YZF-R6T YZF-R6TC SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-45 5SL-28197-12
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R6T / YZF-R6TC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
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 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.
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. The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. Each chapter is divided into sections.
EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols to indicate the following.
CONTENTS GENERAL INFORMATION SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES. . . . . .
ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS GEN INFO EAS00027 GENERAL INFORMATION 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, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: • For U.S.A.
GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Maximum load (except motorcycle) Standard 5SLR (USA except for CAL) 5SLS (CAL) Limit ••• 2,045 mm (80.5 in) 690 mm (27.2 in) 1,105 mm (43.5 in) 830 mm (32.7 in) 1,385 mm (54.5 in) 145 mm (5.7 in) 3,800 mm (149.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Caster angle Trail Front tire Size Model (manufacturer) Rear tire Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 ~ 192 kg (198 ~ 426 lb) (USA except for CAL) 90 ~ 191 kg (198 ~ 423 lb) (CAL) High-speed riding Front brakes Brake lever free play Brake discs Diameter × thickness Min. thickness Master cylinder inside diameter Rear brake Brake pedal freeplay Standard Limit 24.5° 95 mm (3.
CHASSIS SPECIFICATIONS / ELECTRICAL SPECIFICATIONS Item Front suspension Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Inner tube outer diameter Fork oil Quantity (each front fork leg) Level (from the top of the outer tube, with the outer tube fully compressed, and without the fork spring) Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *fr
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Fastener Thread size Q’ty Clutch boss Nut M20 Cylinder identification sensor Bolt M6 Item Tightening torque 1 Nm 90 m•kg 9.0 1 7.5 0.75 Remarks ft•lb 65 Use a lock washer 5.4 Yamaha bond No.
CABLE ROUTING SPEC CABLE ROUTING Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward. Pass the clutch cable through the guide. Plastic locking tie shall be positioned at 15 mm (0.59 in) below from the upper bracket. Clamp the left handlebar switch lead to the front fork with the plastic locking tie and cut the tip of the tie.
CABLE ROUTING Clamp it at the position of 50 mm (1.97 in) to 65 mm (2.56 in) from the upper face of the under bracket with the plastic locking tie. Cut the surplus part of the clamp tip leaving 2 mm (0.08 in) to 4 mm (0.16 in). Point the tip of the clamp to the outside of vehicle. Pass the throttle cables inside the front brake hoses. Set in the coupler between the headlight’s hollow section and the duct. To the wire harness To the front turn signal light (right) Set the sub wire harness in the joint.
CABLE ROUTING Throttle stop screw Coolant reservoir tank hose Cover 8 Radiator fan motor lead (right) Pickup coil lead Rear tail / brake light switch lead Radiator return hose Coolant hose Clutch cable Coolant hose protector Hose clamp assembly Hose clamp Pass the rear tail / brake light switch lead outside of rear engine mount bolt. 8 SPEC Pass the ignition coil lead outside of the radiator hose. Pass the coolant reservoir tank hose under the frame and right side of the throttle body.
CABLE ROUTING Route the radiator fan motor lead (right) by the outside of the clutch cable. Route the radiator fan motor lead (right) and clutch cable by the inner side of the coolant reservoir tank hose and radiator return hoses (2 hoses). The punch mark starting point should be lower than the clamp’s top end. However, the aiming position of the punch mark starting point should be 5 mm (0.20 in) below the clamp’s bottom end. Pass the clutch cable inside of the radiator hose.
CABLE ROUTING SPEC Pass the main switch lead under the left handlebar switch lead and then to the right side of the vehicle. Pass the throttle stop cable by the left side of the side stand switch lead, oil level switch lead, A.C. magneto lead and then to the right side of the vehicle. Route the A.C. magneto lead, sidestand switch lead and oil level switch lead so that they pass the inner side of the barance pipe 3.
