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Yamaha YZF-R6TC Supplementary Service Manual

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YZF-R6T
YZF-R6TC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-18-45
5SL-28197-12

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  • Page 1 YZF-R6T YZF-R6TC SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-45 5SL-28197-12...
  • Page 2 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 Sup- plementary Service Manual together with the following manual. YZF-R6R / YZF-R6SR / YZF-R6RC / YZF-R6SRC SERVICE MANUAL:...
  • Page 3 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.
  • Page 4 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.
  • Page 5 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool...

  • Page 6: Table Of Contents

    CONTENTS GENERAL INFORMATION SPECIAL TOOLS......... SPECIFICATIONS GENERAL SPECIFICATIONS .
  • Page 7 TROUBLESHOOTING ........YZF-R6T / YZF-R6TC WIRING DIAGRAM...

  • Page 8: General Information

    SPECIAL TOOLS INFO 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL 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) •...

  • Page 10: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS 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) •...

  • Page 11: Electrical Specifications

    CHASSIS SPECIFICATIONS / SPEC 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) •...

  • Page 12: Tightening Torques

    Q’ty Remarks size m•kg ft•lb Clutch boss Use a lock washer Cylinder identification sensor Bolt 0.75 Yamaha bond No.1215 CHASSIS TIGHTENING TORQUES Tightening torque Thread Item Remarks size m•kg ft•lb Handlebar and front fork Front fender and front fork Rear brake master cylinder and footrest bracket...

  • Page 13: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Right handlebar switch lead Pass the right handlebar switch lead inside the Clutch cable front brake hoses and over the throttle cables. Main switch lead Install the throttle cables to the hook so that the Left handlebar switch lead pulling side of the throttle cables is routed down- Throttle cable (return side)
  • Page 14 SPEC CABLE ROUTING Clamp it at the position of 50 mm (1.97 in) to 65 Install the relay to the rib of the headlight. mm (2.56 in) from the upper face of the under (Location for the left and right relays is alternative.) bracket with the plastic locking tie.
  • Page 15 SPEC CABLE ROUTING Throttle stop screw Pass the ignition coil lead outside of the radiator Coolant reservoir tank hose hose. Cover 8 Pass the coolant reservoir tank hose under the Radiator fan motor lead (right) frame and right side of the throttle body. Pickup coil lead The tip of the clamp should be pointed to the Rear tail / brake light switch lead...
  • Page 16 SPEC CABLE ROUTING Route the radiator fan motor lead (right) by the out- Clamp the clutch cable so that it is positioned in side of the clutch cable. this range. Route the radiator fan motor lead (right) and clutch Put and apply the hose clamp to it. cable by the inner side of the coolant reservoir Clamp the clutch cable by routing the upper end of tank hose and radiator return hoses (2 hoses).
  • Page 17 SPEC CABLE ROUTING Throttle cable (return side) Pass the main switch lead under the left handlebar Throttle cable (pull side) switch lead and then to the right side of the vehi- Starter motor lead cle. Canister hose (for CAL) Pass the throttle stop cable by the left side of the Canister (for CAL) side stand switch lead, oil level switch lead, A.C.
  • Page 18 SPEC CABLE ROUTING Pass the fuel tank drain hose, fuel tank breather Pass the sidestand switch lead, oil level switch hose through the clamp of the coolant reservoir lead and A.C. magneto lead between the engine tank. stay and the engine. Pass the coolant reservoir tank breather hose To the throttle body through the clamp of under the coolant reservoir...
  • Page 19 SPEC CABLE ROUTING Right handlebar switch lead Fuel tank drain hose (except for Main switch lead Radiator fan motor lead (right) CAL) Wire harness Sub wire harness Fuel hose (return side, except Throttle cables Headlight lead for CAL) Throttle sub-lead 1 (white 6 Meter lead Fuel pump 2 coupler poles)
  • Page 20 SPEC CABLE ROUTING Neutral switch lead coupler (connector 1 pole) Route the headlight and meter leads under the Fuel hose (return side, for CAL) frame’s lower part from the hollow section of the Canister hose (for CAL) cover 2. Fuel hose (feed side, for CAL) Pass the left and right handlebar switch leads out- Fuel tank drain hose (for CAL) side of the air filter case air vent hose.
  • Page 21 SPEC CABLE ROUTING Pass the fuel tank breather hose and fuel tank To the coolant reservoir tank drain hose over the fuel hose and fuel return hose. To the intake air temperature sensor (air filter One rotation is possible for a twist of fuel tank case) breather hose and fuel tank drain hose before an To the oil level switch, sidestand switch and A.C.
  • Page 22 SPEC CABLE ROUTING Upper or lower position relation between the left Point the tip of the plastic locking tie to the rear handlebar switch lead, right handlebar switch lead side of the vehicle. and radiator fan motor lead (right) is no object. To the fuse box and fan motor relay Do not catch the coupler when the air filter case is Pass the throttle cables over the cover 2.
  • Page 23 SPEC CABLE ROUTING The clamp by the side of a hose comes below an attachment clamp. Insert until it sets. Poss the canister hose over fuel return hose and under the fuel hose. Route it above the canister hose.
  • Page 24 SPEC CABLE ROUTING Starter motor lead Push the starter motor lead in the clamping sec- Battery tions (two points) or the battery box assembly and Battery positive lead secure it. Starter relay Install to the deepest position of the rib of the bat- Bolt tery box assembly.
  • Page 25 SPEC CABLE ROUTING Insert it to the back end of the rib in the battery box Route the tail / brake light lead above the projection assembly. part. The 20 mm (0.79 in) knob should be within this There should be no remarkable difference range.
  • Page 26 SPEC CABLE ROUTING Connect the negative lead and the wire harness. Install the starting circuit cut-off relay to the deep- est position after placing the tail / brake light lead and turn signal light lead in the guide.

