Yamaha YZF-R6T(C) Manual

YZF-R6T

5SL-28197-12

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-18-45

YZF-R6TC

YZF-R6T/YZF-R6TC

SUPPLEMENTARY

SERVICE MANUAL

Corporation, U.S.A.

First edition, September 2004

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-11616-18-45

EAS00001

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YZF-R6T/YZF-R6TC. For complete service information procedures it is necessary to use this Sup-

plementary Service Manual together with the following manual.

YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC SERVICE MANUAL:

LIT-11616-16-45 (5SL-28197-10)

YZF-R6S/YZF-R6SC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-17-46 (5SL-28197-11)

EAS00030

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual. 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 vehicle 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

vehicle 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

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

TE:

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS00040

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 motorcycle operator, a bystander or a person checking or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EAS00007

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. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)

appears.

Sub-section titles appear in smaller print than the section title.

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are described

sequentially.

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols to indicate the subject of each

chapter.

General information

Specifications

Periodic checks and adjustments

Chassis

Engine

Cooling system

Fuel injection system

Electrical system

Troubleshooting

Symbols to indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols to in the exploded diagrams

indicate the types of lubricants and lubrication

points.

Engine oil

Gear oil

Molybdenum-disulfide oil

Wheel-bearing grease

Lithium-soap-based grease

Molybdenum-disulfide grease

Symbols to in the exploded diagrams

indicate the following.

Apply locking agent (LOCTITE®)

Replace the part

CONTENTS

GENERAL INFORMATION

SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 5

CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 5

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PERIODIC CHECKS AND ADJUSTMENTS

BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . 20

ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . 22

CHASSIS

FRONT WHEEL AND BRAKE DISCS. . . . . . . . . . . . . . . . . . . . . . . . . 24

FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 26

FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . 36

CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 37

ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . 38

SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CHECKING THE DRIVE CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 43

COOLING SYSTEM

RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ELECTRICAL SYSTEM

ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

YZF-R6T/YZF-R6TC WIRING DIAGRAM

GEN

INFO

EAS00027

GENERAL INFORMATION

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. Special tools, part numbers or both may differ depending on the

country. When placing an order, refer to the list provided below to avoid any mistakes.

TE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool No. Tool name/Function Illustration

90890-01423

YM-01423

Damper rod holder

This tool is used to hold the damper rod

assembly when loosening or tightening the

damper rod assembly bolt.

90890-01434

YM-01434

Rod holder

This tool is used to support the damper

adjusting rod.

90890-01441

YM-01441

Fork spring compressor

This tool is used to disassemble or assemble

the front fork legs.

90890-01442

YM-01442

Fork seal driver

This tool is used to install the front fork’s oil

seal and dust seal.

SPECIAL TOOLS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

Item Standard Limit

Model code 5SLR (USA except for CAL) •••

5SLS (CAL)

Dimensions

Overall length 2,045 mm (80.5 in) •••

Overall width 690 mm (27.2 in) •••

Overall height 1,105 mm (43.5 in) •••

Seat height 830 mm (32.7 in) •••

Wheelbase 1,385 mm (54.5 in) •••

Minimum ground clearance 145 mm (5.7 in) •••

Minimum turning radius 3,800 mm (149.6 in) •••

Weight

Wet (with oil and a full fuel tank) 183 kg (404 lb) (USA except for CAL) •••

184 kg (406 lb) (CAL) •••

Maximum load (except motorcycle) 192 kg (423 lb) (USA except for CAL) •••

191 kg (421 lb) (CAL) •••

Item Standard Limit

Throttle bodies

Model (manufacturer) ×quantity 40EIS (MIKUNI) ×4•••

ID mark 5SLM 30 (5SLR), 5SLS 40 (5SLS) •••

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Frame

Caster angle 24.5° •••

Trail 95 mm (3.74 in) •••

Front tire

Size 120/70 ZR17 M/C (55W) •••

Model (manufacturer) Pilot POWER C (MICHELIN) •••

D218FM (DUNLOP)

Rear tire

Model (manufacturer) Pilot POWER (MICHELIN) •••

D218M (DUNLOP)

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi) •••

90 ~ 192 kg (198 ~ 426 lb) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi) •••

(USA except for CAL)

90 ~ 191 kg (198 ~ 423 lb) (CAL) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi) •••

High-speed riding 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi) •••

Front brakes

Brake lever free play 6.7 ~ 18.1 mm (0.26 ~ 0.71 in) •••

Brake discs

Diameter ×thickness 310 ×4.5 mm (12.20 ×0.18 in) •••

Min. thickness •••4.0 mm

(0.16 in)

Master cylinder inside diameter 16 mm (0.63 in) •••

Rear brake

Brake pedal freeplay 4.3 ~ 9.0 mm (0.17 ~ 0.35 in) •••

CHASSIS SPECIFICATIONS

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