CABLE ROUTING Pass the fuel tank drain hose, fuel tank breather hose through the clamp of the coolant reservoir tank. Pass the coolant reservoir tank breather hose through the clamp of under the coolant reservoir tank. Projection allowance from the coolant reservoir tank cover shall be 30 to 50 mm (1.18 ~ 1.97 in). Pass the oil level switch lead and sidestand switch lead over the bracket 2. Pass the oil level switch lead, and sidestand switch lead through the clamp. 5 ~ 45 mm (0.20 ~ 1.77 in). Clamp the A.
CABLE ROUTING Right handlebar switch lead Radiator fan motor lead (right) Sub wire harness Headlight lead Meter lead Cover 8 Ignition coil lead Throttle position sensor coupler Coolant reservoir tank hose Throttle stop cable Speed sensor lead coupler Crankshaft position sensor lead coupler Fuel tank breather hose (except for CAL) Fuel tank drain hose (except for CAL) Fuel hose (return side, except for CAL) Fuel pump 2 coupler Fuel pump 1 coupler Starter motor lead Fuel hose (feed side, except for CAL) Cran
CABLE ROUTING Neutral switch lead coupler (connector 1 pole) Fuel hose (return side, for CAL) Canister hose (for CAL) Fuel hose (feed side, for CAL) Fuel tank drain hose (for CAL) To the headlight Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it when installing the side cowling. Clamp the plastic locking tie to the cover 8. Place the coupler at the rear side of the vehicle against the plastic locking tie.
CABLE ROUTING Pass the fuel tank breather hose and fuel tank drain hose over the fuel hose and fuel return hose. One rotation is possible for a twist of fuel tank breather hose and fuel tank drain hose before an engine clamp. To the rear tail / brake light switch lead. To the neutral switch Insert the wire harness wrapping clamp to the frame hole. Pass the battery negative lead over the wire harness. To the engine. Upper or lower position relation against the heat protector is no object.
CABLE ROUTING Upper or lower position relation between the left handlebar switch lead, right handlebar switch lead and radiator fan motor lead (right) is no object. Do not catch the coupler when the air filter case is assembled. Clamp the wire harness, left handlebar switch lead, right handlebar switch lead, main switch lead and radiator fan motor lead (right). Match the taping positions of three leads except the wire harness. Point the tip of the clamp to the front side of the vehicle.
CABLE ROUTING The clamp by the side of a hose comes below an attachment clamp. Insert until it sets. Poss the canister hose over fuel return hose and under the fuel hose. Route it above the canister hose.
CABLE ROUTING SPEC Push the starter motor lead in the clamping sections (two points) or the battery box assembly and secure it. Install to the deepest position of the rib of the battery box assembly. Fit in the plastic cover of rivet to the main unit after assembly. Make sure to clamp the wire harness. (Tighten it until the clamp latchet stops.) Insert the turn signal light relay to the back end of the rib in the battery box assembly.
CABLE ROUTING Insert it to the back end of the rib in the battery box assembly. The 20 mm (0.79 in) knob should be within this range. Pass the turn signal lead by the outside of the right side attaching boss of the tail / brake light. Connect the turn signal light lead couplers (two leads). Pass the turn signal light and license light leads between the rear side ribs of the battery box assembly and to the rear part of the vehicle. Connect the license light leads (two leads).
CABLE ROUTING Connect the negative lead and the wire harness. Install the starting circuit cut-off relay to the deepest position after placing the tail / brake light lead and turn signal light lead in the guide.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00135 PERIODIC CHECKS AND ADJUSTMENTS BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ f. Fully pull the brake lever or fully press down the brake pedal and hold it in position. g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j.
ADJUSTING THE FRONT FORK LEGS CHK ADJ EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: • Grooves are provided to indicate the adjustment position. • Never go beyond the maximum or minimum adjustment positions. 1.
ADJUSTING THE FRONT FORK LEGS CHK ADJ 1. Adjust: • rebound damping a. Turn the adjusting screw or . Direction Direction in direction Rebound damping is increased (suspension is harder). Rebound damping is decreased (suspension is softer). Adjusting positions Minimum: 10 clicks in direction * Standard: 6 clicks in direction * Maximum: 1 clicks in direction * * with the adjusting screw fully turned-in direction Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 91 Nm (9.1 m•kg, 66 ft•lb) 21 Nm (2.1 m•kg, 15 ft•lb) 18 Nm (1.
FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 5 Nm (0.5 m•kg, 3.6 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) Order 1 2 3 4 5 6 7 Job / Part Removing the front brake pads Q’ty Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Bleed screw Remarks Remove the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers.
FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER 13 Nm (1.3 m•kg, 9.4 ft•lb) 30 Nm (3.
FRONT AND REAR BRAKES CHAS 13 Nm (1.3 m•kg, 9.4 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order 13 14 Job / Part Brake master cylinder Front brake switch Q’ty 1 1 Remarks For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00585 6 Nm (0.6 m•kg, 4.3 ft•lb) Order Job / Part Disassembling the front brake master cylinder Brake master cylinder kit Bleed screw Brake master cylinder body Q’ty Remarks Disassemble the parts in the order listed. 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) Order Job / Part Removing the front brake calipers Q’ty Brake fluid 1 2 3 4 Remarks Remove the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00615 5 Nm (0.5 m•kg, 3.6 ft•lb) Order Job / Part Disassembling the front brake calipers Q’ty Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw Remarks Disassemble the parts in the order listed. NOTE: The following procedure applies to both of the front brake calipers. 2 1 1 2 4 8 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EAS00607 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: • brake master cylinder kit • circlip • dust boot 2. Install: • brake master cylinder 13 Nm (1.3 m•kg, 9.4 ft•lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up.
FRONT AND REAR BRAKES CHAS 4. Fill: • brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT FORK CHAS EAS00647 FRONT FORK FRONT FORK LEGS 32 Nm (3.2 m•kg, 23 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) Order 1 2 3 4 5 6 Job / Part Removing the front fork legs Front wheel 23 Nm (2.3 m•kg, 17 ft•lb) Q’ty Front brake calipers Front cowling inner panels Front fender Cap bolt Handlebar pinch bolt Upper bracket pinch bolt Under bracket pinch bolt Front fork leg 1 1 1 1 2 1 Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”.
FRONT FORK CHAS EAS00648 15 Nm (1.5 m•kg, 11 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Disassembling the front fork legs Q’ty Cap bolt O-ring Damper adjusting rod Nut Washer Spacer Fork spring Dust seal Oil seal clip Oil seal 1 1 1 1 1 1 1 1 1 1 34 Remarks Disassemble the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs.
FRONT FORK CHAS 15 Nm (1.5 m•kg, 11 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part Washer Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Outer tube Q’ty 1 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: • cap bolt (from the damper adjusting rod) • spacer • nut a. Press down on the spacer with the fork spring compressor . b. Install the rod holder between the nut and the spacer . Fork spring compressor 90890-01441, YM-01441 Rod holder 90890-01434, YM-01434 NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e.
FRONT FORK CHAS 4. Remove: • damper rod assembly bolt • damper rod assembly NOTE: While holding the damper rod assembly with the damper rod holder , loosen the damper rod assembly bolt. Damper rod holder 90890-01423, YM-01423 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube • outer tube Bends / damage / scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2.
FRONT FORK CHAS CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check: • cap bolt O-ring Damage / wear → Replace. EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
FRONT FORK CHAS WARNING Always use new copper washer. CAUTION: Allow the damper rod assembly to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Suspension oil “01” or equivalent 3. Tighten: • damper rod assembly bolt 23 Nm (2.3 m•kg, 17 ft•lb) LOCTITE® NOTE: While holding the damper rod assembly with the damper rod holder , tighten the damper rod assembly bolt.
FRONT FORK CHAS CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 5. Install: • oil seal (with the fork seal driver ) Fork seal driver 90890-01442, YM-01442 6.
FRONT FORK 8. Install: • rod puller • rod puller attachment (onto the damper rod CHAS ) Rod puller 90890-01437, YM-01437 Rod puller attachment 90890-01436, YM-01436 9. Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.475 L (0.418 Imp qt, 0.502 US qt) Recommended oil Suspension oil “01” or equivalent Front fork leg oil level (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) 92 mm (3.
