2.0 mm 0.10 X 0.35 mm End gap (installed) Crankshaft 0.028 X 0.052 mm Crankshaft-journal-to-crankshaft- journal-bearing clearance Carburetors ID mark 5EB1 Jet needle #1, 4: N7RA #2, 3: N7SA 1-1/2 Y 2 Pilot screw turns out ELECTRICAL SPECIFICATIONS...

  • Page 11: Tightening Torque

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks mSkg Engine mounting adjusting bolts Rear shock absorber and frame Pivot shaft adjust bolt –3–...

  • Page 12: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Throttle cables A Install the headlight relays onto the headlight housing bridge. Clutch cable B Route the headlight lead through the plastic guide. Left handlebar switch lead C Route the headlight lead through the headlight bracket right side, and Starter cable connect relay.
  • Page 13 SPEC CABLE ROUTING L Locate the end of band to for ward. Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Cut the end of locking tie. And then, route the horn lead under the brake hose and clamp it to the under cover.
  • Page 14 SPEC CABLE ROUTING Fuel pump lead F Fasten the rear brake switch lead to the footrest Pickup coil lead bracket with a plastic locking tie and cut the end of Thermo switch locking tie. Clutch cable G Fasten the fuel pump lead and rear brake switch Rear brake switch lead lead with a plastic band on the fuel pump bracket.
  • Page 15 SPEC CABLE ROUTING AC magneto lead C Don’t touch the wireharness with the throttle cable Reservoir tank breather hose pully. Route the wire harness under the radiator Sidestand switch lead hose. Oil level switch lead D Route the fuel tank breather hose and fuel tank Speed sensor lead drain hose between reservor tank breather hose Fuel pump lead...
  • Page 16 SPEC CABLE ROUTING I Route the fuel tank drain hose and the fuel tank breather hose through the reservor tank holder from its outside to inside. Don’t kink. J Route the fuel tank drain hose and fuel tank breath- er hose through the holder of the hook and the side- stand.
  • Page 17 SPEC CABLE ROUTING Throttle cable Fuel sender connector Right handlebar switch lead Coolant reservoir tank cap Thermo unit lead Crankcase breather hose Reservoir tank breather hose Heat protector Carburetor idle adjusting cable Radiator fan motor lead Pickup coil connector Clutch cable Neutral switch connector Left handlebar switch lead Rear brake switch connector...
  • Page 18 SPEC CABLE ROUTING E Fasten the wireharness pickup coil lead handlebar L Position the rear turn signal light connectors (left switch lead (left and right) main switch lead TPS and right) and taillight connector between the rear lead with a band. fender and taillight bracket.
  • Page 19 SPEC CABLE ROUTING T Insert the projection of the band (wireharness) into A’ Insert the projection of the band to the hole of the the hole of the frame. frame and faster the starter cable and wireharness. U 1: Speed sensor. Locate the end of band to left outside.

  • Page 20: Periodic Checks And Adjustment

    ADJUSTING THE CLUTCH CABLE FREE PLAY CHASSIS EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm 2.

  • Page 21: Overhauling The Engine

    ENGINE EAS00190 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg) 70 Nm (7.0 mSkg) Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Reserve tank Refer to “CHANGING THE COOLANT” Locknut Shift rod Shift arm Drive sprocket cover Lock washer...

  • Page 22: Engine

    ENGINE ENGINE 24 Nm (2.4 mSkg) 55 Nm (5.5 mSkg) 45 Nm (4.5 mSkg) 38 Nm (3.8 mSkg) 13 Nm (1.3 mSkg) 55 Nm (5.5 mSkg) 24 Nm (2.4 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed.

  • Page 23: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S engine mounting adjust bolts 1 S rear mounting bolts 2 S self-locking nuts 3 S collars 4 S front mounting bolts 5 S collars 6 S button head bolts 7 S pinch bolts 8 NOTE: S Lubricate the rear mounting bolt threads with lithium soap base grease.

  • Page 24: Pickup Coil And Pickup Rotor

    Sheave holder 90890-01701 3. Apply: S sealant (onto the pickup coil lead grommet) Yamaha bond No.1215 90890-85505 4. Install: S pickup coil cover NOTE: S When installing the pickup coil cover, align the timing chain guide (intake side) pin 1 of the with the hole 2 in the pickup coil cover.
  • Page 25 PICKUP COIL AND PICKUP ROTOR 5. Install S Clutch cable holder S Clutch cable Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. –17–...

  • Page 26: Chassis

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear wheel Refer to “REMOVING THE REAR WHEEL”.

  • Page 27: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 28: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 5 Nm (0.5 mSkg) 95 Nm (9.5 mSkg) 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Drive sprocket Refer to “ENGINE”...
  • Page 29 CHAS SWINGARM AND DRIVE CHAIN 5 Nm (0.5 mSkg) 95 Nm (9.5 mSkg) 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Pivot shaft adjust bolt Refer to “REMOVING/INSTALLING THE SWINGARM”. Drive chain Dust cover Oil seal Bush Shim Drive chain guide...

  • Page 30: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EAS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Lithium soap base grease 2. Install: S swingarm S pivot shaft S washer S pivot shaft adjust bolt 1 5 Nm (0.5 mSkg) S pivot shaft nut 95 Nm (9.5 mSkg)

  • Page 31: Yzf-R6 (L) 2000 Wiring Diagram

    YZF-R6 (L) 2000 WIRING DIAGRAM (for EUR) Main switch Fuse (back up) Rectifier / Regulator AC magneto Battery Fuse (main) Starter relay Starter motor Starting circuit cut-off relay Sidestand switch Fuel pump Throttle position sensor Pickup coil CDI unit Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4...
  • Page 32 YZF-R6 (L) 2000 WIRING DIAGRAM (for AUS) Main switch Fuse (back up) Rectifier / Regulator AC magneto Battery Fuse (main) Starter relay Starter motor Starting circuit cut-off relay Sidestand switch Fuel pump Throttle position sensor Pickup coil CDI unit Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4...

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