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Yamaha YZFR6 YZF-R6 2008 2009 2010 Workshop Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZF-R6 Model Designation: YZFR6 Year: 2008-2010 Codes Platform Code: RJ15 👋 Introduction Market Position Market Segment: Supersport / Hyperbike Target Audience: Performance motorcycle enthusiasts, track day riders, competitive racers, professional mechanics Competitive Analysis Key Competitors 2008: Honda CBR600RR, Kawasaki ZX6R, Suzuki GSX-R600, Triumph Daytona 675 Key Features Vehicle Engine Architecture: Inline-four cylinder, DOHC, 4 valves per cylinder Chassis Design: Aluminum Deltabox frame, advanced aerodynamics Technology Highlights: Yamaha Chip Controlled Throttle (YCC-T), Yamaha D-Mode (selectable engine mapping) 📋 Manual Details Coverage Areas Manual Scope: Comprehensive workshop service and repair Page Count Page Count: 429 Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust Drivetrain Systems: Clutch, transmission, final drive (chain and sprockets) Chassis Systems: Frame, suspension (front forks, rear shock), steering, wheels, tires Braking Systems: Front and rear brakes, hydraulic system, ABS (if equipped on specific models within the range) Electrical Systems: Battery, charging system, starting system, lighting, instrumentation, wiring diagrams Bodywork And Fairings: Fairing removal and installation, seat, fuel tank, body panels Procedures Included Maintenance Procedures: Oil change, filter replacement, spark plug replacement, chain adjustment, brake fluid flush, coolant flush, air filter cleaning/replacement Diagnostic Procedures: Troubleshooting guides, fault code interpretation (if applicable), diagnostic connector access Repair Procedures: Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake caliper service, wiring harness repair Inspection Procedures: Pre-ride inspections, component wear checks, torque specifications for critical fasteners Electrical Troubleshooting: Detailed wiring diagrams, component testing, and diagnostic flowcharts for electrical faults. Suspension Adjustment And Service: Specifications for fork spring preload, compression, and rebound damping adjustments. Procedures for fork oil changes and seal replacement. Fuel System Diagnosis: Troubleshooting fuel delivery issues, injector cleaning procedures, and fuel pump testing. Tightening Torque Specifications: Comprehensive list of torque values for all critical fasteners throughout the motorcycle. Technical Depth Technical Depth: Detailed, suitable for professional technicians and experienced home mechanics Rebuild Instructions: Complete engine and transmission rebuild procedures Diagnostic Level: Advanced diagnostics and troubleshooting for all major systems 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High resolution, suitable for printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchable Text Searchable Text: Yes (typical for professionally created PDFs) ⚙️ Engine Specifications Primary Engine Engine Code: 13S Engine Type: Liquid-cooled, four-stroke, DOHC, inline four-cylinder Displacement: 599 cc Bore X Stroke: 67.0 mm x 42.5 mm Compression Ratio: 12.8:1 Performance Horsepower Est Wheel: Approx. 120-125 hp Torque Est Wheel: Approx. 50-53 lb-ft Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual injectors per cylinder Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/90 AKI Ignition Ignition System: TCI (Transistor Controlled Ignition) Lubrication Lubrication System: Wet sump Cooling Cooling System: Liquid-cooled Coolant Type: Yamalube Coolant (Blue) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix) 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed Clutch Type: Wet, multiple-disc Features Gear Ratios: 1st: 2.727, 2nd: 2.063, 3rd: 1.722, 4th: 1.524, 5th: 1.348, 6th: 1.192 Final Drive: Chain drive Transmission Oil Type: Yamalube 10W-40 API SG or better, JASO MA compatible 📐 Dimensions Exterior Length: 2,040 mm (79.9 in) Width: 720 mm (28.3 in) Height: 1,135 mm (44.7 in) Wheelbase: 1,380 mm (54.3 in) Ground Clearance: 130 mm (5.1 in) Weights Dry Weight: 162 kg (357 lbs) Wet Weight Est: Approx. 