YZF-R6T
5SL-28197-12
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-18-45
YZF-R6TC
YZF-R6T / YZF-R6TC
SUPPLEMENTARY
SERVICE MANUAL
©2004 by Yamaha Motor
Corporation, U.S.A.
First edition, September 2004
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-11616-18-45
EAS00001
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R6T / YZF-R6TC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
YZF-R6R / YZF-R6SR / YZF-R6RC / YZF-R6SRC SERVICE MANUAL:
LIT-11616-16-45 (5SL-28197-10)
YZF-R6S / YZF-R6SC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-17-46 (5SL-28197-11)
EAS00030
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
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 dealers 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.
EAS00040
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
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
EAS00007
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. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
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)
appears.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described
sequentially.
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols to indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
Symbols to indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols to in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap-based grease
Molybdenum-disulfide grease
Symbols to in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE
®
)
Replace the part
CONTENTS
GENERAL INFORMATION
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 5
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 5
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PERIODIC CHECKS AND ADJUSTMENTS
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . 20
ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . 22
CHASSIS
FRONT WHEEL AND BRAKE DISCS. . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 26
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . 36
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . 38
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHECKING THE DRIVE CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
COOLING SYSTEM
RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ELECTRICAL SYSTEM
ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
YZF-R6T / YZF-R6TC WIRING DIAGRAM
GEN
INFO
1
EAS00027
GENERAL INFORMATION
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country. When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool No. Tool name / Function Illustration
90890-01423
YM-01423
Damper rod holder
This tool is used to hold the damper rod
assembly when loosening or tightening the
damper rod assembly bolt.
90890-01434
YM-01434
Rod holder
This tool is used to support the damper
adjusting rod.
90890-01441
YM-01441
Fork spring compressor
This tool is used to disassemble or assemble
the front fork legs.
90890-01442
YM-01442
Fork seal driver
This tool is used to install the front fork’s oil
seal and dust seal.
SPECIAL TOOLS
SPEC
2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
Item Standard Limit
Model code 5SLR (USA except for CAL) • • •
5SLS (CAL)
Dimensions
Overall length 2,045 mm (80.5 in) •
• •
Overall width
690 mm (27.2 in)
• • •
Overall height 1,105 mm (43.5 in) • • •
Seat height 830 mm (32.7 in) • • •
Wheelbase 1,385 mm (54.5 in) • • •
Minimum ground clearance 145 mm (5.7 in) • • •
Minimum turning radius 3,800 mm (149.6 in) • • •
Weight
Wet (with oil and a full fuel tank) 183 kg (404 lb) (USA except for CAL) • • •
184 kg (406 lb) (CAL) • • •
Maximum load (except motorcycle) 192 kg (423 lb) (USA except for CAL) • • •
191 kg (421 lb) (CAL) • • •
Item Standard Limit
Throttle bodies
Model (manufacturer)
× quantity 40EIS (MIKUNI) × 4• • •
ID mark 5SLM 30 (5SLR), 5SLS 40 (5SLS) • • •
GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS
SPEC
3
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Caster angle 24.5° • • •
