FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZFR6S/YZF-R6SC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YZF-R6R/YZF-R6SR/YZF-R6RC/YZF-R6SRC SERVICE MANUAL: LIT-11616-16-45 (5SL-28197-10) EAS00001 YZF-R6S/YZF-R6SC SUPPLEMENTARY SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, September 2003 All rights reserved.
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. 1 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”. 2 Each chapter is divided into sections.
EAS00008 1 2 GEN INFO SYMBOLS SPEC 3 4 CHK ADJ CHAS 5 6 COOL ENG 7 8 FI ELEC Symbols 10 to 17 indicate the following. 10 9 10 11 12 13 14 15 16 17 TRBL SHTG 11 12 13 14 15 16 17 18 19 20 21 24 The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter.
CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES .
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Standard 5SLD (USA except for CAL) 5SLE (CAL) Limit SSS ENGINE SPECIFICATIONS Item Throttle bodies ID mark Throttle valve size Standard 5SL1 00 (5SLD), 5SL4 10 (5SLE) #100 Limit SSS SSS CHASSIS SPECIFICATIONS Item Front tire Model (manufacturer) Rear tire Model (manufacturer) Standard Limit Pilot SPORT N (MICHELIN) D208 FJ (DUNLOP) SSS Pilot SPORT B (MICHELIN) D208 AJ (DUNLOP) SSS ELECTRICAL SPECIFICATIONS Item
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Oil cooler Cylinder identification sensor Fastener Bolt Bolt Thread Q’ty Q ty size M20 M6 –2– 1 1 Tightening torque Nm mSkg ftSlb 63 6.0 6.3 0.6 46 4.3 Remarks Yamaha bond No.
CABLE ROUTING SPEC CABLE ROUTING 1 Right handlebar switch lead 2 Clutch cable 3 Immobilizer unit lead, main switch lead and left han4 5 6 7 8 9 dlebar switch lead Throttle cable (return side) Throttle cable (pull side) Front brake hoses Throttle cables Joint Under bracket A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward.
CABLE ROUTING F Pass the horn lead by the outside of the throttle cable and clamp it to the forefront of upper face of the under bracket. Next, route it under the front brake hose and clamp it to the pawl of the under cover. G Clamp it at the position of 40 (1.57 in.) to 60 mm (2.36 in.) from the upper face of the under bracket with the plastic locking tie. Cut the surplus part of the clamp tip leaving 2 (0.08 in.) to 4 mm (0.16 in.). Point the tip of the clamp to the outside of vehicle.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 Throttle stop screw Coolant reservoir tank hose Pickup coil lead Rear brake light switch lead Coolant hose Clutch cable Coolant hose protector Hose clamp assembly Hose clamp A Pass the rear brake light switch lead outside of rear engine mount bolt. B Pass the ignition coil lead outside of the radiator hose. C Pass the coolant reservoir tank hose under the frame and right side of the throttle body.
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.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Throttle cable (return side) Throttle cable (pull side) Starter motor lead Coolant reservoir tank breather hose Bracket 2 Sidestand switch lead Oil level switch lead A.C.
CABLE ROUTING F Pass the coolant reservoir tank breather hose through the clamp of under the coolant reservoir tank. G Projection allowance from the coolant reservoir tank cover shall be 30 to 50 mm (1.18 X 1.97 in). H Pass the oil level switch lead and sidestand switch lead over the bracket 2. I Pass the oil level switch lead, and sidestand switch lead through the clamp. J 5 X 45 mm (0.20 X 1.77 in). K Clamp the A.C. magneto lead, oil level switch lead and sidestand switch lead.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Right handlebar switch lead Sub wire harness Head light lead Meter lead Cover 8 Ignition coil lead Throttle position sensor coupler Coolant reservoir tank hose Throttle stop cable Speed sensor lead coupler 11 Crankshaft position sensor lead 12 13 14 15 16 17 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 –9– SPEC 18 Fuel hose (fee
CABLE ROUTING 28 Throttle cables 29 Throttle sub-lead 1 (white 6 32 Sidestand switch lead coupler (blue 2 poles) poles) 33 A.C.
CABLE ROUTING A To the headlight B Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it when installing the side cowling. C Clamp the plastic locking tie to the cover 8. Place the coupler at the rear side of the vehicle against the plastic locking tie. Point the tip of the plastic locking tie to the downward in the inner side of the vehicle. D Route the head light and meter leads under the frame’s lower part from the hollow section of the cover 2.
CABLE ROUTING L To the neutral switch M Insert the wire harness wrapping clamp to the frame hole. N Pass the battery negative lead over the wire harness. O There should be no interference between the wire harness and the tip of the rear frame attaching bolts. P To the coolant reservoir tank Q To the intake air temperature sensor (air filter case) R To the oil level switch, sidestand switch and A.C. magneto S Install the wire harness wrapping clamp to the stay of the throttle body.
