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FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theYZF-R6 2001. For complete service information procedures it is necessary to use this SupplementaryService Manual together with the following manual.

YZF-R6 99 SERVICE MANUAL: 5EB1-AE1YZF-R6 (L) 2000 SUPPLEMENTARY SERVICE MANUAL: 5EB1-AE2

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NOTE:

WARNING

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-al, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamahamotorcycles has a basic understanding of the mechanical ideas and the procedures of motorcyclesrepair.

Repairs attempted by anyone without this knowledge are likely to render the motorcycles unfit for use.Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Fail re to follo WARNING instr ctions co ld res lt in se ere inj r or death to

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YP002000

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and inspection procedures arelaid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter. Refer to SYMBOLS on the following page.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 (Periodic Inspections and Adjustments), where the sub-section title (-s) appear.

(In Chapter 3, Periodic Inspections and Adjustments, the sub-section title appears at the top of eachpage, instead of the section title.)

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

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

removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly step.

6 Symbols indicate parts to be lubricated or replaced (see SYMBOLS).

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

8 J b i i i f ti ( h i l t l d t h i l d t ) d ib d

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1

3

5

7

9

2

4

8

6

11 12

10

GENINFO

SPEC

ENG

CARB

ELEC

CHK

ADJ

TRBLSHTG

COOL

CHAS

EB003000

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.1 General information

2 Specifications

3 Periodic checks and adjustment4 Engine

5 Cooling system

6 Carburetor(-s)

7 Chassis

8 Electrical system

9 Troubleshooting

Symbols 10 to 17 indicate the following.10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Ti ht i t

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CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 8. . . . . .

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GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard Limit

Model code 5MT1 (N) (D) (B) (GB) (GR) (DK) (NL) (S) (I) (E)5MT2 (N) (D) (A) (SF)5MT3 (F)

5MT4 (AUS) (NZ)

SSS

SSS

SSS

SSS

DimensionsOverall length

Overall widthOverall heightSeat heightWheelbase

Minimum ground clearanceMinimum turning radius

2025 mm (except for N, S, F, AUS, NZ)2080 mm (for N, S, F, AUS, NZ)690 mm1105 mm820 mm1380 mm

135 mm3400 mm

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

WeightWet (with oil and a full fuel tank)

Dry (without oil and fuel)

Maximum load (total of cargo, rider,d i )

186 kg

167 kg

375 kg

SSS

SSS

SSS

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ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

CamshaftsDrive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaftcapclearance

Chain drive (right)23.000 X 23.021 mm22.967 X 22.980 mm0.028 X 0.064 mm

SSS

SSS

SSS

0.08 mm

CarburetorsModel (manufacturer) quantityThrottle cable free play (at theflange of the throttle grip)ID markMain jet

Main air jetJet needle

Needle jetPilot air jetPilot outletPilot jetBypass 1

CVRD37 (KEIHIN) 46X 8 mm

5EB00, 5EB200 (G), 5EB300 (F)Carburetors 1 and 4: #152

Carburetors 2 and 3: #148#110Carburetors 1 and 4: N7RACarburetors 2 and 3: N7SA2.6#1100.9#380.8

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

SSS

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CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Front tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0X 90 kg90X 189 kgHigh-speed riding

Min. tire tread depth

Tubeless120/60ZR17 (55W)MICHELIN Pilot SPORT BDUNLOP D207F.J

250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)SSS

SSS

SSS

SSS

SSS

SSS

SSS

1.6 mm

Rear tire

Tire typeSizeModel (manufacturer)

Tire pressure (cold)0X 90 kg90X 189 kgHigh-speed riding

Min. tire tread depth

Tubeless180/55 ZR17 (73 W)MICHELIN Pilot SPORT BDUNLOP D207.N

250 kPa (2.5 kg/cm2, 2.5 bar)290 kPa (2.9 kg/cm2, 2.9 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

SSS

SSS

SSS

SSS

SSS

SSS

1.6 mm

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ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Ignition systemIgnition system typeIgnition timingAdvanced timingAdvancer type

Pickup coil resistance/colorTransistorized coil ignition unit model

(manufacturer)

C.D.I.10_ BTDC at 1300 r/min55_ BTDC at 5250 r/minThrottle position sensor and electrical