  • Page 27: Periodic Checks And Adjustments

    BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 PERIODIC CHECKS AND ADJUSTMENTS BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. •...
  • Page 28 BLEEDING THE HYDRAULIC BRAKE SYSTEM f. Fully pull the brake lever or fully press down the brake pedal and hold it in posi- tion. g. Loosen the bleed screw. NOTE: NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend.

  • Page 29: Adjusting The Front Fork Legs

    ADJUSTING THE FRONT FORK LEGS EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. •...
  • Page 30 ADJUSTING THE FRONT FORK LEGS 1. Adjust: • rebound damping a. Turn the adjusting screw in direction Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction decreased (suspension is softer). Adjusting positions Minimum: 10 clicks in direction Standard: 6 clicks in direction Maximum: 1 clicks in direction * with the adjusting screw fully turned-in...

  • Page 31: Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 91 Nm (9.1 m•kg, 66 ft•lb) 21 Nm (2.1 m•kg, 15 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) Order Job / Part...

  • Page 32: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 5 Nm (0.5 m•kg, 3.6 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) Order Job / Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.

  • Page 33: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 13 Nm (1.3 m•kg, 9.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order Job / Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Drain.
  • Page 34 CHAS FRONT AND REAR BRAKES 13 Nm (1.3 m•kg, 9.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order Job / Part Q’ty Remarks Brake master cylinder Front brake switch For installation, reverse the removal procedure.
  • Page 35 CHAS FRONT AND REAR BRAKES EAS00585 6 Nm (0.6 m•kg, 4.3 ft•lb) Order Job / Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Brake master cylinder kit Bleed screw Brake master cylinder body For assembly, reverse the disassembly procedure.

  • Page 36: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) Order Job / Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. NOTE: NOTE: The following procedure applies to both of...
  • Page 37 CHAS FRONT AND REAR BRAKES EAS00615 5 Nm (0.5 m•kg, 3.6 ft•lb) Order Job / Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers NOTE: NOTE: The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...