Trail 95 mm (3.74 in) • • •
Front tire
Size 120 / 70 ZR17 M / C (55W) • • •
Model (manufacturer) Pilot POWER C (MICHELIN) • • •
D218FM (DUNLOP)
Rear tire
Model (manufacturer) Pilot POWER (MICHELIN) • • •
D218M (DUNLOP)
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) • • •
90 ~ 192 kg (198 ~ 426 lb) 290 kPa (2.9 kgf / cm
2
, 2.9 bar, 41.3 psi) • • •
(USA except for CAL)
90 ~ 191 kg (198 ~ 423 lb) (CAL) 290 kPa (2.9 kgf / cm
2
, 2.9 bar, 41.3 psi) • • •
High-speed riding 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) • • •
Front brakes
Brake lever free play 6.7 ~ 18.1 mm (0.26 ~ 0.71 in) • • •
Brake discs
Diameter × thickness 310 × 4.5 mm (12.20 × 0.18 in) • • •
Min. thickness • • • 4.0 mm
(0.16 in)
Master cylinder inside diameter 16 mm (0.63 in) • • •
Rear brake
Brake pedal freeplay 4.3 ~ 9.0 mm (0.17 ~ 0.35 in) • • •
CHASSIS SPECIFICATIONS
SPEC
4
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Front suspension
Spring
Free length 248.8 mm (9.80 in) 243.8 mm
(9.60 in)
Installed length 244.3 mm (9.62 in) • • •
Spring rate (K1) 8.8 N / mm (0.90 kg / mm, 50.22 lb / in) • • •
Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.7244 in) • • •
Inner tube outer diameter 41 mm (1.61 in) • • •
Fork oil
Quantity (each front fork leg) 0.475 L (0.418 lmp qt, 0.502 US qt) • • •
Level (from the top of the outer tube,
with the outer tube fully compressed,
and without the fork spring)
92 mm (3.62 in) • • •
Spring preload adjusting positions
Minimum 8 • • •
Standard 7 • • •
Maximum 0 • • •
Rebound damping adjusting positions
Minimum* 10 • • •
Standard* 6 • • •
Maximum* 1 • • •
Compression damping adjusting
positions
Minimum* 13 • • •
Standard* 6 • • •
Maximum* 1 • • •
*from the fully turned-in position
Rear suspension
Spring
Free length 167.5 mm (6.59 in) •
• •
Installed length 157.5 mm (6.2 in) • • •
Spring rate (K1) 103 N / mm (10.5 kg / mm, 587.83 lb / in) • • •
Drive chain
Maximum 15-link section •
• • 239.3 mm
(9.42 in)
Item Standard Limit
Ignition system
CDI unit model (manufacturer) F8T828 (MITSUBISHI) •
• •
Fuses (amperage × quantity)
Radiator fan motor fuse 15 A × 2• • •
CHASSIS SPECIFICATIONS /
ELECTRICAL SPECIFICATIONS
SPEC
5
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
NOTE:NOTE:
1. Insert the front wheel axle from the right
side and tighten it with the flange bolt from
the left side to 91 Nm (9.1 m•kg, 66 ft•lb).
2. In the order from the pinch bolt → pinch
bolt → pinch bolt , tighten each bolt to
21 Nm (2.1 m•kg, 15 ft•lb) without performing temporary tightening.
3. Check that the end face of the axle head
and the end face of the fork side are flushmounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to
the end face of the fork, align them so that
one point of the axle circumference is positioned on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt → pinch
bolt → pinch bolt , tighten each bolt to
21 Nm (2.1 m•kg, 15 ft•lb) without performing temporary tightening.
Item Fastener
Thread
size
Q’ty
Tightening torque
Remarks
Nm m•kg ft•lb
Clutch boss Nut M20 1 90 9.0 65 Use a lock
washer
Cylinder identification sensor Bolt M6 1 7.5 0.75 5.4
Yamaha bond No.1215
Item
Thread
size
Tightening torque
Remarks
Nm m•kg ft•lb
Handlebar and front fork M8 32 3.2 2.3
Front fender and front fork M6 6 0.6 4.3
Rear brake master cylinder and footrest bracket M8 13 1.3 9.4
Front brake caliper and front fork M10 35 3.5 25
Front master cylinder bleed screw M8 6 0.6 4.3
Brake caliper bleed screw M8 5 0.5 3.6
Front wheel axle pinch bolt M8 21 2.1 15 See NOTE
TIGHTENING TORQUES
SPEC
6
CABLE ROUTING
Right handlebar switch lead
Clutch cable
Main switch lead
Left handlebar switch lead
Throttle cable (return side)
Throttle cable (pull side)
Horn lead
Steering cover
Front brake hose
Throttle cables
Joint
Pass the right handlebar switch lead inside the
front brake hoses and over the throttle cables.
Install the throttle cables to the hook so that the
pulling side of the throttle cables is routed downward.
