SERVICE MANUAL

YZFR6X(C)

13S-28197-10

LIT-11616-21-61

2008

EAS20050

YZFR6X(C)

SERVICE MANUAL

©2007 by Yamaha Motor

Corporation, U.S.A.

First edition, October 2007

All rights reserved. Any reproduction

or unauthorized use without the written

permission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-21-61

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. If there is any question about a service procedure, it is imperative

that you contact a Yamaha dealer for any service information changes that apply to this model. This

policy is intended to provide the customer with the most satisfaction from his vehicle and to conform

to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

NOTE:

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS20080

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section

title “1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described

sequentially.

CLUTCH

5-36

EAS25060

CLUTCH

Removing the clutch cover

Order

Job/Parts to remove

Q’ty

Remarks

.

1

-

4

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A

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e

f

e

R

ylb

m

e

s

s

a

g

nil

w

o

c

e

di

S

Engine oil

Drain.

Refer to “CHANGING THE ENGINE OIL” on

page 3-12.

Coolant

Drain.

Refer to “CHANGING THE COOLANT” on

page 3-21.

.tc

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n

n

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si

D

1

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1

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1

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2

1

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P

3

1

g

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P

4

1

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e

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5

1

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s

a

g

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e

v

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h

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6

2

nip

le

w

o

D

7

For installation, reverse the removal proce-

dure.

5

2

6

7

1

3

4

7

LT

New

New

LT

New

LS

T R

.

.

12 Nm (1.2 m • kg, 8.9 ft • Ib)

T R

.

.

12 Nm (1.2 m • kg, 8.9 ft • Ib)

T R

.

.

12 Nm (1.2 m • kg, 8.9 ft • Ib)

CLUTCH

5-40

EAS25070

REMOVING THE CLUTCH

1. Remove:

• Oil strainer

Refer to “OIL PUMP” on page 5-48.

• Water pump

Refer to “WATER PUMP” on page 6-8.

• Friction plates

• Clutch plates

NOTE:

Be sure to mark the friction plates and clutch

plates or note the position of each part so that

they are installed in their original positions.

2. Loosen:

• Clutch boss nut “1”

NOTE:

While holding the clutch boss “2” with the uni-

versal clutch holder “3”, loosen the clutch boss

nut.

3. Remove:

• Spacer “1”

• Bearing

• Clutch housing “2”

• Oil pump drive chain

NOTE:

Remove the spacer and bearing from the main

axle, then remove the oil pump drive chain

from the oil pump driven sprocket, and then

remove the clutch housing and oil pump drive

chain from the main axle.

EAS25100

CHECKING THE FRICTION PLATES

The following procedure applies to all of the

friction plates.

1. Check:

• Friction plate

Damage/wear

Replace the friction

plates as a set.

2. Measure:

• Friction plate thickness

Out of specification

Replace the fric-

tion plates as a set.

NOTE:

Measure the friction plate at four places.

EAS25110

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the

clutch plates.

1. Check:

• Clutch plate

Damage

Replace the clutch plates as

a set.

2. Measure:

• Clutch plate warpage

(with a surface plate and thickness gauge

“1”)

Out of specification

Replace the clutch

plates as a set.

Universal clutch holder

90890-04086

YM-91042

1

2

3

Friction plate thickness

2.92–3.08 mm (0.115–0.121 in)

Wear limit

2.80 mm (0.1102 in)

2

1

EAS20100

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum-disulfide oil

12.Brake fluid

13.Wheel-bearing grease

14.Lithium-soap-based grease

G

M

LS

M

E

9

10

11

16

17

18

B

13

12

14

15

LT

New

T R

.

.

1

2

3

4

5

6

7

8

BF

15.Molybdenum-disulfide grease

16.Silicone grease

17.Apply locking agent (LOCTITE®)

18.Replace the part

1

2

3

4

5

6

7

8

9

EAS20110 TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

1

GENERAL INFORMATION

IDENTIFICATION..........................................................................................1-1

VEHICLE IDENTIFICATION NUMBER...................................................1-1

MODEL LABEL.......................................................................................1-1

FEATURES ...................................................................................................1-2

OUTLINE OF THE FI SYSTEM ..............................................................1-2

FI SYSTEM.............................................................................................1-3

YCC-T (Yamaha Chip Controlled Throttle)

YCC-I (Yamaha Chip Controlled Intake) .................................................1-4

INSTRUMENT FUNCTIONS ..................................................................1-8

IMPORTANT INFORMATION .....................................................................1-12

PREPARATION FOR REMOVAL AND DISASSEMBLY........................1-12

REPLACEMENT PARTS.......................................................................1-12

GASKETS, OIL SEALS AND O-RINGS................................................1-12

LOCK WASHERS/PLATES AND COTTER PINS .................................1-12

BEARINGS AND OIL SEALS ...............................................................1-13

CIRCLIPS .............................................................................................1-13

CHECKING THE CONNECTIONS .............................................................1-14

SPECIAL TOOLS........................................................................................1-15

IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is

stamped on the right side of the steering head

pipe.

EAS20150

MODEL LABEL

The model label “1” is affixed to the frame

under the passenger seat. This information will

be needed to order spare parts.

1

1

FEATURES

1-2

EAS20170

FEATURES

ET2C01025

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-

mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-

ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the

combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet

used in the respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating

conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that

meter the fuel through the use of jets have been provided with various auxiliary devices, so that an

optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-

ditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases

increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-

ner. To accommodate this need, this model has adopted an electronically controlled fuel injection

(FI) system, in place of the conventional carburetor system. This system can achieve an optimum

air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel

injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine

response, better fuel economy, and reduced exhaust emissions.