248X 372 /Gy-BF8T383 (MITSUBISHI)

SSS

SSS

SSS

SSS

SSS

SSS

BatteryBattery typeBattery voltage/capacity

GT9B-412 V/8 AH

SSS

SSS

Bulbs (voltage/wattage quantity)

HeadlightAuxiliary lightTail/brake lightTurn signal lightLicense plate lightMeter light

12 V 60 W/55 W 212 V 5 W 213.5 V 6.1 W/1 W 20 (LED)12 V 21 W 412 V 5 W 112 V 1.4 W 2

SSS

SSS

SSS

SSS

Sidestand relayModel

C il i

G8R-30Y-M

SSS

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TIGHTENING TORQUES SPEC

ENGINE TIGHTENING TORQUES

Item FastenerThread

Qty

Tighteningtorque Remarks

s zeNm mSkg

Cap bolt (timing chain tensioner)Neutral switch

BoltScrew

M6M6

12

720

0.72.0

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CABLE ROUTING SPEC

A Fasten the battery box and starter motor lead with a plastic clamp.B Fasten the wire positive lead and starter motor lead with clamp at the

end of the cover of the battery positive terminal.The end of the clamp is facing frontward.

C Route the under of the CDI unit coupler.D Clamp the lead at the rear of the two holes.

E Route the leads into the hole.F Route the lead along the inside of the two ribs.G Route the license plate light lead and taillight lead along the outside of

the battery box so that the leads do not get caught between the rib ofthe battery box and the fender.

1 Reservoir tank2 Fuse box3 Tool kit4 Wire minus lead5 Wire harness6 Battery box

7 Frame

EB206000

CABLE ROUTING

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O Fasten the main harness, ground lead and batterybox with a plastic clamp.

P The end of the clamp is facing upward.Q The end of the clamp is facing upward.R Licence and flasher light sub harness on the

taillight unit.S Licence and flasher light sub harness on the

taillight unit.T Clamp the leads.

U Store the ends of all leads at the inside of the rib.V Fasten the licence light lead. And bend the licence

light lead.W Fasten the flasher light lead. And bend the flasher

light lead.

CABLE ROUTING SPEC

H Route the seat lock cable into the hole of the frame.Mount the cable so that the side covered with acable protector up the end is positioned at rear.

I Fasten the seat lock cable with a steel clamp.J Do not fasten the seat lock cable.K Route the wire negative lead under the starter relay

lead.L Fasten the main harness, starter relay lead and

wire negative lead with a plastic clamp.

M Route the wire negative lead under the mainharness.

N Position the wire negative lead coupler under themain harness.

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INTRODUCTION/PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

NOTE:

EB300000

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.EB301000

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

SThe annual checks must be performed every year, except if a kilometer-based maintenance isperformed instead.

SFrom 50,000 km, repeat the maintenance intervals starting from 10,000 km.S Items marked with an asterisk should be performed by a Yamaha dealer as they require special

tools, data and technical skills.

ODOMETER READING ( 1,000 km) ANNUALNO. ITEM CHECK OR MAINTENANCE JOB

1 10 20 30 40 CHECK

1 * Fuel line S Check fuel hoses for cracks or damage.

2 * Fuel filter S Check condition.

S Check condition.

S Clean and regap.

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INTRODUCTION/PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

NOTE:

ODOMETER READING ( 1,000 km) ANNUALNO. ITEM CHECK OR MAINTENANCE JOB

1 10 20 30 40 CHECK

17 SidestandS Check operation.

S Lubricate.

18 * Sidestand switch S Check operation.

19 * Front fork S Check operation and for oil leakage.

20 *Rear shock absorber

assemblyS Check operation and shock absorber for oil leakage.

*Rear suspensionrelay arm and

S Check operation. 21 *

connecting arm

pivoting points S Lubricate with lithium-soap-based grease.

22 * CarburetorsS Check starter (choke) operation.

S Adjust engine idling speed and synchronization.

23 Engine oil S Change.

24Engine oil filter

cartridgeS Replace.

*

S Check coolant level and vehicle for coolant leakage.

25 * Cooling systemS Change. Every 3 years

26Moving parts and

cablesS Lubricate.

27 *Lights, signals and

switches

S Check operation.

