EAS00001

YZF-R6L/YZF-R6CL

SERVICE MANUAL

 1999 by Yamaha Motor Corporation,

U.S.A.

First edition, February 1999

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-11616-12-62

NOTE:

WARNING

CAUTION:

EAS00003

NOTICE

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

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

al. 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 ve-

hicle 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 in necessary to ensure that the ve-

hicle 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 with fed-

eral environmental quality objectives.

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 and

will appear in future editions of this manual where paalicable.

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.

EB002000

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 motorcycle operator, a bystander or a person checking or repairing the mo-

torcycle.

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

to the motorcycle.

NOTE:

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

1

2

6

4

5

7

3

8

EB003000

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.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) ap-

pears.

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 a

disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

22

1

3

5

7

9

2

4

8

6

24

25

23

21

19

20

18

16

17

15

14

13

11

12

10

GEN

INFO

SPEC

ENG

CARB

ELEC

CHAS

COOL

CHK

ADJ

TRBL

SHTG

EB004000

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1 to 9 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 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 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols ¹⁸ to ²³ in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum disulfide oil

21 Wheel bearing grease

22 Lithium soap base grease

23 Molybdenum disulfide grease

Symbols ²⁴ to ²⁵ in the exploded diagrams indi-

cate the following.

24 Apply locking agent (LOCTITE^)

25 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETORS

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO 1

SPEC 2

3

ENG 4

COOL 5

CARB 6

CHAS 7

ELEC 8

TRBL

SHTG 9

CHK

ADJ

INDEX

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER

1-1

. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL CODE

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION

1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL AND DISASSEMBLY

1-2

. . . . . . . . . .

REPLACEMENT PARTS

1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS

1-2

. . . . . . . . . . . . . . . . . . . . . . . .

USING A DYNAMOMETER

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS

1-3

. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS

1-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES

1-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INTAKE SYSTEM

1-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT

1-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM

1-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS

1-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN

INFO

1-1

MOTORCYCLE IDENTIFICATION

GEN

INFO

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

EB100010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped

into the right side of the steering head pipe.

EB100020

MODEL CODE

The model code label 1 is affixed to the frame.

This information will be needed to order spare

parts.

1-2

IMPORTANT INFORMATION

GEN

INFO

EB102000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DIS-

ASSEMBLY

1. Before removal and disassembly, remove all

dirt, mud, dust, and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to “SPECIAL TOOLS”.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have been

“mated” through normal wear. Mated parts

must always be reused or replaced as an as-

sembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of disas-

sembly. This will speed up assembly and al-

low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB102010

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs.

Other brands may be similar in function and ap-

pearance, but inferior in quality.

EB102020

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals, and O-rings. All gasket sur-

faces, oil seal lips, and O-rings must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

1-3

IMPORTANT INFORMATION

GEN

INFO

CAUTION:

USING A DYNAMOMETER

The YZF-R6L/YZF-R6CL has a carbon muffler

that may change color when exposed to high

temperatures. Therefore, when using a dy-

namometer always use a fan to cool the muffler.

EB102030

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

1 and cotter pins. After the bolt or nut has been

tightened to specification, bend the lock washer

tabs and the cotter pin ends along a flat of the

bolt or nut.

EB102040

BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-

ible. When installing oil seals, lubricate the

oil seal lips with a light coat of lithium soap

base grease. Oil bearings liberally when

installing, if appropriate.

1 Oil seal

Do not spin the bearing with compressed air

because this will damage the bearing sur-

faces.

1 Bearing

EB102050

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips. Al-

ways replace piston pin clips after one use.

When installing a circlip 1 , make sure that the

sharp-edged corner 2 is positioned opposite

the thrust 3 that the circlip receives.

4 Shaft

1-4

CHECKING THE CONNECTIONS

GEN

INFO

NOTE:

NOTE:

NOTE:

EB103000

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for

stains, rust, moisture, etc.

1. Disconnect:

lead

coupler

connector

2. Check:

lead

coupler

connector

Moisture
Dry with an air blower.

Rust/stains
Connect and disconnect sev-

eral times.

3. Check:

all connections

Loose connection
Connect properly.

If the pin 1 on the terminal is flattened, bend it

up.

4. Connect:

lead

coupler

connector

Make sure that all connections are tight.

5. Check:

continuity

(with the pocket tester)

Pocket tester

90890-03112

If there is no continuity, clean the terminals.

When checking the wire harness, perform

steps (1) to (3).

As a quick remedy, use a contact revitalizer

available at most part stores.

1-5

FEATURES

GEN

INFO

Former thermostat

Temperature

Time

New thermostat

Temperature

Time

FEATURES

AIR INTAKE SYSTEM

System diagram

This system is designed to improve the power while riding a motorcycle at a high speed by increasing

the air intake efficiency by means of pressurizing the air filter case 2 where the air is taken in via the air

duct 1 from the air intake port located under the headlight.

The system also delivers air pressure from the air filter case to the carburetor side.

The air pressure is operated to the fuel level in the carburetor to supply the appropriate fuel to increase

the power.

The air chamber 3 is also installed between the air filter case and carburetor for delivery of stabilized

air pressure to the carburetor.

THERMOSTAT

Coolant flow is controlled by the thermostat of

which flow control valve 1 is newly developed

for avoiding quick temperature change.

(Refer to the graphs)

2 Notch groove