182 kg (401 lbs) (fully fueled, ready to ride) Fuel Capacity: 17.0 Liters (4.5 US gal) Oil Capacity: 3.40 Liters (3.59 US qt) (with filter change) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is assessed differently than automotive) Active Features Braking System: Dual 310mm hydraulic disc front brakes, Single 220mm hydraulic disc rear brake ABS Availability: Optional on some markets/versions within the model years Passive Features Frame Construction: Rigid aluminum Deltabox frame for stability and handling 💡 Technology Features Infotainment Infotainment System: N/A (Focus on performance, not infotainment) Driver Assistance Engine Management: Yamaha Chip Controlled Throttle (YCC-T) for precise throttle response, Yamaha D-Mode for selectable engine mapping (Standard, A-mode, B-mode). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Filter Change Interval: Every 4,000 miles or 6 months Air Filter Cleaning Interval: Every 4,000 miles or 6 months Spark Plug Replacement Interval: Every 12,000 miles or 12 months Valve Clearance Check Interval: Every 16,000 miles or 24 months Brake Fluid Flush Interval: Every 12,000 miles or 12 months Coolant Flush Interval: Every 12,000 miles or 24 months Fluid Specifications Engine Oil Grade: Yamalube 10W-40 API SG or better, JASO MA Brake Fluid Type: DOT 4 Fork Oil Type: Yamaha Suspension Fluid (Type 0) or SAE 10W fork oil Fork Oil Quantity: 377 ml (0.40 US qt) per fork leg (standard) / 367 ml (0.39 US qt) (with aftermarket fork kits) Known Issues Common...
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Yamaha YZFR6 YZF-R6 2008 2009 2010 Workshop Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZF-R6
Model Designation:
YZFR6
Year:
2008-2010
Codes
Platform Code:
RJ15
👋 Introduction
Market Position
Market Segment:
Supersport / Hyperbike
Target Audience:
Performance motorcycle enthusiasts, track day riders, competitive racers, professional mechanics
Competitive Analysis
Key Competitors 2008:
Honda CBR600RR, Kawasaki ZX6R, Suzuki GSX-R600, Triumph Daytona 675
Key Features Vehicle
Engine Architecture:
Inline-four cylinder, DOHC, 4 valves per cylinder
Chassis Design:
Aluminum Deltabox frame, advanced aerodynamics
Technology Highlights:
Yamaha Chip Controlled Throttle (YCC-T), Yamaha D-Mode (selectable engine mapping)
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive workshop service and repair
Page Count
Page Count:
429
Manual Type
Manual Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust
Drivetrain Systems:
Clutch, transmission, final drive (chain and sprockets)
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, wheels, tires
Braking Systems:
Front and rear brakes, hydraulic system, ABS (if equipped on specific models within the range)
Electrical Systems:
Battery, charging system, starting system, lighting, instrumentation, wiring diagrams
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank, body panels
Procedures Included
Maintenance Procedures:
Oil change, filter replacement, spark plug replacement, chain adjustment, brake fluid flush, coolant flush, air filter cleaning/replacement
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation (if applicable), diagnostic connector access
Repair Procedures:
Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake caliper service, wiring harness repair
Inspection Procedures:
Pre-ride inspections, component wear checks, torque specifications for critical fasteners
Electrical Troubleshooting:
Detailed wiring diagrams, component testing, and diagnostic flowcharts for electrical faults.
Suspension Adjustment And Service:
Specifications for fork spring preload, compression, and rebound damping adjustments. Procedures for fork oil changes and seal replacement.
Fuel System Diagnosis:
Troubleshooting fuel delivery issues, injector cleaning procedures, and fuel pump testing.
Tightening Torque Specifications:
Comprehensive list of torque values for all critical fasteners throughout the motorcycle.