S Adjust headlight beam.

EAU03541

D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

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CHECKING THE BRAKE FLUID LEVELCHKADJ

A

B

NOTE:

WARNING

CHASSISEB304020CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.

SPlace the motorcycle on a suitable stand.SMake sure that the motorcycle is upright.

2. Check:Sbrake fluid levelBelow the minimum level mark a! Add therecommended brake fluid to the proper lev-el.

Recommended brake fluidDOT 4

A Front brake

B Rear brake

SUse only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage and

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CHECKING THE TIRESCHKADJ

WARNING

EB304170

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Measure:S tire pressureOut of specification ! Regulate.

SThe tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.

SThe tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated riding

speed.SOperation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.

NEVER OVERLOAD THE MOTORCYCLE.

Basic weight(with oil

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CHECKING THE TIRESCHKADJ

A B

WARNING

2. Check:S tire surfaces

Damage/wear ! Replace the tire.

Minimum tire tread depth1.6 mm

1 Tire tread depth

2 Side wall

SDo not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire failureand personal injury from sudden deflation.

SWhen using a tube tire, be sure to install thecorrect tube.

SAlways replace a new tube tire and a new tubeas a set.

STo avoid pinching the tube, make sure thatthe wheel rim band and tube are centered inthe wheel groove.

SPatching a punctured tube is not recom-mended. If it is absolutely necessary to do so,use great care and replace the tube as soonas possible with a good quality replacement.

A Tire B Wheel

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CHECKING THE TIRES/CHECKING THE WHEELSCHKADJ

WARNING

NOTE:

Rear tire

Manufacturer Size Model

MICHELIN180/55 ZR17

(73W)Pilot

SPORT B

DUNLOP180/55 ZR17

(73W)D207SN

New tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 kmsould be traveled at normal speed beforeany highspeed riding is done.

For tires with a direction of rotation mark 1 :S

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SWINGARM AND DRIVE CHAIN CHAS

95 Nm (9.5 mSkg)

6 Nm (0.6 mSkg)

EAS00700

CHASSISSWINGARM AND DRIVE CHAIN

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SWINGARM AND DRIVE CHAIN CHAS

95 Nm (9.5 mSkg)

6 Nm (0.6 mSkg)

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SWINGARM AND DRIVE CHAIN CHAS

NOTE:

EAS00709

CHECKING THE DRIVE CHAIN1. Measure:S ten-link section a of the drive chainOut of specification ! Replace the drivechain.

Max. ten-link drive chain section150.1 mm

SWhile measuring the ten-link section, pushdown on the drive chain to increase its tension.

SMeasure the length between drive chain roller1 and 11 as shown.

SPerform this measurement at two or three dif-

ferent places.

2. Check:Sdrive chainStiffness! Clean and lubricate or replace.

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COLOR CODEB Black. . . . . .

Br Brown. . . . .C h C ho co la te. . . .

D g D ark g re en. . . .G Green. . . . .

Gy Gray. . . .L Blue. . . . . .

L g B lu e g re en. . . . .

O Orange. . . . .P Pink. . . . . .

R Red. . . . . .

Sb Sky blue. . . . .W White. . . . .

Y Yellow. . . . . .B / L B la ck / Blu e. . . .

B / R B la ck / Re d. . . .B /Y B lack/Ye llow. . . .

Br/B Brown/Black. . .

Br /L Brown/B lue. . .Br /R Brown/Red. . .

Br/W Brown/White. . .

G /R Green/Red. . .G/W Green/White. . .

G/Y Green/Yel low. . . .Gy/B Gray/Black. . .

L /B B lue/Black. . . .L / R Bl ue / Re d. . . .

L /W B lue/White. . .

L /Y B lue/Ye llow. . . .O /B Orange/Black. . . .

R / B R ed / Bla ck. . . .

R / G R ed / Gree n. . .R / L R ed / Blu e. . . .

R /W Red/Whi te. . .R /Y Red/Yellow. . . .

Sb/W Sky blue/White. .W/G Whi te /Green. . .

W/R Whi te /Red. . .W/Y White/Yel low. . .

Y/B Yellow/Black. . . .

