Summary of 2002 YZF-R6R
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Eas00010 yzf-r6r / yzf-r6sr yzf-r6rc / yzf-r6src service manual 2002 by yamaha motor corporation, u.S.A. First edition, december 2002 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S....
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Note: warning caution: eas00030 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintena...
Page 4: How To Use This Manual
1 2 4 8 3 5 6 7 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. 1 ...
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22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng fi elec cool chk adj trbl shtg chas eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic che...
Page 6: General Information
General information specifications periodic checks and adjustments chassis engine cooling system fuel injection system electrical system troubleshooting gen info 1 spec 2 3 eng 4 cool 5 fi 6 chas 7 elec 8 trbl shtg 9 chk adj eas00012 table of contents.
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Chapter 1 general information motorcycle identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle identification number 1-1 . . . . . . . . . . . . . . . . . . . . . . . . Model label 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Engine oil lubrication chart 2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication diagrams 2-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable routing 2-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapt...
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Chassis 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the front brake 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the rear brake 3-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the...
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Front and rear brakes 4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front brake pads 4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear brake pads 4-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacin...
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Rear shock absorber assembly 4-68 . . . . . . . . . . . . . . . . . . . . . . . . Handling the rear shock absorber and gas cylinder 4-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposing of a rear shock absorber and gas cylinder 4-70 . . . . . . . . . ...
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Valves and valve springs 5-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the valves 5-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the valves and valve guides 5-24 . . . . . . . . . . . . . . . Checking the valve seats 5-26 . . . . . ....
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Oil pan and oil pump 5-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the oil pan 5-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the oil pump 5-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking th...
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Chapter 6 cooling system radiator 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the radiator 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the radiator 6-4 . . . . . . . . . . . . . . . . . . . . . ...
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Chapter 8 electrical electrical components 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking switch continuity 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the switches 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Fuel pump system 8-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 8-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump system 8-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
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Unstable handling 9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faulty lighting or signaling system 9-6 . . . . . . . . . . . . . . . . . . . Headlight does not come on 9-6 . . . . . . . . . . . . . . . . . . . . . . . . . Headlight bulb burnt out 9-6 . . . . . . ...
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1-1 1 motorcycle identification gen info eas00014 general information motorcycle identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the right side of the steering head pipe. Eas00018 model label the model label 1 is affixed to the frame. This in...
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1-2 features gen info 8 intake air pressure sensor 9 throttle position sen- sor 10 fuel injector 11 catalytic converter 12 crankshaft position sensor 13 coolant temperature sensor 14 spark plug 15 cylinder identification sensor 16 pressure regulator 17 battery 18 ecu 19 atmospheric pressure sensor 2...
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1-3 features gen info illustration is for reference only. 6 throttle position sen- sor 7 intake air pressure sensor 8 ecu 9 atmospheric pressure sensor 10 coolant temperature sensor 11 cylinder identification sensor 12 crankshaft position sensor a fuel system b air system c control system 1 fuel pum...
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1-4 features gen info 1 multi-function display 2 “select” button 3 “reset” button 4 engine trouble warning light note: instrument function multi-function display the multi-function display is equipped with the following: sa speedometer (which shows the riding speed) san odometer (which shows the tot...
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1-5 features gen info 1 shift timing indicator light 2 “select” button 3 “reset” button note: display brightness and shift timing indica- tor light control mode this mode cycles through five control functions, allowing you to make the following settings in the order listed below. 1. Display brightne...
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1-6 features gen info note: note: to set the shift timing indicator light activation function sthe indicator light activation function can be set between 10,000 and 16,000 r/min. Sfrom 10,000 r/min to 12,000 r/min, the indicatar light can be set in increments of 500 r/min. Sfrom 12,000 r/min to 16,0...
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1-7 spring lip oil grease lip important information gen info eas00020 important information preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “special tools”. 3...
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1-8 important information gen info caution: eas00023 lock washers/ plates and cotter pins after removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eas00024 bearings and oil seals...
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1-9 checking the connections gen info note: note: note: eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: slead scoupler sconnector 2. Check: slead scoupler sconnector moisture ! Dry with an air blower. Rust / stains ! Connect...
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1-10 special tools gen info note: eas00027 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 inappropriate tools or improvised techniques. Special tools,...
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1-11 special tools gen info tool no. Tool name / function illustration 90890-01426 yu-38411 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. Rod puller 90890-01437 ym-01437 rod puller attachment 90890-01436 rod puller rod puller attachment these tools are used to ...
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1-12 special tools gen info tool no. Tool name / function illustration 90890-04044 ym-04044 piston ring compressor this tool is used to compress piston rings when installing the cylinder. 90890-03158 carburetor angle driver this tool is used to turn the pilot screw when adjusting the engine idling s...
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1-13 special tools gen info tool no. Tool name / function illustration 90890-06756 yb-35956 vacuum/pressure pump gauge set this tool used to measure the vacuum pres- sure. 90890-85505 acc-11001- 05-01 yamaha bond no. 1215 this bond is used to seal two mating surfaces (e.G., crankcase mating surfaces...