Pass the clutch cable through the guide.
Plastic locking tie shall be positioned at 15 mm
(0.59 in) below from the upper bracket.
Clamp the left handlebar switch lead to the front fork
with the plastic locking tie and cut the tip of the tie.
Clamp it to the protector section.
Clamping position should be 10 mm (0.39 in) or
lower from the top end of the under bracket.
Attach the horn lead to the hook on the steering
cover.
CABLE ROUTING
SPEC
7
Clamp it at the position of 50 mm (1.97 in) to 65
mm (2.56 in) from the upper face of the under
bracket with the plastic locking tie. Cut the surplus
part of the clamp tip leaving 2 mm (0.08 in) to 4
mm (0.16 in). Point the tip of the clamp to the outside of vehicle.
Pass the throttle cables inside the front brake
hoses.
Set in the coupler between the headlight’s hollow
section and the duct.
To the wire harness
To the front turn signal light (right)
Set the sub wire harness in the joint.
Do not catch the sub wire harness when the duct
is assembled.
To the front turn signal light (left)
Install the relay to the rib of the headlight.
(Location for the left and right relays is alternative.)
Point the tip of the plastic locking tie to the front
side of the vehicle. Cut the tip leaving 2 ~ 10 mm
(0.08 ~ 0.39 in).
Point the tip of the plastic locking tie to the outside
of the vehicle. Cut the tip leaving 2 ~ 10 mm (0.08
~ 0.39 in).
Attach the horn lead pointing to the front side of
the vehicle.
CABLE ROUTING
SPEC
8
Throttle stop screw
Coolant reservoir tank hose
Cover 8
Radiator fan motor lead (right)
Pickup coil lead
Rear tail / brake light switch lead
Radiator return hose
Coolant hose
Clutch cable
Coolant hose protector
Hose clamp assembly
Hose clamp
Pass the rear tail / brake light switch lead outside of
rear engine mount bolt.
Pass the ignition coil lead outside of the radiator
hose.
Pass the coolant reservoir tank hose under the
frame and right side of the throttle body.
The tip of the clamp should be pointed to the
inside above the vehicle. Items to be clamped here
are the radiator fan motor lead (right), coolant reservoir tank hose and radiator return hoses (2
hoses).
Coupler should be placed within the shaded area
of the cover 8. (Extrusion below the shaded area is
prohibited.)
Radiator fan motor lead (right) should be entered
into the inside of the vehicle through the frame
hole.
Clamp the clutch cable.
CABLE ROUTING
SPEC
9
Route the radiator fan motor lead (right) by the outside of the clutch cable.
Route the radiator fan motor lead (right) and clutch
cable by the inner side of the coolant reservoir
tank hose and radiator return hoses (2 hoses).
The punch mark starting point should be lower
than the clamp’s top end.
However, the aiming position of the punch mark
starting point should be 5 mm (0.20 in) below the
clamp’s bottom end.
Pass the clutch cable inside of the radiator hose.
Assemble as “ ” shown below when clamping.
Pass the pickup coil lead over the throttle stop
cable.
Tip of the plastic locking tie shall be pointed to the
inner side at the rear part of the vehicle.
Clamp the clutch cable so that it is positioned in
this range.
Put and apply the hose clamp to it.
Clamp the clutch cable by routing the upper end of
the clamp along with the bottom end of the hose
clamp assembly.
CABLE ROUTING
SPEC
10
Throttle cable (return side)
Throttle cable (pull side)
Starter motor lead
Canister hose (for CAL)
Canister (for CAL)
Balance hose (for CAL)
Coolant reservoir tank breather hose
Bracket 2
Sidestand switch lead
Oil level switch lead
A.C. magneto lead
Radiator fan motor lead (left)
Fuel tank breather hose
Fuel tank drain hose
Coolant reservoir tank cover
Drive sprocket cover
Coolant reservoir tank
Pass the main switch lead under the left handlebar
switch lead and then to the right side of the vehicle.