1 Main switch2 Fuse (back up)3 Rectifier/Regulator4 AC magneto5 Battery6 Fuse (main)7 Starter relay8 Starter motor9 Starting circuit cut-off relay10 Sidestand switch11 Fuel pump12 Throttle position sensor13 Pickup coil14 CDI unit15 Ignition coil #1

16 Ignition coil #217 Ignition coil #318 Ignition coil #419 Spark plug20 Meter assembly21 Fuel level indicator light22 Oil level/coolant temperature

warning light23 Neutral indicator light24 Tachometer25 Combination meter26 Hi beam indicator light27 Turn signal indicator light28 Illumination light29 Speed sensor30 Neutral switch31 Thermo unit32 Fuel sender

33 Oil level switch34 Right handlebar switch35 Front brake light switch36 Light switch37 Engine stop switch38 Start switch39 Left handlebar switch40 Pass switch41 Dimmer switch42 Horn switch43 Clutch switch44 Turn signal switch45 Horn46 Flasher relay47 Headlight relay (Hi)

48 Headlight relay (Lo)49 Headlight50 Auxiliary light51 Front turn signal light (left)52 Front turn signal light (right)53 Rear turn signal light (left)54 Rear turn signal light (right)55 Rear brake light switch56 Tail/brake light57 Licence light58 Fuse (ignition)59 Alarm60 Fuse (signaling system)61 Fuse (headlight)62 Fuse (radiator fan motor)63 Thermo switch64 Radiator fan motor

YZF-R6 2001 WIRING DIAGRAM (for EUR)

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1 Main switch2 Fuse (back up)3 Rectifier/Regulator4 A.C. magneto5 Battery6 Fuse (main)7 Starter relay8 Starter motor9 Starting circuit cut-off relay10 Sidestand switch11 Fuel pump12 Throttle position sensor13 Pickup coil14 CDI unit15 Ignition coil #116 Ignition coil #217 Ignition coil #318 Ignition coil #419 Spark plug20 Meter assembly21 Fuel level indicator light22 Oil level/coolant temperature warning light23 Neutral indicator light24 Tachometer25 Combination meter26 Hi beam indicator light27 Turn signal indicator light28 Meter lights29 Speed sensor30 Neutral switch31 Thermo unit32 Fuel sender33 Right handlebar switch34 Front brake light switch35 Engine stop switch36 Start switch37 Left handlebar switch38 Pass switch39 Dimmer switch40 Horn switch41 Clutch switch42 Turn signal switch43 Horn44 Flasher relay45 Frotn turn signal light (left)46 Front turn signal light (right)47 Rear turn signal light (left)48 Rear turn signal light (right)49 Oil level switch50 Headlight51 Rear brake light switch52 Tail/brake light53 Licence light54 Fuse (ignition)55 Fuse (signal)56 Fuse (headlight)57 Fuse (radiator fan motor)58 Thermo switch59 Radiator fan motor60 Headlight relay

YZF-R6 WIRING DIAGRAM (for AUS)

COLOR CODEB Black. . . . . .Br Brown. . . . .

C h C ho co la te. . . .D g D ark g re en. . . .

G Green. . . . .

Gy Gray. . . .L Blue. . . . . .L g B lu e g re en. . . . .

O Orange. . . . .

P Pink. . . . . .

R Red. . . . . .Sb Sky blue. . . . .

W White. . . . .Y Yellow. . . . . .

B / L B la ck / Bl ue. . . .

B / R B la ck / Re d. . . .B /W B lack/Whi te. . .B/Y Black/Yel low. . . .

Br/B Brown/Black. . .

Br /L Brown/Blue. . .

Br/W Brown/White. . .G / R G re en / Re d. . .

G /W Green/Whi te. . .G/Y Green/Yel low. . . .

Gy/B Gray/Black. . .

L / B B lu e/ Bl ac k. . . .L / R B lu e/ Re d. . . .L /W B lue/White. . .

L /Y B lue/Ye llow. . . .O /B Orange/Black. . . .

R / B Re d/ Bl ac k. . . .R / L Re d/ Bl ue. . . .

R /W Red/Whi te. . .R /Y Red/Yellow. . . .

Sb/W Sky blue/White. .

W/G Whi te /Green. . .W/R Whi te /Red. . .W/Y White/Yel low. . .

Y/B Yellow/Black. . . .