Yamaha_YZF-R6(R,SR,RC,SRC)_2003_Service_Repair_Maintenance Manual
Pages 437

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION -
VEHICLE IDENTIFICATION NUMBER -
MODEL LABEL -
FEATURES -
OUTLINE OF FI SYSTEM-FI SYSTEM-INSTRUMENT FUNCTION -
IMPORTANT INFORMATION-
PREPARATION FOR REMOVAL AND DISASSEMBLY-REPLACEMENT PARTS -GASKETS, OIL SEALS AND O-RINGS-LOCK WASHERS/PLATES AND COTTER PINS -BEARINGS AND OIL SEALS -CIRCLIPS-
CHECKING THE CONNECTIONS-
SPECIAL TOOLS-

CHAPTER 1
SPECIFICATIONS
GENERAL SPECIFICATIONS -
ENGINE SPECIFICATIONS -
CHASSIS SPECIFICATIONS-
ELECTRICAL SPECIFICATIONS-
CONVERSION TABLE-
GENERAL TIGHTENING TORQUE SPECIFICATIONS -
TIGHTENING TORQUES -
ENGINE TIGHTENING TORQUES-CHASSIS TIGHTENING TORQUES -
LUBRICATION POINTS AND LUBRICANT TYPES-
ENGINE -CHASSIS-
COOLING SYSTEM DIAGRAMS-
ENGINE OIL LUBRICATION CHART -
LUBRICATION DIAGRAMS -
CABLE ROUTING -
CHAPTER
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION -
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM-
GENERAL MAINTENANCE AND LUBRICATION CHART-
SEATS-
FUEL TANK -
REMOVING THE FUEL TANK-REMOVING THE FUEL PUMP -INSTALLING THE FUEL PUMP
INSTALLING THE FUEL TANK -
COWLINGS -
REMOVAL -INSTALLATION -
AIR FILTER CASE -
ENGINE-
ADJUSTING THE VALVE CLEARANCE -SYNCHRONIZING THE THROTTLE BODIES-ADJUSTING THE ENGINE IDLING SPEED-ADJUSTING THE THROTTLE CABLE FREE PLAY
CHECKING THE SPARK PLUGS -MEASURING THE COMPRESSION PRESSURE -CHECKING THE ENGINE OIL LEVEL -CHANGING THE ENGINE OIL -MEASURING THE ENGINE OIL PRESSURE-ADJUSTING THE CLUTCH CABLE FREE PLAY-CLEANING THE AIR FILTER ELEMENT -CLEANING THE AIR INTAKE SYSTEM SURGE TANKS -CHECKING THE THROTTLE BODY JOINTS -CHECKING THE FUEL AND BREATHER HOSES-CHECKING THE CRANKCASE BREATHER HOSE -CHECKING THE EXHAUST SYSTEM -CHECKING THE COOLANT LEVEL -CHECKING THE COOLING SYSTEM -CHANGING THE COOLANT -
CHASSIS -
ADJUSTING THE FRONT BRAKE-ADJUSTING THE REAR BRAKE -CHECKING THE BRAKE FLUID LEVEL -ADJUSTING THE REAR BRAKE LIGHT SWITCH-CHECKING THE FRONT AND REAR BRAKE PADS-CHECKING THE FRONT AND REAR BRAKE HOSES-BLEEDING THE HYDRAULIC BRAKE SYSTEM-ADJUSTING THE SHIFT PEDAL -ADJUSTING THE DRIVE CHAIN SLACK-LUBRICATING TH DRIVE CHAIN -CHECKING AND ADJUSTING THE STEERING HEAD-CHECKING THE FRONT FORK-ADJUSTING THE FRONT FORK LEGS -
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY-CHECKING THE TIRES -
CHECKING THE WHEELS -CHECKING AND LUBRICATING THE CABLES-LUBRICATING THE LEVERS AND PEDALS -LUBRICATING THE SIDESTAND -LUBRICATING THE REAR SUSPENSION -
ELECTRICAL SYSTEM -
CHECKING AND CHARGING THE BATTERY-CHECKING THE FUSES-REPLACING THE HEADLIGHT BULBS -ADJUSTING THE HEADLIGHT BEAMS -
CHAPTER
CHASSIS
FRONT WHEEL AND BRAKE DISCS-
REMOVING THE FRONT WHEEL-CHECKING THE FRONT WHEEL -CHECKING THE BRAKE DISCS-INSTALLING THE FRONT WHEEL-ADJUSTING THE FRONT WHEEL STATIC BALANCE-
REAR WHEEL AND BRAKE DISC -
REAR WHEEL-REAR BRAKE DISC AND REAR WHEEL SPROCKET-REMOVING THE REAR WHEEL-CHECKING THE REAR WHEEL-CHECKING THE REAR WHEEL DRIVE HUBCHECKING AND REPLACING THE REAR WHEEL SPROCKET -INSTALLING THE REAR WHEEL -ADJUSTING THE REAR WHEEL STATIC BALANCE-
FRONT AND REAR BRAKES -
