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Yamaha 1999 YZF-R6 Service Manual

Yamaha 1999 YZF-R6
400 pages
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Table of Contents

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Yamaha 1999 YZF-R6 Specifications

General IconGeneral
Bore x Stroke65.5 mm x 44.5 mm
Compression Ratio12.4:1
IgnitionDigital TCI
Transmission6-speed
Final DriveChain
Front SuspensionTelescopic fork
Front BrakesDual 298 mm discs
Front Tire120/60-ZR17
Rear Tire180/55-ZR17
Wheelbase1, 380 mm (54.3 in)
Seat Height820 mm (32.3 in)
Engine Typeliquid-cooled, DOHC, inline 4-cylinder
Rear SuspensionSingle shock
Rear Brakes220mm disc
Fuel Capacity17 l (4.5 US gal)
Dry Weight169 kg

Summary

General Information

How To Use This Manual

Explains the structure and conventions of the service manual for easy navigation and understanding.

Symbols

Provides a key to the various symbols used throughout the manual for quick reference.

Special Tools

Lists and illustrates specialized tools required for maintenance and assembly procedures.

Specifications

General Specifications

Details the overall dimensions, weight, and load capacity of the motorcycle.

Engine Specifications

Provides technical data for the engine, including displacement, bore, and compression ratio.

Chassis Specifications

Lists specifications for the frame, wheels, brakes, suspension, and steering systems.

Electrical Specifications

Details electrical system components, voltages, resistances, and capacities.

Tightening Torques

Specifies torque values for various fasteners to ensure proper assembly and prevent damage.

Lubrication Points and Lubricant Types

Identifies all lubrication points and the recommended lubricants for each component.

Periodic Checks and Adjustments

Periodic Maintenance and Lubrication Intervals

Outlines the recommended maintenance schedule for checks and lubrication based on mileage or time.

Engine

Covers checks and adjustments for engine components, including valve clearance and carburetors.

Chassis

Covers checks and adjustments for chassis components, including brakes, suspension, and drive chain.

Electrical System

Covers checks and maintenance for the motorcycle's electrical system components.

Engine

Clutch

Covers the removal, inspection, and installation of the clutch assembly.

Oil Pan and Oil Pump

Details the removal, checking, and installation procedures for the oil pan and oil pump.

Crankcase

Details the separation, disassembly, checking, and assembly of the crankcase.

Connecting Rods and Pistons

Covers the removal, checking, and installation of connecting rods and pistons.

Crankshaft

Details the removal, checking, and installation procedures for the crankshaft.

Transmission

Covers the removal, checking, and installation procedures for the transmission.

Camshafts

Covers the removal, checking, and installation procedures for the camshafts.

Cylinder Head

Details the removal, checking, and installation of the cylinder head assembly.

Valves and Valve Springs

Covers the removal, checking, and installation of valves and related components.

Starter Clutch and Generator

Covers the removal, checking, and installation of the starter clutch and generator.

Shift Shaft

Covers the removal, checking, and installation of the shift shaft.

Cooling System

Radiator

Details the removal, checking, and installation procedures for the radiator.

Oil Cooler

Covers the removal, checking, and installation procedures for the oil cooler.

Thermostat

Covers checking and installing the thermostat to regulate engine coolant temperature.

Water Pump

Details the disassembly, checking, and assembly of the water pump.

Carburetors

Carburetors

Covers the removal, checking, assembly, and installation of the carburetor system.

Measuring and Adjusting the Fuel Level

Explains how to measure and adjust the fuel level in the float chamber for correct fuel delivery.

Checking and Adjusting the Throttle Position Sensor

Details how to check and adjust the throttle position sensor for accurate engine response.

Checking the Fuel Pump

Explains how to check the fuel pump operation and resistance for proper fuel delivery.

Chassis

Front Wheel and Brake Discs

Covers the removal, checking, and installation of the front wheel and brake discs.

Rear Wheel, Brake Disc, and Rear Wheel Sprocket

Covers the removal, checking, and installation of the rear wheel, brake disc, and sprocket.

Front and Rear Brakes

Covers the maintenance and replacement of brake pads, master cylinders, and calipers.

Front Fork

Details the removal, disassembly, checking, assembly, and installation of the front fork legs.

Handlebars

Covers the removal, checking, and installation of handlebars and related controls.

Steering Head

Details the removal, checking, and installation of the steering head components.

Rear Shock Absorber Assembly

Covers removal, checking, and installation of the rear shock absorber assembly.

Swingarm and Drive Chain

Covers checks and maintenance for the swingarm and drive chain.

Electrical

Electrical Components

Provides an overview and identification of major electrical system components.

Instrument Functions

Explains the functions of the instrument panel indicators and meters.

Switches

Covers the checking and testing procedures for various electrical switches.

Checking the Bulbs and Bulb Sockets

Guides on inspecting bulbs and sockets for damage, wear, and continuity.

Ignition System

Covers the ignition system's circuit diagram and troubleshooting procedures.

Electric Starting System

Details the circuit diagram and troubleshooting for the electric starting system.

Starter Motor

Covers the removal, disassembly, checking, and assembly of the starter motor.

Charging System

Covers the circuit diagram and troubleshooting for the battery charging system.

Lighting System

Covers the circuit diagram and troubleshooting for the motorcycle's lighting systems.

Signaling System

Covers the circuit diagram and troubleshooting for turn signals, horn, and indicators.

Cooling System

Covers the circuit diagram and troubleshooting for the cooling fan and temperature sensors.

Fuel Pump System

Covers the circuit diagram and troubleshooting for the fuel pump operation.

Self-Diagnosis

Explains the motorcycle's self-diagnosis system for identifying circuit faults.

Troubleshooting

Starting Problems

Lists common causes for engine starting issues across engine, fuel, and electrical systems.

Incorrect Engine Idling Speed

Identifies potential causes for incorrect engine idling speed in engine, fuel, and electrical systems.

Faulty Gear Shifting

Covers common problems related to difficult gear shifting and the shift mechanism.

Faulty Clutch

Lists causes for clutch slippage or drag, related to clutch components and engine oil.

Overheating

Identifies potential causes for engine overheating across various systems like cooling, fuel, and electrical.

Poor Braking Performance

Covers issues affecting brake performance, including worn pads, fluid leaks, and hydraulic system air.

Faulty Front Fork Legs

Addresses problems like oil leaks, bent tubes, and improper damping adjustments in the front forks.

Unstable Handling

Lists causes for unstable handling, including issues with handlebars, steering head, and suspension.

Faulty Lighting and Signaling Systems

Provides diagnostic steps for lighting and signaling system failures, such as burnt-out bulbs or faulty switches.

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