2003-2005 Yamaha YZF-R6 parts catalog + service manual

Table of Contents:

General Information

1. Motorcycle Identification
   • Vehicle Identification Number
   • Model Label
2. Features
   • Outline of FI System
   • FI System
   • Instrument Function
3. Important Information
   • Preparation for Removal and Disassembly
   • Replacement Parts
   • Gaskets, Oil Seals, and O-rings
   • Lock Washers/Plates and Cotter Pins
   • Bearings and Oil Seals
   • Circlips
   • Checking the Connections
4. Special Tools

Specifications

1. General Specifications
2. Engine Specifications
3. Chassis Specifications
4. Electrical Specifications
5. Conversion Table
6. General Tightening Torque Specifications
7. Tightening Torques
   • Engine Tightening Torques
   • Chassis Tightening Torques
8. Lubrication Points and Lubricant Types
   • Engine
   • Chassis
9. Cooling System Diagrams
10. Engine Oil Lubrication Chart
11. Lubrication Diagrams
12. Cable Routing

Periodic Checks and Adjustments

1. Introduction
2. Periodic Maintenance Chart for the Emission Control System
3. General Maintenance and Lubrication Chart
4. Seats
5. Fuel Tank
   • Removing the Fuel Tank
   • Removing the Fuel Pump
   • Installing the Fuel Pump
   • Installing the Fuel Tank
6. Cowlings
   • Removal
   • Installation
7. Air Filter Case
8. Engine
   • Adjusting the Valve Clearance
   • Synchronizing the Throttle Bodies
   • Adjusting the Engine Idling Speed
   • Adjusting the Throttle Cable Free Play
   • Checking the Spark Plugs
   • Measuring the Compression Pressure
   • Checking the Engine Oil Level
   • Changing the Engine Oil
   • Measuring the Engine Oil Pressure
   • Adjusting the Clutch Cable Free Play
   • Cleaning the Air Filter Element
   • Cleaning the Air Intake System Surge Tanks
   • Checking the Throttle Body Joints
   • Checking the Fuel and Breather Hoses
   • Checking the Crankcase Breather Hose
   • Checking the Exhaust System
   • Checking the Coolant Level
   • Checking the Cooling System
   • Changing the Coolant
9. Chassis
   • Adjusting the Front Brake
   • Adjusting the Rear Brake
   • Checking the Brake Fluid Level
   • Adjusting the Rear Brake Light Switch
   • Checking the Front and Rear Brake Pads
   • Checking the Front and Rear Brake Hoses
   • Bleeding the Hydraulic Brake System
   • Adjusting the Shift Pedal
   • Adjusting the Drive Chain Slack
   • Lubricating the Drive Chain
   • Checking and Adjusting the Steering Head
   • Checking the Front Fork
   • Adjusting the Front Fork Legs
   • Adjusting the Rear Shock Absorber Assembly
   • Checking the Tires
   • Checking the Wheels
   • Checking and Lubricating the Cables
   • Lubricating the Levers and Pedals
   • Lubricating the Sidestand
   • Lubricating the Rear Suspension
10. Electrical System
    • Checking and Charging the Battery
    • Checking the Fuses
    • Replacing the Headlight Bulbs
    • Adjusting the Headlight Beams

