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YZF-R6T
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CHAS
27
Order
Job / P
ar
t
Q’ty
Remarks
13
Brake master cylinder
1
14
F
ront brak
e switch
1
F
or installation, re
verse the remo
v
al
procedure.
13 Nm (1.3 m•kg, 9.4
ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
FRONT AND REAR BRAKES
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys
email: info@motomatrix.co.uk
33
35
Table of Contents
Main Page
Table of Contents
6
Important Manual Information
3
How to Use this Manual
4
General Information
8
Special Tools
8
Specifications
9
General Specifications
9
Engine Specifications
9
Chassis Specifications
10
Electrical Specifications
11
Tightening Torques
12
Chassis Tightening Torques
12
Engine Tightening Torques
12
Cable Routing
13
Periodic Checks and Adjustments
27
Bleeding the Hydraulic Brake System
27
Adjusting the Front Fork Legs
29
Chassis
31
Front Wheel and Brake Discs
31
Front and Rear Brakes
32
Front Brake Pads
32
Front Brake Master Cylinder
33
Front Brake Calipers
36
Assembling and Installing the Front Brake Master Cylinder
38
Front Fork
40
Front Fork Legs
40
Disassembling the Front Fork Legs
43
Checking the Front Fork Legs
44
Assembling the Front Fork Legs
45
Swingarm and Drive Chain
50
Checking the Drive Chain
50
Cooling System
52
Radiator
52
Electrical System
54
Electric Starting System
54
Circuit Diagram
54
Troubleshooting
55
Cooling System
58
Circuit Diagram
58
Table of Contents
71
Specifications
73
General Specifications
73
Engine Specifications
73
Chassis Specifications
73
Electrical Specifications
73
Tightening Torques
74
Engine Tightening Torques
74
Cable Routing
75
Periodic Checks and Adjustments
87
Fuel Tank
87
Installing the Fuel Pump
88
Fuel Injection System
89
Air Induction System
89
Air Induction System Diagrams
89
Electrical
90
Electrical Components
90
Ignition System
92
Troubleshooting
92
Lighting System
97
Circuit Diagram
97
Checking the Lighting System
99
Yzf-R6S/Yzf-R6Sc Wiring Diagram
103
Table of Contents
111
Chapter 1 General Information
122
Motorcycle Identification
122
Model Label
122
Vehicle Identification Number
122
Features
123
Outline of Fi System
123
Fi System
124
Instrument Function
125
Important Information
128
Gaskets, Oil Seals and O-Rings
128
Preparation for Removal and Disassembly
128
Replacement Parts
128
Bearings and Oil Seals
129
Circlips
129
Lock Washers/Plates and Cotter Pins
129
Checking the Connections
130
Special Tools
131
Chapter 2 Specifications
135
General Specifications
135
Engine Specifications
136
Chassis Specifications
145
Electrical Specifications
149
Conversion Table
152
General Tightening Torque Specifications
152
Tightening Torques
153
Engine Tightening Torques
153
Chassis Tightening Torques
156
Lubrication Points and Lubricant Types
158
Engine
158
Chassis
159
Engine Oil Lubrication Chart
164
Lubrication Diagrams
165
Cable Routing
171
Chapter 3 Periodic Checks and Adjustments
184
General Maintenance and Lubrication Chart
184
Introduction
184
Periodic Maintenance Chart for the Emission Control
184
System
184
Seats
186
Fuel Tank
187
Removing the Fuel Pump
188
Removing the Fuel Tank
188
Installing the Fuel Pump
189
Installing the Fuel Tank
189
Cowlings
190
Installation
191
Removal
191
Air Filter Case
192
Engine
193
Adjusting the Valve Clearance
193
Synchronizing the Throttle Bodies
199
Adjusting the Engine Idling Speed
201
Adjusting the Throttle Cable Free Play
202
Checking the Spark Plugs
204
Measuring the Compression Pressure
205
Checking the Engine Oil Level
207
Changing the Engine Oil
208
Measuring the Engine Oil Pressure
210
Adjusting the Clutch Cable Free Play
212
Cleaning the Air Filter Element
213
Checking the Throttle Body Joints
214
Cleaning the Air Intake System Surge Tanks
214
Checking the Crankcase Breather Hose
215
Checking the Fuel and Breather Hoses
215
