FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YZF-R6N/YZF-R6NC. For complete service information procedures it is necessary to use this Supple-

mentary Service Manual together with the following manual.

YZF-R6L/YZF-R6LC SERVICE MANUAL: LIT-11616-12-62 (5GV-28197-E0)

YZF-R6M/YZF-R6MC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-13-43

(5GV-28197-E1)

EAS00001

YZF-R6N/YZF-R6NC

SUPPLEMENTARY SERVICE MANUAL

 2000 by Yamaha Motor Corporation,

U.S.A.

First edition, September 2000

All rights reserved. Any reproduction or

unauthorized use without the written

permission of Yamaha Motor Corpora-

tion, U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-14-39

NOTE:

WARNING

CAUTION:

EB001000

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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha

motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycles

repair.

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 and

will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

IMPORTANT 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 inspecting or repairing the

motorcycle.

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

5

6

7

8

3

4

YP002000

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 inspection 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” 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 each

page, 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 a

disassembly 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 of

parts, notes in jobs, etc.

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

tially.

EB003000

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 adjustment

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 Apply engine oil

19 Apply gear oil

20 Apply molybdenum disulfide oil

21 Apply wheel bearing grease

22 Apply lightweight lithium-soap base grease

23 Apply molybdenum disulfide grease

Symbols ²⁴ to ²⁵ in the exploded diagrams indi-

cate the following:

24 Apply locking agent (LOCTITE^)

25 Use new one

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

INSP

ADJ

TRBL

SHTG

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

CHASSIS

8

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

CHECKING THE BRAKE FLUID LEVEL

8

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

ADJUSTING THE FRONT FORK LEGS

9

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

CHECKING THE TIRES

11

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

CHASSIS

SWINGARM AND DRIVE CHAIN

14

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

CHECKING THE DRIVE CHAIN

16

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

YZF-R6N/YZF-R6NC WIRING DIAGRAM

–1–

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Limit

Model code

YZF-R6N: 5MT5, 5MT8 (U.S.A.)

YZF-R6NC:5MT6, 5MT9 (California)

YZF-R6N: 5MT7, 5MTA (Canada)

Weight

Wet (with oil and a full fuel tank)

Dry (without oil and fuel)

Maximum load (total of cargo, rider,

passenger, and accessories)

186 kg (410 lb)

187 kg (412 lb) (California)

167 kg (368 lb)

168 kg (370 lb) (California)

375 kg (827 lb)

–2–

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item

Standard

Limit

Camshafts

Drive system

Camshaft cap inside diameter

Camshaft journal diameter

Camshaft-journal-to-camshaftcap

clearance

Chain drive (right)

23.000  23.021 mm (0.9055  0.9063 in)

22.967  22.980 mm (0.9042  0.9047 in)

0.028  0.062 mm (0.0011  0.0025 in)

0.08 mm

(0.0031 in)

Carburetors

Model (manufacturer)
quantity

Throttle cable free play (at the

flange of the throttle grip)

ID mark

Main jet

Main air jet

Jet needle

Needle jet

Pilot air jet

Pilot outlet

Pilot jet

Bypass 1

Bypass 2

Bypass 3

Valve seat size

CVRD37 (KEIHIN)
4

6  8 mm (0.24  0.31 in)

5GV101, 5GV210 (California)

Carburetors 1 and 4: #152, #148 (California)

Carburetors 2 and 3: #148

#110

Carburetors 1 and 4: N7SB

Carburetors 1 and 4: N7SD (California)

Carburetors 2 and 3: N7SA

Carburetors 2 and 3: N7SE (California)

2.6

Carburetors 1 and 4: #105

Carburetors 2 and 3: #110

0.9

#38, #35 (California)

0.8

0.8

0.8

1.2

–3–

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS

Item

Standard

Limit

Front tire

Tire type

Size

Model (manufacturer)

Tire pressure (cold)

0
90 kg (0
198 lb)

90
189 kg (198
417 lb)

90
188 kg (198
415 lb) (California)

High-speed riding

Min. tire tread depth

Tubeless

120/60ZR17 (55W)

MICHELIN

Pilot SPORT B

DUNLOP

D207F^.J

250 kPa (2.5 kg/cm², 36.3 psi)

250 kPa (2.5 kg/cm², 36.3 psi)