Chassis

1. Front Wheel and Brake Discs
   • Removing the Front Wheel
   • Checking the Front Wheel
   • Checking the Brake Discs
   • Installing the Front Wheel
   • Adjusting the Front Wheel Static Balance
2. Rear Wheel and Brake Disc
   • Rear Wheel
   • Rear Brake Disc and Rear Wheel Sprocket
   • Removing the Rear Wheel
   • Checking the Rear Wheel
   • Checking the Rear Wheel Drive Hub
   • Checking and Replacing the Rear Wheel Sprocket
   • Installing the Rear Wheel
   • Adjusting the Rear Wheel Static Balance
3. Front and Rear Brakes
   • Front Brake Pads
   • Rear Brake Pads
   • Replacing the Front Brake Pads
   • Replacing the Rear Brake Pads
   • Front Brake Master Cylinder
   • Rear Brake Master Cylinder
   • Disassembling the Front Brake Master Cylinder
   • Disassembling the Rear Brake Master Cylinder
   • Checking the Front and Rear Brake Master Cylinders
   • Assembling and Installing the Front Brake Master Cylinder
   • Assembling the Rear Brake Master Cylinder
   • Front Brake Calipers
   • Rear Brake Caliper
   • Disassembling the Front Brake Calipers
   • Disassembling the Rear Brake Caliper
   • Checking the Front and Rear Brake Calipers
   • Assembling and Installing the Front Brake Calipers
   • Assembling and Installing the Rear Brake Caliper
4. Front Fork
   • Front Fork Legs
   • Removing the Front Fork Legs
   • Disassembling the Front Fork Legs
   • Checking the Front Fork Legs
   • Assembling the Front Fork Legs
   • Installing the Front Fork Legs
5. Handlebars
   • Removing the Handlebars
   • Checking the Handlebars
   • Installing the Handlebars
6. Steering Head
   • Under Bracket
   • Removing the Under Bracket
   • Checking the Steering Head
   • Installing the Steering Head
7. Rear Shock Absorber Assembly
   • Handling the Rear Shock Absorber and Gas Cylinder
   • Disposing of a Rear Shock Absorber and Gas Cylinder
   • Removing the Rear Shock Absorber Assembly
   • Checking the Rear Shock Absorber Assembly and Gas Cylinder
   • Checking the Connecting Rod and Relay Arms
   • Installing the Rear Shock Absorber Assembly
8. Swingarm and Drive Chain
   • Removing the Swingarm
   • Removing the Drive Chain
   • Checking the Swingarm
   • Checking the Drive Chain
   • Installing the Swingarm

Overhauling the Engine

1. Engine
   • Drive Sprocket
   • Exhaust Pipe
   • Leads and Hoses
   • Installing the Engine
2. Camshafts
   • Cylinder Head Cover
   • Camshafts
   • Removing the Camshafts
   • Checking the Camshafts
   • Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
   • Checking the Timing Chain Tensioner
   • Installing the Camshafts
3. Cylinder Head
   • Removing the Cylinder Head
   • Checking the Cylinder Head
   • Installing the Cylinder Head
4. Valves and Valve Springs
   • Removing the Valves
   • Checking the Valves and Valve Guides
   • Checking the Valve Seats
   • Checking the Valve Springs
   • Checking the Valve Lifters
   • Installing the Valves
5. Starter Clutch and Generator
   • Stator Coil Assembly
   • Removing the Generator
   • Removing the Starter Clutch
   • Checking the Starter Clutch
   • Installing the Starter Clutch
   • Installing the Generator
6. Shift Shaft
   • Shift Shaft and Stopper Lever
   • Checking the Shift Shaft
   • Checking the Stopper Lever
   • Installing the Shift Shaft
7. Crankshaft Position Sensor and Pickup Rotor
   • Removing the Pickup Rotor
   • Installing the Pickup Rotor
8. Clutch
   • Clutch Cover
   • Clutch
   • Removing the Clutch
   • Checking the Friction Plates
   • Checking the Clutch Plates
   • Checking the Clutch Springs
   • Checking the Clutch Housing
   • Checking the Clutch Boss
   • Checking the Pressure Plate
   • Checking the Pull Lever Shaft and Pull Rod
   • Installing the Clutch
9. Oil Pan and Oil Pump
   • Removing the Oil Pan
   • Checking the Oil Pump
   • Checking the Relief Valve
   • Checking the Oil Delivery Pipe and Oil Pipe
   • Checking the Oil Strainer
   • Checking the Oil Nozzles
   • Assembling the Oil Pump
   • Installing the Oil Pump
   • Installing the Oil Strainer
   • Installing the Oil Pan
10. Crankcase
    • Disassembling the Crankcase
    • Checking the Crankcase
    • Checking the Bearings and Oil Seals
    • Checking the Timing Chain
    • Assembling the Crankcase
11. Connecting Rods and Pistons
    • Removing the Connecting Rods and Pistons
    • Removing the Crankshaft Assembly
    • Checking the Cylinder and Piston
    • Checking the Piston Rings
    • Checking the Piston Pins
    • Checking the Big End Bearings
    • Installing the Connecting Rod and Piston
12. Crankshaft
    • Checking the Crankshaft
    • Checking the Crankshaft Journal Bearings
    • Installing the Crankshaft
13. Transmission
    • Transmission, Shift Drum Assembly and Shift Forks
    • Removing the Transmission
    • Checking the Shift Forks
    • Checking the Shift Drum Assembly
    • Checking the Transmission
    • Installing the Transmission

