YZF-R6 2008 Service Manual.pdf

2008

SERVICE MANUAL

YZFR6X(C)

LIT-11616-21-61

13S-28197-10

EAS20050

YZFR6X(C)

SERVICE MANUAL

Corporation, U.S.A.

First edition, October 2007

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-11616-21-61

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers 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 deal-

ers 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.

EAS20080

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!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

EAS20090

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 and each chapter is divided into sections. The current section

title “1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described

sequentially.

CLUTCH

EAS25060

CLUTCH

Removing the clutch cover

EAS25070

REMOVING THE CLUTCH

1. Remove:

• Oil strainer

Refer to “OIL PUMP” on page 5-48.

• Water pump

Refer to “WATER PUMP” on page 6-8.

• Friction plates

• Clutch plates

NOTE:

Be sure to mark the friction plates and clutch

plates or note the position of each part so that

they are installed in their original positions.

2. Loosen:

• Clutch boss nut “1”

NOTE:

While holding the clutch boss “2” with the uni-

versal clutch holder “3”, loosen the clutch boss

nut.

12 Nm (1.2 m • kg, 8.9 ft • Ib)

EAS25100

CHECKING THE FRICTION PLATES

The following procedure applies to all of the

friction plates.

1. Check:

• Friction plate

Damage/wear Replace the friction

plates as a set.

2. Measure:

• Friction plate thickness

Out of specification Replace the fric-

tion plates as a set.

NOTE:

Measure the friction plate at four places.

New

12 Nm (1.2 m • kg, 8.9 ft • Ib)

Universal clutch holder

90890-04086

YM-91042

Friction plate thickness

2.92–3.08 mm (0.115–0.121 in)

Wear limit

2.80 mm (0.1102 in)

New

12 Nm (1.2 m • kg, 8.9 ft • Ib)

Order

Job/Parts to remove

Q’ty

Remarks

Engine oil

“tR

po”

3. Remove:

• Spacer “1”

• Bearing

• Clutch housing “2”

• Oil pump drive chain

NOTE:

Remove the spacer and bearing from the main

axle, then remove the oil pump drive chain

from the oil pump driven sprocket, and then

remove the clutch housing and oil pump drive

chain from the main axle.

Drain.

Refer to “CHANGING THE ENGINE OIL” on

page 3-12.

Coolant

Drain.

Refer to “CHANGING THE COOLANT” on

page 3-21.

EAS25110

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the

clutch plates.

1. Check:

• Clutch plate

Damage Replace the clutch plates as

a set.

2. Measure:

• Clutch plate warpage

(with a surface plate and thickness gauge

“1”)

Out of specification Replace the clutch

plates as a set.

bpW

sll

gcl

For installation, reverse the removal proce-

dure.

5-36

5-40

EAS20100

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

15.Molybdenum-disulfide grease

16.Silicone grease

17.Apply locking agent (LOCTITE®)

18.Replace the part

New

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum-disulfide oil

12.Brake fluid

13.Wheel-bearing grease

14.Lithium-soap-based grease

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