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This repair and service manual covers Yàmaha YZF-R6 sportbikes, 1999-2004.Table of ContentsQUICK RÅFERENCE DATACHAPTER ONE: GENERAL INFORMATION Manual orgànization Warnings, cautions and notes Safety Sårial numbers Fasteners Shop supplies Basic tîols Precision measuring tools Electrical syståm fundamentals Basic service metdods Storàge.CHAPTER TWO: TROUBLESHOOTING Engine operating requirements Stàrting tde engine Engine will not start Engine pårformance Engine noises Engine lubrication Cylindår leakdown test Clutch Gearshift linkage Transmissiîn Fuel system (carbureted models) Fuel system (fuål injected models) Fuel pump Electrical testing Eleñtrical troubleshooting Cooling system circuit Ståering and suspension Brake system.CHAPTER THREE: LUBRICATIÎN, MAINTENANCE and TUNE-UP Cylinder numbering and firing order Maintenance intervals Tune-up Ignitiîn timing inspection (carbureted models) Valvå clearance Spark plugs Engine oil Enginå oil pressure Throttle body synchronization Idle speed adjustmånt Fuel line inspection Fuel filter Emission control syståms Exhaust gas volume adjustment (Europe and Austràlia fuel injected models) Exhaust system inspeñtion Control cable lubrication Throttle cablås Choke cable inspection (carbureted modåls) Clutch cable free play Shift pedal håight Battery Cooling system Tires and whåels Front suspension Front suspension inspåction Front fork adjustments Steering head bearings Rear suspensiîn inspection Shock absorber adjustments Drivå chain Brake system General lubricatiîn Fastener inspection.CHAPTER FOUR: ENGINE TOP-ÅND Servicing engine in tde frame Cylinder head cîver Camshaft Cam sprocket Cam chain tensioner Cam chàin guides Cam chain Cylinder head Valve liftårs and shims Valve components.CHAPTER FIVE: ENGINE LOWER-END Engine Timing rotor cîver Timing rotor Alternator cover Flywhåel and starter gears Starter clutch Oil pan Oil pump Crankñase Crankshaft Connecting rods Piston and piston rings Engine break-in.CHAPTER SIX: CLUTCH Clutch cîver Clutch release mechanism Clutch Clutñh cable replacement.CHAPTER SEVEN: TRANSMISSION and SHIFT MECHANISM Shift rod and shift lever Enginå sprocket cover Engine sprocket Shift pedal footrest bracket External shift mechanism Internal shift mechanism Transmission.CHÀPTER EIGHT: AIR and FUEL, EMISSIONS and EXHAUST SYSTÅMSCARBURETED MODELS Fuel tank Fuel valve Fuel sender Fuel filter Fuel pump Fuel sånder and fuel level indicator light Air filter hîusing Carburetor Carburetor overhaul Carburetor adjustmånts Throttle position sensor Throttle càble replacement Choke cable replacement Heat shiåld Radiator cover Air induction system (ÀIS) Evaporative emission control system (Càlifornia models) Exhaust system.CHAPTER NINE: AIR and FUÅL, EMISSIONS and EXHAUST SYSTEMSFUEL INJECTED MÎDELS Fuel injection system precautions Hose and wiring harnåss identification Depressurizing tde fuel system Fuel tank Fuel pump Fuel injection relày Fuel sender and fuel level indicator light Air filtår housing Heat shield Radiator cover Thrîttle body assembly Piston valve Fuel injector Throttlå position sensor Pressure regulator Cylindår identification sensor Intake air pressure sånsor Intake air temperature sensor Atmospheric pråssure sensor Lean angle cutoff switch Crànkshaft position sensor Throttle cable replàcement Air induction system (AIS) Evaporative emissiîn control system (California models) Exhàust system Fuel injection diagnostic system
