Related Manuals for Yamaha YZF-R6(S)
Summary of Contents for Yamaha YZF-R6(S)
- Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
- Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
- Page 3 Service Manual together with the following manual. YZF-R6 (R) 2003 SERVICE MANUAL: 5SL1-AE1 YZF-R6 (S) 2004 SUPPLEMENTARY SERVICE MANUAL E2003 by Yamaha Motor Co., Ltd. First Edition, September 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
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Page 4: Important Manual Information
EAS00002 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 maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. -
Page 5: How To Use This Manual
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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. - Page 6 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis...
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Page 7: Table Of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS . - Page 8 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
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Page 9: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit 5SLB (EUR), 5SLC (F), 5SLG/5SLL (AUS) SSS Model code ENGINE SPECIFICATIONS Item Standard Limit Throttle bodies ID mark 5SL1 00 (5SLB/5SLG/5SLL), 5SL2 20 (5SLC) Throttle valve size... -
Page 10: Tightening Torques
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Oil cooler Bolt Yamaha bond Cylinder identification sensor Bolt No.1215 email: info@motomatrix.co.uk –2–... -
Page 11: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING CABLE ROUTING Right handlebar switch lead A Pass the right handlebar switch lead inside the front Clutch cable brake hoses and over the throttle cables. Immobilizer unit lead, main switch lead and left han- B Install the throttle cables to the hook so that the pull- dlebar switch lead... - Page 12 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING F Pass the horn lead by the outside of the throttle I Set in the coupler between the head light’s hollow cable and clamp it to the forefront of upper face of section and the duct.
- Page 13 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle stop screw D Pass the clutch cable inside of the coolant reservoir Coolant reservoir tank hose tank hose and radiator return hoses. Pickup coil lead E Assemble as “...
- Page 14 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING L Clamp the clutch cable by routing the upper end of the clamp along with the bottom end of the hose clamp assembly. email: info@motomatrix.co.uk –6–...
- Page 15 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Throttle cable (return side) A Pass the main switch lead under the left handlebar Throttle cable (pull side) switch lead and immobilizer unit lead and then to the Starter motor lead right side of the vehicle.
- Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING E Pass the fuel tank drain hose, fuel tank breather L Pass the side stand switch lead, oil level switch lead hose through the clamp of the coolant reservoir and A.C.
- Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Right handlebar switch lead Fuel pump 2 coupler Throttle cables Sub wire harness Fuel pump 1 coupler Throttle sub-lead 1 (white 6 Head light lead Starter motor lead poles) Meter lead...
- Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING A To the headlight H To the rear brake light switch lead B Clamp the plastic locking tie to the cover 8. Place I Pass the fuel tank breather hose and fuel tank drain the coupler at the rear side of the vehicle against the hose over the fuel hose and fuel return hose.
- Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING N To the coolant reservoir tank W Clamp the wire harness, left and right handlebar O To the oil level switch, sidestand switch and A.C. switch leads and main switch lead.
- Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING AD Clamp the wire harness, main switch lead branch AK Insert until it sets. section, radiator fan motor lead and immobilizer AL The clamp by the side of a hose comes below an unit lead.
- Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Fuel pump assembly A Install the O-ring with its lip pointed upward. Fuel tank drain hose B Pass the fuel tank drain hose and fuel tank breather Fuel tank breather hose hose through the clamp.
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Page 22: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS00040 PERIODIC CHECKS AND ADJUSTMENTS FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) Order Job/Part Q’ty... -
Page 23: Installing The Fuel Pump
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK INSTALLING THE FUEL PUMP 1. Install: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump. -
Page 24: Fuel Injection System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys AIR INDUCTION SYSTEM FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve A To cylinder #1 and #2 2 Reed valve B To cylinder #3 and #4 3 To air filter case email: info@motomatrix.co.uk... -
Page 25: Electrical
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS Coolant temperature sensor Speed sensor Intake air temperature sensor Crankshaft position sensor Intake air pressure sensor Cylinder identification sensor Lean angle cut-off switch Radiator fan motor relay Atmospheric pressure sensor Headlight relay (on / off) -
Page 26: Ignition System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Ignition coil Battery Spark plug Fuse (main) Neutral switch Fuse (ignition) Crankshaft position sensor Starting circuit cut-off relay Lean angle cut-off switch Sidestand switch Engine stop switch... -
Page 27: Troubleshooting
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark). - Page 28 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker and ignition coil...
- Page 29 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00748 EAS00750 8. Engine stop switch 6. Crankshaft position sensor resistance S Check the engine stop switch for continuity. S Disconnect the crankshaft position sensor Refer to “CHECKING THE SWITCHES”.
- Page 30 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM EAS00753 12. Starting circuit cut-off relay NOTE: When you switch the positive and negative S Disconnect the starting circuit cut-off relay tester probes, the readings in the above chart coupler from the wire harness.
- Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC IGNITION SYSTEM Replace lean angle cut-off switch. EAS00754 14. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Replace the ignitor Properly connect or...
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Page 32: Lighting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM email: info@motomatrix.co.uk –24–... - Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM Main switch Battery Fuse (main) High beam indicator light Meter light Fuse (headlight) Headlight relay (on / off) Headlight relay (dimmer) Fuse (park) Pass switch Dimmer switch Headlight License light...
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Page 34: Checking The Lighting System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00788 Headlight CHECKING THE LIGHTING SYSTEM Positive tester probe ! black/yellow 1. The headlight and the high beam indicator Negative tester probe ! black light fail to come on. - Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light (LEDs) 1. Tail/brake light (LEDs) S Check the meter light for continuity.
- Page 36 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELEC LIGHTING SYSTEM EAS00792 4. The license light fails to come on. 1. License light bulb and socket S Check the license light bulb and socket for continuity.
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Page 37: Yzf-R6 (S) 2004 Wiring Diagram
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6 (S) 2004 WIRING DIAGRAM Main switch Hazard switch A.C. magneto Turn signal switch Rectifier/ regulator Horn Fuse (back up) Turn signal relay Battery Rear turn signal light (right) Fuse (main) Rear turn signal light (left) Starter relay... - Page 38 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
- Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
- Page 40 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
- Page 41 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys YZF-R6 (S) 2004 WIRING DIAGRAM email: info@motomatrix.co.uk...