FRONT FORK CHAS e. Press down on the spacer with the fork spring compressor . f. Pull up the rod puller and install the rod holder between the nut and the spacer . NOTE: Use the side of the rod holder that is marked “B”. Fork spring compressor 90890-01441, YM-01441 Rod holder 90890-01434, YM-01434 g. Remove the rod puller and adapter. h. Install the nut and position it as specified . Distance 11 mm (0.43 in) i. Set the cap bolt distance tion. to specifica- Distance 13 mm (0.51 in) j.
SWINGARM AND DRIVE CHAIN CHAS EAS00709 SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension ) / 2 • 15-link section of the drive chain Out of specification → Replace the drive chain, front drive sprocket and rear drive sprocket as a set. 15-link drive chain section limit (maximum) 239.3 mm (9.
SWINGARM AND DRIVE CHAIN CHAS CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosine to clean the drive chain. 4.
RADIATOR EAS00454 COOL COOLING SYSTEM RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 1 2 3 4 5 6 7 8 7 Nm (0.7 m•kg, 5.1 ft•lb) Job / Part Removing the radiator Rider seat Fuel tank Air filter case Side cowlings and bottom cowling Coolant Q’ty Coolant reservoir hose Throttle body hose Radiator outlet hose Coolant pipe Radiator inlet hose Oil cooler outlet hose Radiator Radiator fan 1 2 1 1 1 1 1 2 45 12 Nm (1.2 m•kg, 8.7 ft•lb) Remarks Remove the parts in the order listed.
RADIATOR 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 9 Job / Part Radiator cap 7 Nm (0.7 m•kg, 5.1 ft•lb) Q’ty 1 COOL 12 Nm (1.2 m•kg, 8.7 ft•lb) Remarks For installation, reverse the removal procedure.
ELECTRIC STARTING SYSTEM EAS00755 ELEC ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starter relay Starter motor Fuse (ignition) Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch Start switch Clutch switch 47
ELECTRIC STARTING SYSTEM ELEC EAS00739 EAS00757 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cut-off relay 5. starter relay 6. main switch 7. engine stop switch 8. neutral switch 9. sidestand switch 10. clutch switch 11. start switch 12.
ELECTRIC STARTING SYSTEM ELEC EAS00759 4. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relay coupler from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown.
ELECTRIC STARTING SYSTEM ELEC EAS00766 EAS00752 9. Sidestand switch 12. Wiring • Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the sidestand switch OK? • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES NO YES Replace the sidestand switch. The starting system circuit is OK. EAS00763 10. Clutch switch • Check the clutch switch for continuity.
COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Fuse (ignition) ECU Coolant temperature sensor Radiator fan motor relay Fuse (radiator fan motor left) Fuse (radiator fan motor right) Radiator fan motor (left) Radiator fan motor (right) 51 ELEC
COOLING SYSTEM ELEC EAS00739 EAS00808 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. • The radiator fan motor fails to turn. • The coolant temperature indicator light fails to light when the engine is warm. Minimum open-circuit voltage 12.8 V or more at 20°C (68°F) Check: 1. main, ignition, and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan motor 5. radiator fan motor relay 6.
COOLING SYSTEM ELEC EAS00809 4. Radiator fan motor (left and right) 5. Radiator fan motor relay • Disconnect the radiator fan motor coupler from the wire harness. • Connect the battery (DC 12 V) as shown. • Disconnect the radiator fan motor relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor terminal as shown. • Check the radiator fan motor of continuity.
COOLING SYSTEM ELEC EAS00812 6. Coolant temperature sensor • Remove the coolant temperature sensor. • Connect the pocket tester (Ω × 1k) to the coolant temperature sensor as shown. • Immerse the coolant temperature sensor in a container filled with coolant . NOTE: Make sure the coolant temperature sensor terminals do not get wet. • Place a thermometer in the coolant. • Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table.
YZF-R6T/YZF-R6TC WIRING DIAGRAM
YZF-R6T / YZF-R6TC WIRING DIAGRAM Main switch A.C.
YAMAHA MOTOR CO., LTD.