250 kPa (2.5 kg/cm², 36.3 psi)

250 kPa (2.5 kg/cm², 36.3 psi)

1.0 mm

(0.04 in)

Rear tire

Tire type

Size

Model (manufacturer)

Tire pressure (cold)

0
90 kg (0
198 lb)

90
189 kg (198
417 lb)

90
188 kg (198
415 lb) (California)

High-speed riding

Min. tire tread depth

Tubeless

180/55 ZR17 (73 W)

MICHELIN

Pilot SPORT B

DUNLOP

D207^.N

250 kPa (2.5 kg/cm², 36.3 psi)

290 kPa (2.9 kg/cm², 42.1 psi)

290 kPa (2.9 kg/cm², 42.1 psi)

250 kPa (2.5 kg/cm², 36.3 psi)

1.0 mm

(0.04 in)

Drive chain

Model (manufacturer)

Link quantity

Drive chain slack

Maximum ten-link section

532ZLV KAI (DID)

116

40
50 mm (1.57
1.97 in)

150.1 mm (5.91 in)

–4–

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS

Item

Standard

Limit

Ignition system

Ignition system type

Ignition timing

Advanced timing

Advancer type

Pickup coil resistance/color

Transistorized coil ignition unit model

(manufacturer)

C.D.I.

10 BTDC at 1300 r/min

5 BTDC at 1300 r/min (California)

55 BTDC at 5250 r/min

Throttle position sensor and electrical

248  372 Ω/Gy-B

F8T383 (MITSUBISHI)

Battery

Battery type

Battery voltage/capacity

GT9B-4

12 V/8 AH

Bulbs (voltage/wattage
quantity)

Headlight

Tail/brake light

Turn signal/position light

Licence plate light

Meter light

12 V 60 W/55 W
2

13.5 V 6.1 W/0.6 W
20 (LED)

12 V 27 W/8 W
2 (front)

12 V 27 W
2 (rear)

12 V 5 W
1

12 V 1.4 W
2

Sidestand relay

Model

Coil resistance

G8R-30Y-M

162  198 Ω

Fuel pump relay model (manufacturer)

Resistance

G8R-30Y-M (OMRON)

162  198 Ω

Fuses (amperage
quantity)

Main fuse

Headlight fuse

Signaling system fuse

Ignition fuse

Radiator fan fuse

Backup fuse (odometer)

Reserve

30 A
1

20 A
1

20 A
1

15 A
1

7.5 A
1

7.5 A
1

30 A
1

20 A
1

15 A
1

7.5 A
1

–5–

TIGHTENING TORQUES

SPEC

ENGINE TIGHTENING TORQUES

Item

Fastener

Thread

size

Q’ty

Tightening

torque

Remarks

size

y

Nm

m
kg

ft
lb

Cap bolt (timing chain tensioner)

Neutral switch

Bolt

Screw

M6

M6

1

2

7

20

0.7

2.0

5.1

14

–6–

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 of

the battery box and the fender.

1 Reservoir tank

2 Fuse box

3 Tool kit

4 Wire minus lead

5 Wire harness

6 Battery box

7 Frame

EB206000

CABLE ROUTING

–7–

O Fasten the main harness, ground lead and battery

box 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 a

cable 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 main

harness.

N Position the wire negative lead coupler under the

main harness.

–8–

CHECKING THE BRAKE FLUID LEVEL

CHK

ADJ

A

B

NOTE:

WARNING

CAUTION:

NOTE:

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

EB304020

CHECKING THE BRAKE FLUID LEVEL

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure that the motorcycle is upright.

2. Check:

brake fluid level

Below the minimum level mark ^a
Add the

recommended brake fluid to the proper level.

Recommended brake fluid

DOT 4

A Front brake

B Rear brake

Use only the designated brake fluid.

Other brake fluids may cause the rubber

seals to deteriorate, causing leakage and

poor brake performance.

Refill with the same type of brake fluid that

is already in the system. Mixing brake

fluids may result in a harmful chemical

reaction, leading to poor brake perfor-

mance.

When refilling, be careful that water does

not enter the brake fluid reservoir. Water

will significantly lower the boiling point of

the brake fluid and could cause vapor lock.

Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean

up any spilt brake fluid immediately.

In order to ensure a correct reading of the brake

fluid level, make sure that the top of the brake

fluid reservoir is horizontal.