  • Page 38: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents.
  • Page 39 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 40: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK FRONT FORK LEGS 32 Nm (3.2 m•kg, 23 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed.
  • Page 41 CHAS FRONT FORK EAS00648 15 Nm (1.5 m•kg, 11 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed. NOTE: NOTE: The following the procedure applies to...
  • Page 42 CHAS FRONT FORK 15 Nm (1.5 m•kg, 11 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Q’ty Remarks Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube For assembly, reverse the disassembly procedure.

  • Page 43: Disassembling The Front Fork Legs

    CHAS FRONT FORK EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: • cap bolt (from the damper adjusting rod) • spacer • nut a. Press down on the spacer with the fork spring compressor b.

  • Page 44: Checking The Front Fork Legs

    CHAS FRONT FORK 4. Remove: • damper rod assembly bolt • damper rod assembly NOTE: NOTE: While holding the damper rod assembly with the damper rod holder , loosen the damper rod assembly bolt. Damper rod holder 90890-01423, YM-01423 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

  • Page 45: Assembling The Front Fork Legs

    CHAS FRONT FORK CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
  • Page 46 CHAS FRONT FORK WARNING Always use new copper washer. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2.
  • Page 47 CHAS FRONT FORK CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. •...
  • Page 48 CHAS FRONT FORK 8. Install: • rod puller • rod puller attachment (onto the damper rod Rod puller 90890-01437, YM-01437 Rod puller attachment 90890-01436, YM-01436 9. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.475 L (0.418 Imp qt, 0.502 US qt)
  • Page 49 CHAS FRONT FORK e. Press down on the spacer with the fork spring compressor f. Pull up the rod puller and install the rod holder between the nut and the spacer NOTE: NOTE: Use the side of the rod holder that is marked “B”.

  • Page 50: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00709 SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension...
  • Page 51 CHAS SWINGARM AND DRIVE CHAIN CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol- vents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 52: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) Order Job / Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat Refer to “SEATS”...
  • Page 53 COOL RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) Order Job / Part Q’ty Remarks Radiator cap For installation, reverse the removal procedure.

  • Page 54: Electrical System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starter relay Starter motor Fuse (ignition) Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch Start switch Clutch switch...

  • Page 55: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.
  • Page 56 ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
  • Page 57 ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12. Wiring • Check the sidestand switch for continuity. • Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. • Is the sidestand switch OK? •...

  • Page 58: Cooling System

    ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Coolant temperature sensor Battery Radiator fan motor relay Fuse (main) Fuse (radiator fan motor left) Fuse (ignition) Fuse (radiator fan motor right) Radiator fan motor (left) Radiator fan motor (right)

  • Page 59: Troubleshooting

    ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • The radiator fan motor fails to turn. Refer to “CHECKING AND CHARGING • The coolant temperature indicator light THE BATTERY” in chapter 3. fails to light when the engine is warm. Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) Check:...
  • Page 60 ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor (left and right) • Disconnect the radiator fan motor relay from • Disconnect the radiator fan motor coupler the wire harness. from the wire harness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 61 ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor • Remove the coolant temperature sensor. • Connect the pocket tester (Ω × 1k) to the coolant temperature sensor as shown. • Immerse the coolant temperature sensor in a container filled with coolant NOTE: NOTE: Make sure the coolant temperature sensor...
  • Page 62 YZF-R6T/YZF-R6TC WIRING DIAGRAM...

  • Page 63: Yzf-R6T / Yzf-R6Tc Wiring Diagram

    YZF-R6T / YZF-R6TC WIRING DIAGRAM Main switch Horn A.C. magneto Turn signal relay Rectifier / regulator Rear turn signal light (right) Fuse (backup) Rear turn signal light (left) Battery Front turn signal / position light (right) Fuse (main) Front turn signal / position light (left)
  • Page 64 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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