Checking the Coolant Level
216
Checking the Exhaust System
216
Checking the Cooling System
217
Changing the Coolant
218
Chassis
222
Adjusting the Front Brake
222
Adjusting the Rear Brake
223
Checking the Brake Fluid Level
224
Adjusting the Rear Brake Light Switch
225
Checking the Front and Rear Brake Hoses
226
Checking the Front and Rear Brake Pads
226
Bleeding the Hydraulic Brake System
227
Adjusting the Shift Pedal
228
Adjusting the Drive Chain Slack
229
Lubricating the Drive Chain
230
Checking and Adjusting the Steering Head
231
Checking the Front Fork
233
Adjusting the Front Fork Legs
234
Adjusting the Rear Shock Absorber Assembly
236
Checking the Tires
238
Checking the Wheels
240
Checking and Lubricating the Cables
241
Lubricating the Levers and Pedals
241
Lubricating the Rear Suspension
241
Lubricating the Sidestand
241
Electrical System
242
Checking and Charging the Battery
242
Checking the Fuses
247
Replacing the Headlight Bulbs
249
Adjusting the Headlight Beams
250
Front Wheel and Brake Discs
251
Chapter 4
253
Checking the Front Wheel
253
Removing the Front Wheel
253
Checking the Brake Discs
255
Installing the Front Wheel
256
Adjusting the Front Wheel Static Balance
257
Rear Wheel and Brake Disc
259
Rear Wheel and Brake Disc Rear Wheel
259
Rear Brake Disc and Rear Wheel Sprocket
260
Removing the Rear Wheel
262
Checking and Replacing the Rear Wheel Sprocket
263
Checking the Rear Wheel
263
Checking the Rear Wheel Drive Hub
263
Installing the Rear Wheel
264
Adjusting the Rear Wheel Static Balance
265
Front and Rear Brakes
267
Rear Brake Pads
267
Replacing the Front Brake Pads
268
Replacing the Rear Brake Pads
271
Front Brake Master Cylinder
273
Rear Brake Master Cylinder
276
Disassembling the Front Brake Master Cylinder
278
Disassembling the Rear Brake Master Cylinder
278
Checking the Front and Rear Brake Master Cylinders
279
Assembling and Installing the Front Brake Master
280
Assembling the Rear Brake Master Cylinder
282
Cylinder
282
Front Brake Calipers
284
Rear Brake Caliper
286
Calipers
288
Disassembling the Front Brake Calipers
288
Assembling and Installing the Rear Brake Caliper
293
Front Fork
295
Front Fork Legs
295
Removing the Front Fork Legs
295
Under Bracket
295
Handlebars
308
Steering Head
313
Checking the Steering Head
315
Removing the under Bracket
315
Installing the Steering Head
316
Rear Shock Absorber Assembly
318
Disposing of a Rear Shock Absorber and Gas Cylinder
320
Handling the Rear Shock Absorber and Gas Cylinder
320
Checking the Rear Shock Absorber Assembly and Gas Cylinder
321
Removing the Rear Shock Absorber Assembly
321
Checking the Connecting Rod and Relay Arms
322
Installing the Rear Shock Absorber Assembly
322
Swingarm and Drive Chain
323
Removing the Swingarm
325
Checking the Swingarm
326
Removing the Drive Chain
326
Checking the Drive Chain
327
Installing the Swingarm
329
Chapter 5 Overhauling the Engine
330
Engine
330
Drive Sprocket
330
Exhaust Pipe
331
Engine
332
Leads and Hoses
332
Installing the Engine
335
Camshafts
337
Cylinder Head Cover
337
Removing the Camshafts
339
Checking the Camshafts
340
Checking the Timing Chain Tensioner
342
Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
342
Installing the Camshafts
343
Cylinder Head
347
Checking the Cylinder Head
348
Removing the Cylinder Head
348
Installing the Cylinder Head
349
Valves and Valve Springs
350
Starter Clutch and Generator
360
Shift Shaft
367
Oil Pan and Oil Pump
383
Connecting Rods and Pistons
395
Oil Cooler
426
Water Pump
431
Throttle Bodies
463
Checking Switch Continuity
477
Checking the Bulbs and Bulb Sockets
479
Starter Motor
493
Charging System
497
Signaling System
512
Fuel Pump System
520
Incorrect Engine Idling Speed
529
Faulty Gear Shifting
530
Poor Braking Performance
531
Unstable Handling
532
Faulty Lighting or Signaling System
533
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