FRONT BRAKE PADS -REAR BRAKE PADS-REPLACING THE FRONT BRAKE PADS-REPLACING THE REAR BRAKE PADS -FRONT BRAKE MASTER CYLINDER -
REAR BRAKE MASTER CYLINDER-DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER -DISASSEMBLING THE REAR BRAKE MASTER CYLINDER -CHECKING THE FRONT AND REAR BRAKE MASTERCYLINDERS-ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTERCYLINDER -ASSEMBLING THE REAR BRAKE MASTER CYLINDER-FRONT BRAKE CALIPERS-REAR BRAKE CALIPER -DISASSEMBLING THE FRONT BRAKE CALIPERS-DISASSEMBLING THE REAR BRAKE CALIPER -CHECKING THE FRONT AND REAR BRAKE CALIPERS -ASSEMBLING AND INSTALLING THE FRONT BRAKECALIPERS-ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER-
FRONT FORK -
FRONT FORK LEGS-REMOVING THE FRONT FORK LEGS-DISASSEMBLING THE FRONT FORK LEGS-CHECKING THE FRONT FORK LEGS-ASSEMBLING THE FRONT FORK LEGS-
INSTALLING THE FRONT FORK LEGS -
HANDLEBARS-
REMOVING THE HANDLEBARS -CHECKING THE HANDLEBARS-INSTALLING THE HANDLEBARS-
STEERING HEAD-
UNDER BRACKET-REMOVING THE UNDER BRACKET-CHECKING THE STEERING HEAD -
INSTALLING THE STEERING HEAD-
REAR SHOCK ABSORBER ASSEMBLY -
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER -DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER -REMOVING THE REAR SHOCK ABSORBER ASSEMBLY-CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER -
CHECKING THE CONNECTING ROD AND RELAY ARMS -INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY-
SWINGARM AND DRIVE CHAIN-
REMOVING THE SWINGARM-REMOVING THE DRIVE CHAIN-CHECKING THE SWINGARM-
CHECKING THE DRIVE CHAIN-INSTALLING THE SWINGARM -
CHAPTER
OVERHAULING THE ENGINE
ENGINE-
DRIVE SPROCKET -EXHAUST PIPE-LEADS AND HOSES-ENGINE -INSTALLING THE ENGINE-
CAMSHAFTS-
CYLINDER HEAD COVER -CAMSHAFTS-REMOVING THE CAMSHAFTS-CHECKING THE CAMSHAFTS -CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDES -CHECKING THE TIMING CHAIN TENSIONER -INSTALLING THE CAMSHAFTS-
CYLINDER HEAD-
REMOVING THE CYLINDER HEAD -CHECKING THE CYLINDER HEAD -INSTALLING THE CYLINDER HEAD-
VALVES AND VALVE SPRINGS
-REMOVING THE VALVES -CHECKING THE VALVES AND VALVE GUIDES-CHECKING THE VALVE SEATS-CHECKING THE VALVE SPRINGS -CHECKING THE VALVE LIFTERS-INSTALLING THE VALVES-
STARTER CLUTCH AND GENERATOR-
STATOR COIL ASSEMBLY-REMOVING THE GENERATOR-REMOVING THE STARTER CLUTCH -CHECKING THE STARTER CLUTCH -INSTALLING THE STARTER CLUTCH-
INSTALLING THE GENERATOR-
SHIFT SHAFT -
SHIFT SHAFT AND STOPPER LEVER-CHECKING THE SHIFT SHAFT-CHECKING THE STOPPER LEVER-INSTALLING THE SHIFT SHAFT -
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR-
REMOVING THE PICKUP ROTOR-INSTALLING THE PICKUP ROTOR -
CLUTCH-
CLUTCH COVER -CLUTCH -REMOVING THE CLUTCH -CHECKING THE FRICTION PLATES-CHECKING THE CLUTCH PLATES -CHECKING THE CLUTCH SPRINGS -
CHECKING THE CLUTCH HOUSING -CHECKING THE CLUTCH BOSS -
CHECKING THE PRESSURE PLATE -CHECKING THE PULL LEVER SHAFT AND PULL ROD-INSTALLING THE CLUTCH-
OIL PAN AND OIL PUMP -
REMOVING THE OIL PAN -CHECKING THE OIL PUMP-CHECKING THE RELIEF VALVE -
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE-CHECKING THE OIL STRAINER -
CHECKING THE OIL NOZZLES-ASSEMBLING THE OIL PUMP -INSTALLING THE OIL PUMP-INSTALLING THE OIL STRAINER-INSTALLING THE OIL PAN-CRANKCASE -
