by Clymer Staff
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Quote order code CM461
Yamaha YZF-R6 1999 - 2004 Clymer Owners Service & Repair Manual Covers the Yamaha YZF-R6 sportbikes 1999 - 2004
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage
Engine operating requirements / Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system / Fuel pump / Electrical testing / Electrical troubleshooting / Cooling system circuit / Steering and suspension / Brake system
● LUBRICATION, MAINTENANCE AND TUNE-UP
Cylinder numbering and firing order / Maintenance intervals / Tune-up / Ignition timing inspection(carbureted models) / Valve clearance / Spark plugs / Engine oil / Engine oil pressure / Carburetor synchronization / Idle speed adjustment / Fuel line inspection / Fuel filter / Emission control systems / Exhaust gas volume adjustment (Europe and Australia fuel injected models) / Exhaust system inspection / Control cable lubrication / Throttle cables / Choke cable inspection (carbureted models) / Clutch cable free play / Shift pedal height / Battery / Cooling system / Tyres and wheels / Front suspension / Front fork adjustments / Steering head bearings / Rear suspension inspection / Shock absorber adjustments / Drive chain / Brake system / General lubrication / Fastener inspection / Specifications
● ENGINE TOP END
Servicing engine in the frame / Cylinder head cover / Camshaft / Cam sprocket / Cam chain tensioner / Cam chain guides / Cam chain / Cylinder head / Valve lifters and shims / Valve components / Specifications
● ENGINE LOWER END
Engine removal and installation / Timing rotor cover / Timing rotor / Alternator cover / Flywheel and starter gears / Starter clutch / Oil pan / Oil pump / Crankcase / Crankshaft / Connecting rods / Piston and piston rings / Engine break-in / Specifications
Clutch cover / Clutch release mechanism / Clutch cable
● TRANSMISSION AND SHIFT MECHANISM
Shift rod and shift lever / Engine sprocket cover / Engine sprocket / Shift pedal footrest / External internal shift mechanism
● AIR/FUEL, EMISSIONS AND EXHAUST SYSTEMS - CARBURETED MODELS
Fuel tank / Fuel valve / Fuel sender / Fuel filter / Fuel pump / Fuel sender and fuel level indicator light / Air filter / Carburetor overhaul adjustments / Throttle position sensor / Throttle cable / Choke cable / Air induction system AIS / Evaporative emission control system / Exhaust system
● AIR/FUEL, EMISSIONS AND EXHAUST SYSTEMS - FUEL INJECTED MODELS
Depressurizing the fuel system / Fuel tank / Fuel pump / Fuel injection relay / Fuel sender and fuel level indicator light / Air filter / Throttle body assembly / Piston valve / Fuel injector / Throttle position sensor / Pressure regulator / Cylinder identification sensor / Intake air pressure sensor / Intake air temperature sensor / Atmospheric pressure sensor / Lean angle cutoff switch / Crankshaft position sensor / Throttle cable replacement / Air induction system / Evaporative emission control system / Exhaust system / Fuel injection diagnostic system
● ELECTRICAL SYSTEM
Charging system / Stator / Voltage regulator rectifier / Ignition system / Spark plug / Direct ignition coil / Pickup coil Crankshaft position sensor / Ignition control unit / Engine control unit / Starting system / Starting circuit cutoff relay / Starter / Lights / Meter assembly / Oil level warning light / Oil level switch / Oil level relay / Fuel level indicator / Fuel sender / Horn / Clock / Speedometer / Speed sensor / Diagnostic system / Switches
● COOLING SYSTEM
Inspection / Coolant reservoir / Radiator / Radiator fan / Thermo switch / Radiator fan relay / Temperature sensor thermostat / Water pump / Oil cooler / Carburetor heater system / Fast idle plunger
● WHEELS AND TYRES
Motorcycle stand / Brake rotor protection / Wheel inspection / Front wheel / Front hub / Front wheel bearings / Rear wheel / Rear hub / Rear wheel bearing replacement / Wheel sprocket / Wheel balance / Tyres / Specifications
● FRONT SUSPENSION AND STEERING
Fork / Handlebar / Steering head / Steering head bearing races / Steering stem bearing
● REAR SUSPENSION AND DRIVE CHAIN
Shock absorber / Rear suspension linkage / Swing arm / Drive chain
Brake service / Preventing brake fluid damage / Brake bleeding / Brake fluid draining / Brake pad inspection / Front brake caliper / Front master cylinder / Rear brake caliper / Rear brake master cylinder / Brake disc / Brake hose replacement / Brake pedal/footrest assembly / Specifications
● FRAME AND BODY
Riders seat / Passenger seat / Body panel fasteners / Fairing service / Lower fairing / Console panel / Side fairing / Side cover / Windshield / Mirror / Front fairing / Tail cover / Rear fender / Front fender / Passenger footpeg / Sidestand / Specifications
● COLOUR WIRING DIAGRAMS
Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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