Cooling System

1. Radiator
   • Checking the Radiator
   • Installing the Radiator
2. Oil Cooler
   • Checking the Oil Cooler
   • Installing the Oil Cooler
3. Thermostat
   • Checking the Thermostat
   • Installing the Thermostat
4. Water Pump
   • Disassembling the Water Pump
   • Checking the Water Pump
   • Assembling the Water Pump
   • Installing the Water Pump

Fuel Injection System

1. Fuel Injection System
   • Wiring Diagram
   • ECU’s Self-Diagnostic Function
   • Alternate Instructions Operation Control (Fail-Safe Action)
   • Fail-Safe Actions Table
   • Troubleshooting Chart
   • Diagnostic Mode
   • Troubleshooting Details
2. Throttle Bodies
   • Checking the Injector
   • Checking the Throttle Body
   • Checking the Pressure Regulator
   • Checking the Fuel Pump and Pressure Regulator Operation
   • Checking and Adjusting the Throttle Position Sensor
3. Air Induction System
   • Air Injection
   • Air Cut-Off Valve
   • Air Induction System Diagrams
   • Checking the Air Induction System

Electrical

1. Electrical Components
   • Checking Switch Continuity
   • Checking the Switches
   • Checking the Bulbs and Bulb Sockets
   • Types of Bulbs
   • Checking the Condition of the Bulbs
   • Checking the Condition of the Bulb Sockets
   • Checking the LEDs
2. Ignition System
   • Circuit Diagram
   • Troubleshooting
3. Electric Starting System
   • Circuit Diagram
   • Starting Circuit Cut-Off System Operation
   • Troubleshooting
4. Starter Motor
   • Checking the Starter Motor
   • Assembling the Starter Motor
5. Charging System
   • Circuit Diagram
   • Troubleshooting
6. Lighting System
   • Circuit Diagram
   • Troubleshooting
   • Checking the Lighting System
7. Signaling System
   • Circuit Diagram
   • Troubleshooting
   • Checking the Signaling System
8. Cooling System
   • Circuit Diagram
   • Troubleshooting
9. Fuel Pump System
   • Circuit Diagram
   • Fuel Pump System
   • Troubleshooting
   • Checking the Fuel Pump
10. Self-Diagnosis
    • Troubleshooting

Troubleshooting

1. Starting Failures
   • Engine
   • Fuel System
   • Electrical Systems
2. Incorrect Engine Idling Speed
   • Engine
   • Fuel System
   • Electrical Systems
3. Poor Medium-and-High-Speed Performance
   • Engine
   • Fuel System
4. Faulty Gear Shifting
   • Shifting is Difficult
   • Shift Pedal Does Not Move
   • Jumps Out of Gear
5. Faulty Clutch
   • Clutch Slips
   • Clutch Drags
6. Overheating
   • Engine
   • Cooling System
   • Fuel System
   • Chassis
   • Electrical Systems
7. Overcooling
   • Cooling System
8. Poor Braking Performance
9. Faulty Front Fork Legs
   • Leaking Oil
   • Malfunction
10. Unstable Handling
11. Faulty Lighting or Signaling System
    • Headlight Does Not Come On
    • Headlight Bulb Burnt Out
    • Tail/Brake Light Does Not Come On
    • Tail/Brake Light Bulb Burnt Out
    • Turn Signal Does Not Come On
    • Turn Signal Blinks Slowly