Pass the throttle stop cable by the left side of the
side stand switch lead, oil level switch lead, A.C.
magneto lead and then to the right side of the vehicle.
Route the A.C. magneto lead, sidestand switch
lead and oil level switch lead so that they pass the
inner side of the barance pipe 3. (for CAL)
Pass the fuel tank drain hose and fuel tank
breather hose inside of the coolant reservoir tank
breather hose, coolant reservoir tank hose and
wire harness and then route it by the out side of
the starter motor lead.
Pass the coolant reservoir tank hose outside of the
fuel tank drain hose and fuel tank breather hose.
CABLE ROUTING
SPEC
11
Pass the fuel tank drain hose, fuel tank breather
hose through the clamp of the coolant reservoir
tank.
Pass the coolant reservoir tank breather hose
through the clamp of under the coolant reservoir
tank.
Projection allowance from the coolant reservoir
tank cover shall be 30 to 50 mm (1.18 ~ 1.97 in).
Pass the oil level switch lead and sidestand switch
lead over the bracket 2.
Pass the oil level switch lead, and sidestand switch
lead through the clamp.
5 ~ 45 mm (0.20 ~ 1.77 in).
Clamp the A.C. magneto lead, oil level switch lead
and sidestand switch lead.
Pass the sidestand switch lead, oil level switch
lead and A.C. magneto lead between the engine
stay and the engine.
To the throttle body
To the radiator fan motor relay and fuse box
Route the radiator fan motor lead (left) by the outside of the radiator inlet hose.
Pass the throttle cable between the guide of the
cover 2 and the frame.
Pass the radiator fan motor lead (left) through the
hole of the frame to the inner side of the vehicle.
To the horn
Pass the coolant reservoir tank breather hose
through the hole of the coolant reservoir tank
cover.
Order of ups and downs means no object.
Route it below the coolant reservoir tank.
CABLE ROUTING
SPEC
12
Right handlebar switch lead
Radiator fan motor lead (right)
Sub wire harness
Headlight lead
Meter lead
Cover 8
Ignition coil lead
Throttle position sensor coupler
Coolant reservoir tank hose
Throttle stop cable
Speed sensor lead coupler
Crankshaft position sensor lead
coupler
Fuel tank breather hose (except
for CAL)
Fuel tank drain hose (except for
CAL)
Fuel hose (return side, except
for CAL)
Fuel pump 2 coupler
Fuel pump 1 coupler
Starter motor lead
Fuel hose (feed side, except for
CAL)
Crankcase breather hose
Throttle air vent hose
Fuse box
Cover 7
Radiator fan motor relay
Radiator fan motor lead (left)
Left handlebar switch lead
Main switch lead
Wire harness
Throttle cables
Throttle sub-lead 1 (white 6
poles)
Throttle sub-lead 2 (black 6
poles)
Oil level switch lead coupler
(white 1 pole)
Sidestand switch lead coupler
(blue 2 poles)
A.C. magneto lead coupler
(white 3 poles)
Rear tail / brake light switch lead
coupler (brown 2 poles)
CABLE ROUTING
SPEC
13
Neutral switch lead coupler (connector 1 pole)
Fuel hose (return side, for CAL)
Canister hose (for CAL)
Fuel hose (feed side, for CAL)
Fuel tank drain hose (for CAL)
To the headlight
Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it
when installing the side cowling.
Clamp the plastic locking tie to the cover 8. Place
the coupler at the rear side of the vehicle against
the plastic locking tie. Point the tip of the plastic
locking tie to the downward in the inner side of the
vehicle.
Route the headlight and meter leads under the
frame’s lower part from the hollow section of the
cover 2.
Pass the left and right handlebar switch leads outside of the air filter case air vent hose.
Connect the couplers (4 units) at the frame side
hole. Do not catch each lead and wire harness
when the cover 8 is attached.
From the radiator
Pass the coolant reservoir tank hose through forward the starter motor lead and speed sensor
lead.
Pass the speed sensor lead coupler and crankshaft position sensor lead coupler over the throttle
stop cable.
CABLE ROUTING
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