1

10

13

22

21

20

2

6

7

8

3

4

5

9

11

12

14

15

16

17

18

19

23

1. Intake air temperature sensor

2. Atmospheric pressure sensor

3. Engine trouble warning light

4. Air induction system solenoid

5. Throttle servo motor

6. Secondary injectors

7. Primary injectors

8. Intake air pressure sensor

9. Fuel pump

10.Relay unit (fuel pump relay)

11.Lean angle sensor

12.ECU (engine control unit)

13.EXUP servo motor

14.O2 sensor

15.Speed sensor

16.Coolant temperature sensor

17.Crankshaft position sensor

18.Throttle position sensor (for throttle cable

pulley)

19.Throttle position sensor (for throttle valves)

20.Spark plug

21.Ignition coil

22.Cylinder identification sensor

23.Intake funnel servo motor

FEATURES

1-3

ET2C01019

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the

fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly,

when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus-

ing the fuel to be injected into the intake manifold only during the time the passage remains open.

Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater

the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is ener-

gized (injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from

the throttle position sensor (for throttle cable pulley), throttle position sensor (for throttle valves),

coolant temperature sensor, atmospheric pressure sensor, cylinder identification sensor, lean angle

sensor, crankshaft position sensor, intake air pressure sensor, air temperature sensor, speed sensor

and O2 sensor enable the ECU to determine the injection duration. The injection timing is deter-

mined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is

required by the engine can be supplied at all times in accordance with the driving conditions.

2

19

18

B

17

15

14

13

12

A

3

1

16

4

11

5

C

8

6

7

9

#3

#1 #2

#4

#3

#1 #2

#4

10

20

1. Secondary injector

2. Fuel pump

3. Primary injector

4. Cylinder identification sensor

5. ECU (engine control unit)

6. Throttle position sensor (for throttle cable

pulley)

7. Throttle position sensor (for throttle valves)

8. Speed sensor

9. Air temperature sensor

10.Lean angle sensor

11.O2 sensor

12.Catalytic converter

13.Coolant temperature sensor

14.Crankshaft position sensor

15.Intake air pressure sensor

16.Throttle servo motor

17.Throttle body

18.Atmospheric pressure sensor

19.Air filter case

20.Intake funnel servo motor

A. Fuel system

B. Air system

C. Control system

FEATURES

1-4

EAS4C81011

YCC-T (Yamaha Chip Controlled Throttle)

YCC-I (Yamaha Chip Controlled Intake)

Mechanism characteristics

Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control

technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has

developed a faster, more compact system specifically for the needs of a sports motorcycle. The

Yamaha-developed system has a high-speed calculating capacity that produces computations of

running conditions every 1/1000th of a second.

The YCC-T system is designed to respond to the throttle action of the rider by having the ECU

instantaneously calculate the ideal throttle valve opening and generate signals to operate the motor-

driven throttle valves and thus actively control the intake air volume.

The ECU contains three CPUs with a capacity about five times that of conventional units, making it

possible for the system to respond extremely quickly to the slightest adjustments made by the rider.

In particular, optimized control of the throttle valve opening provides the optimum volume of intake

air for easy-to-use torque, even in a high-revving engine.

The YCC-I system calculates the value from the engine revolution number and throttle opening rate,

activates the intake air funnel with the electronic control motor drive to control the intake pipe length

in order to gain the high power output in all revolution ranges from low speeds to high speeds.

Aims and advantages of using YCC-T system

• Increased engine power

By shortening the air intake path, higher engine speed is possible → Increased engine power.

• Improved driveability

Air intake volume is controlled according to the operating conditions → Improved throttle response

to meet engine requirement.

Driving force is controlled at the optimal level according to the transmission gear position and

engine speed → Improved throttle control.

• Engine braking control

Due to the throttle control, optimal engine braking is made possible.

• Simplified idle speed control (ISC) mechanism

The bypass mechanism and ISC actuator are eliminated → A simple mechanism is used to main-

tain a steady idle speed.

• Reduced weight

Compared to using a sub-throttle mechanism, weight is reduced.

1. Throttle position sensor (for throttle cable

pulley)

2. Throttle servo motor

3. Throttle position sensor (for throttle valves)

4. Throttle valves

5. Throttle cable pulley with linkage guard

A. To throttle grip

FEATURES

1-5

Aims and advantages of using YCC-I system

• Improvement of the engine power characteristics

The high power design in all ranges is now provided by having both two features of the short

intake function to ensure the power at the high speed revolution of engine, and the long intake

function to ensure the power in the practical use range.

• Intake pipe length switching control using the motor

The intake pipe length switching operation in a minute time is now available by means of the motor

drive using the electronic control.The smooth power characteristic is provided, which does not let

an operator feel the switching action by the optimization of its switching revolution number and the

most suitable application of engine at the time of changing the revolution.

A

B

A. Down position (long intake)

(Low rpm to Mid rpm)

B. Up position (short intake)

(High rpm)

FEATURES

1-6

YCC-T/YCC-I system outline

1. Throttle position sensor (for throttle cable

pulley)

2. Throttle servo motor

3. Throttle position sensor (for throttle valves)

4. ECU (engine control unit)

5. ETV main CPU (32 bit)

6. ETV sub CPU (16 bit)

7. FI CPU (32 bit)

8. Throttle servo motor driver

9. Throttle servo motor driver operation sens-

ing/shut off circuit

10.Throttle servo motor driver operation sensing

feedback/emergency stop

11.Emergency stop

12.Engine revolution (pulse signal)

13.Sensor input

14.Neutral switch

15.Crankshaft position sensor

16.Speed sensor

17.Coolant temperature sensor

18.Atmospheric pressure sensor

19.Intake funnel servo motor driver

20.Intake funnel servo motor