DISASSEMBLING THE CRANKCASE -CHECKING THE CRANKCASE -CHECKING THE BEARINGS AND OIL SEALS -CHECKING THE TIMING CHAIN -ASSEMBLING THE CRANKCASE-
CONNECTING RODS AND PISTONS-
REMOVING THE CONNECTING RODS AND PISTONS -REMOVING THE CRANKSHAFT ASSEMBLY-CHECKING THE CYLINDER AND PISTON-CHECKING THE PISTON RINGS -
CHECKING THE PISTON PINS-CHECKING THE BIG END BEARINGS-
INSTALLING THE CONNECTING ROD AND PISTON -
CRANKSHAFT-
CHECKING THE CRANKSHAFT-
CHECKING THE CRANKSHAFT JOURNAL BEARINGS -INSTALLING THE CRANKSHAFT -
TRANSMISSION -
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS -REMOVING THE TRANSMISSION-CHECKING THE SHIFT FORKS-CHECKING THE SHIFT DRUM ASSEMBLY-CHECKING THE TRANSMISSION-INSTALLING THE TRANSMISSION -
CHAPTER
COOLING SYSTEM
RADIATOR-
CHECKING THE RADIATOR -INSTALLING THE RADIATOR-
OIL COOLER-
CHECKING THE OIL COOLER -INSTALLING THE OIL COOLER-
THERMOSTAT-
CHECKING THE THERMOSTAT-INSTALLING THE THERMOSTAT -
WATER PUMP -
DISASSEMBLING THE WATER PUMP-CHECKING THE WATER PUMP-ASSEMBLING THE WATER PUMP -INSTALLING THE WATER PUMP -
CHAPTER
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM -
WIRING DIAGRAM -ECU‘S SELF-DIAGNOSTIC FUNCTION -ALTERNATE INSTRUCTIONS OPERATION CONTROL-(FAIL-SAFE ACTION)-FAIL-SAFE ACTIONS TABLE-TROUBLESHOOTING CHART -DIAGNOSTIC MODE-TROUBLESHOOTING DETAILS-
THROTTLE BODIES -
CHECKING THE INJECTOR -CHECKING THE THROTTLE BODY-CHECKING THE PRESSURE REGULATOR -CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION-CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR -
AIR INDUCTION SYSTEM-
AIR INJECTION-AIR CUT-OFF VALVE -AIR INDUCTION SYSTEM DIAGRAMS-CHECKING THE AIR INDUCTION SYSTEM -
CHAPTER
ELECTRICAL
ELECTRICAL COMPONENTS -
CHECKING SWITCH CONTINUITY-
CHECKING THE SWITCHES-
CHECKING THE BULBS AND BULB SOCKETS-
TYPES OF BULBS-CHECKING THE CONDITION OF THE BULBS -CHECKING THE CONDITION OF THE BULB SOCKETS-CHECKING THE LEDs-
IGNITION SYSTEM-
CIRCUIT DIAGRAM -TROUBLESHOOTING -
ELECTRIC STARTING SYSTEM -
CIRCUIT DIAGRAM -STARTING CIRCUIT CUT-OFF SYSTEM OPERATION-ROUBLESHOOTING -
STARTER MOTOR -
CHECKING THE STARTER MOTOR-ASSEMBLING THE STARTER MOTOR -
CHARGING SYSTEM-
CIRCUIT DIAGRAM -TROUBLESHOOTING -
LIGHTING SYSTEM-
CIRCUIT DIAGRAM -TROUBLESHOOTING -CHECKING THE LIGHTING SYSTEM -
SIGNALING SYSTEM-
CIRCUIT DIAGRAM -TROUBLESHOOTING -CHECKING THE SIGNALING SYSTEM -
COOLING SYSTEM-
CIRCUIT DIAGRAM -TROUBLESHOOTING -
FUEL PUMP SYSTEM-
CIRCUIT DIAGRAM -FUEL PUMP SYSTEM -TROUBLESHOOTING -CHECKING THE FUEL UMP-
SELF-DIAGNOSIS -
TROUBLESHOOTING -
CHAPTER
TROUBLESHOOTING
STARTING FAILURES-
ENGINE -FUEL SYSTEM -ELECTRICAL SYSTEMS-
INCORRECT ENGINE IDLING SPEED -
ENGINE -FUEL SYSTEM -ELECTRICAL SYSTEMS-
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE -
ENGINE -FUEL SYSTEM -
FAULTY GEAR SHIFTING-
SHIFTING IS DIFFICULT-SHIFT PEDAL DOES NOT MOVE-JUMPS OUT OF GEAR-
FAULTY CLUTCH-
CLUTCH SLIPS-CLUTCH DRAGS -
OVERHEATING-
ENGINE -COOLING SYSTEM -FUEL SYSTEM -CHASSIS-ELECTRICAL SYSTEMS-
OVERCOOLING -
COOLING SYSTEM -
POOR BRAKING PERFORMANCE-
FAULTY FRONT FORK LEGS -
LEAKING OIL-MALFUNCTION-

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