2009 Yamaha YZF-R6Y(C) Factory Service Manual (P/N LIT-11616-22-51)

Yamaha publication P/N LIT-11616-22-51 (first edition, July 2008) covers the 2009 YZF-R6Y(C), including 13SE/13SH (USA) and 13SF/13SJ (California). The cover also carries document code 13S-28197-11. Vehicle identification and model-label locations are illustrated.

Supplied as a single 434-page PDF in English, with nine main chapters and the wiring-diagram sheets included in the total.

• Engine repair: Engine removal, camshaft timing, cylinder-head and valve service, piston inspection, crankshaft bearing selection, and oil-pump inspection.

• Clutch and transmission: Wet-clutch disassembly, clutch-pack width adjustment, gearbox removal, shift-drum and shift-fork inspection, and shaft assembly.

• Fuel injection and intake: Throttle-body synchronization, fuel-pressure testing, primary and secondary injector checks, and YCC-T/YCC-I diagnostics.

• Brakes and chassis: Caliper and master-cylinder repair, hydraulic brake bleeding, front-fork overhaul, steering-head service, and swingarm inspection.

• Cooling system: Radiator pressure testing, thermostat checks, oil-cooler inspection, and water-pump seal replacement.

• Electrical diagnosis: ECU fault-code charts, sensor and actuator tests, ignition and charging checks, starting-interlock circuits, and wiring diagrams.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes a working knowledge of motorcycle mechanics and repair techniques.

Engine Repair and Service Data

Periodic service coverage includes maintenance charts, valve-clearance adjustment and pad selection, compression testing and engine oil-pressure measurement.

Internal engine procedures pair exploded views and job charts with camshaft lobe dimensions, piston-to-cylinder limits, connecting-rod oil-clearance checks using Plastigauge, and oil-pump rotor clearances.

Separate cylinder-head and crankcase tightening sequences accompany bearing color-code selection charts and fluid-capacity data. The manual explains how mixing up connecting-rod bearings can alter oil clearance and damage the engine.

The constant-mesh 6-speed transmission procedures include gear-dog and shaft-runout checks. Clutch plate selection tables identify replacement thickness options by part number for correcting clutch-pack width.

YCC-T, YCC-I and Fuel-System Service

The YCC-T/YCC-I control outline explains electronic throttle and variable intake-funnel operation. Service procedures distinguish the throttle-valve position sensor from the throttle-cable-pulley position sensor, with separate adjustment instructions for each.

Intake-funnel operation checks, EXUP cable adjustment and EXUP servo-motor diagnosis are covered. California-specific sections address the evaporative canister, purge hoses and rollover valve; throttle-body identification marks distinguish the regional assemblies.

Brakes, Suspension and Steering

Brake data includes disc thickness and runout limits, piston-seal inspection and master-cylinder checks. Front-fork procedures cover damper-rod disassembly, seal installation, oil-level setting and air bleeding.

The fork instructions flag the cap-bolt collar projections as vulnerable to breakage during loosening or tightening. Rear suspension coverage includes linkage bearings, swingarm pivots, and rear shock absorber assembly removal, inspection, installation and adjustment.

Follow the factory precautions for hydraulic brake service and the nitrogen-charged rear shock absorber; Yamaha warns against opening the shock body.

Cooling, Lubrication and Special Tools

The engine oil lubrication chart traces the wet-sump circuit, while cooling-system diagrams identify radiator, oil-cooler and water-pump connections. Tool references include fuel-pressure adapter YM-03176 and water-pump seal installer YM-33221-A.

ECU Troubleshooting and Electrical Repair

Ignition and fuel-injection circuit diagrams sit alongside cable-routing drawings and checks for ignition coils, the multi-function meter and starting interlocks. The Self-Diagnostic Function table, Sensor operation table and Actuator operation table support ECU diagnosis and post-repair fault-history clearing.

Fault-code troubleshooting links symptoms to connector checks, harness tests and sensor readings. This helps distinguish a wiring fault from a failed sensor before parts are replaced.

File Format and Readability

Included pages: The total includes the front and rear covers, seven blank or separator pages, and two large-format wiring-diagram sheets: one monochrome and one color.

Text search: The manual's text is searchable. Some circuit-diagram lettering and graphical labels are not searchable.

Navigation: Embedded bookmarks cover all nine chapters, major sections and the wiring diagram. The “Back to Main” bookmark points to a separate Main.pdf file.

Wiring readability: Small wire-color codes and connector details require zooming for close inspection.