Technical Depth
Technical Depth:
Detailed, suitable for professional technicians and experienced home mechanics
Rebuild Instructions:
Complete engine and transmission rebuild procedures
Diagnostic Level:
Advanced diagnostics and troubleshooting for all major systems
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High resolution, suitable for printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchable Text
Searchable Text:
Yes (typical for professionally created PDFs)
⚙️ Engine Specifications
Primary Engine
Engine Code:
13S
Engine Type:
Liquid-cooled, four-stroke, DOHC, inline four-cylinder
Displacement:
599 cc
Bore X Stroke:
67.0 mm x 42.5 mm
Compression Ratio:
12.8:1
Performance
Horsepower Est Wheel:
Approx. 120-125 hp
Torque Est Wheel:
Approx. 50-53 lb-ft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual injectors per cylinder
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/90 AKI
Ignition
Ignition System:
TCI (Transistor Controlled Ignition)
Lubrication
Lubrication System:
Wet sump
Cooling
Cooling System:
Liquid-cooled
Coolant Type:
Yamalube Coolant (Blue) or equivalent ethylene glycol-based coolant with distilled water (50/50 mix)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed
Clutch Type:
Wet, multiple-disc
Features
Gear Ratios:
1st: 2.727, 2nd: 2.063, 3rd: 1.722, 4th: 1.524, 5th: 1.348, 6th: 1.192
Final Drive:
Chain drive
Transmission Oil Type:
Yamalube 10W-40 API SG or better, JASO MA compatible
📐 Dimensions
Exterior
Length:
2,040 mm (79.9 in)
Width:
720 mm (28.3 in)
Height:
1,135 mm (44.7 in)
Wheelbase:
1,380 mm (54.3 in)
Ground Clearance:
130 mm (5.1 in)
Weights
Dry Weight:
162 kg (357 lbs)
Wet Weight Est:
Approx. 182 kg (401 lbs) (fully fueled, ready to ride)
Fuel Capacity:
17.0 Liters (4.5 US gal)
Oil Capacity:
3.40 Liters (3.59 US qt) (with filter change)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is assessed differently than automotive)
Active Features
Braking System:
Dual 310mm hydraulic disc front brakes, Single 220mm hydraulic disc rear brake
ABS Availability:
Optional on some markets/versions within the model years
Passive Features
Frame Construction:
Rigid aluminum Deltabox frame for stability and handling
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on performance, not infotainment)
Driver Assistance
Engine Management:
Yamaha Chip Controlled Throttle (YCC-T) for precise throttle response, Yamaha D-Mode for selectable engine mapping (Standard, A-mode, B-mode).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Filter Change Interval:
Every 4,000 miles or 6 months
Air Filter Cleaning Interval:
Every 4,000 miles or 6 months
Spark Plug Replacement Interval:
Every 12,000 miles or 12 months
Valve Clearance Check Interval:
Every 16,000 miles or 24 months
Brake Fluid Flush Interval:
Every 12,000 miles or 12 months
Coolant Flush Interval:
Every 12,000 miles or 24 months
Fluid Specifications
Engine Oil Grade:
Yamalube 10W-40 API SG or better, JASO MA
Brake Fluid Type:
DOT 4
Fork Oil Type:
Yamaha Suspension Fluid (Type 0) or SAE 10W fork oil
Fork Oil Quantity:
377 ml (0.40 US qt) per fork leg (standard) / 367 ml (0.39 US qt) (with aftermarket fork kits)
Known Issues
Common Issues:
While generally reliable, potential areas for attention include occasional throttle position sensor (TPS) issues, stator wear, and radiator fan switch failures. Regular maintenance as per the manual is key.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha's long history in performance motorcycle racing and innovation
Model Evolution
Generation Notes:
The 2006-2007 model was a significant redesign, and the 2008-2010 model continued this performance-oriented platform with refinements.
Production
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Historical Acclaim:
The YZF-R6 platform has consistently received accolades for its class-leading handling, engine performance, and track capabilities among 600cc supersports.
Ratings
Track Performance Ratings:
Highly rated by motorcycle journalists and track day enthusiasts for agility and cornering prowess.
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