CABLE ROUTING AA Branching leads to the fuse box and radiator fan motor relay shall pass through the guide section of the cover 2 under the wire harness and then to the outside of the frame. AB To the fuse box and fan motor relay AC Pass the throttle cables over the cover 2. AD Point the tip of the plastic locking tie to the rear side of the vehicle. AE To the main switch lead coupler SPEC AF Tip of the plastic locking tie should point to the downward outside of the vehicle.
CABLE ROUTING Fuel pump assembly Fuel tank drain hose Fuel tank breather hose (except for CAL) Clamp Clip Canister (for CAL) Blance hose (for CAL) Canister hose (for CAL) A Install the O-ring with its lip pointed upward. B Pass the fuel tank drain hose and fuel tank breather hose through the clamp. There needs to be no crookedness in fuel tank drain hose and fuel tank breather hose between fuel tank’s nipple and clamp. 1 2 3 4 5 6 7 8 SPEC C Direction of which is sufficient as the knob of a clip.
FUEL TANK CHK ADJ 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 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the fuel tank Rider seat Fuel hose connector cover Fuel hose Fuel return hose Fuel sender coupler Fuel pump coupler Clamp Fuel tank overflow hose Fuel tank breather hose Fuel tank Fuel pump Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS”. 1 1 1 1 1 1 1 1 1 1 Disconnect. Disconnect.
FUEL TANK CHK ADJ 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. S Always use a new fuel pump gasket. S Install the fuel pump as shown in the illustration. S Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque.
AIR INDUCTION SYSTEM FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve 2 Reed valve 3 To air filter case A To cylinder #1 and #2 B To cylinder #3 and #4 –17– FI
ELECTRICAL COMPONENTS ELEC ELECTRICAL ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 Coolant temperature sensor Intake air temperature sensor Intake air pressure sensor Lean angle cut-off switch Atmospheric pressure sensor ECU Starting circuit cut-off relay Turn signal relay 9 10 11 12 13 14 –18– Speed sensor Crankshaft position sensor Cylinder identification sensor Radiator fan motor relay Headlight relay (on / off) Headlight relay (dimmer)
ON OFF 1 W R W W W W W L/B - L/Y L/B L/B L/Y 10 R Br/L R Br/L Br/L R W W W B 3 R/W R 4 R Br/L Br/L 48 47 46 B R/W L BrG G/Y 49 BrG R/Y Br L/B B/L R/Y R B L B L 50 Y B/L B YW B/Y 52 51 B Br Y B B 5 R R B B B L/W R/W 53 B B 67 Y - Br/WR/Y R G/Y B Y L/R Ch L/Y B B/Y Br Dg Y Br B R/B L 6 R R/B B Br 42 R R L/WR/W R/W L/W G/Y 8 R G/Y L/W R/W 7 R R B L/Y W W 9 66 43 54 Y Dg B 187 55 B B/Y B B/Y H B/Y B/L C B
IGNITION SYSTEM EAS00737 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. The ignition system fails to operate (no spark or intermittent spark). Check: 1. Main and ignition fuses 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Ignition coil resistance 6. Crankshaft position sensor 7. Main switch 8. Engine stop switch 9. Neutral switch 10. Sidestand switch 11. Clutch switch 12. Starting circuit cut-off relay 13.
IGNITION SYSTEM ELEC 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 1 and ignition coil 2 as shown. S Set the main switch to “ON”. S Measure the ignition spark gap a . S Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs. S Measure the primary coil resistance. Primary coil resistance 0.24 X 0.
IGNITION SYSTEM EAS00748 ELEC EAS00750 6. Crankshaft position sensor resistance 8. Engine stop switch S Disconnect the crankshaft position sensor coupler from the wire harness. S Connect the pocket tester (Ω 100) to the crankshaft position sensor coupler as shown. S Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? YES Positive tester probe ! gray 1 Negative tester probe ! black 2 NO Replace the right handlebar switch. EAS00751 9.
IGNITION SYSTEM ELEC EAS00753 12. Starting circuit cut-off relay NOTE: When you switch the positive and negative tester probes, the readings in the above chart will be reversed. S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) to the starting circuit cut-off relay coupler as shown. S Check the starting circuit cut-off relay for continuity.
IGNITION SYSTEM YES NO Replace the 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 connected and without defects? YES Replace the ignitor unit. NO Properly connect or repair the ignition system’s wiring.
ON OFF 1 W R W W W W W L/B R Br/L Br/L R L G/Y B L BrG L R/W B 48 47 10 L/Y L/B L/B L/Y Br/L R Br/L R Br/L 46 - W W W B 3 B 49 BrG R/Y Br 50 R/W R Y L/B B/Y B/L B/L R/Y 4 R B YW R/G 52 51 B Br Y B B 5 R R B B B L/W R/W 53 B B 67 Y - Br/WR/Y R G/Y B Y L/R Ch L/Y B B/Y Br Dg Y Br B R/B L 6 R R/B B Br 42 R R L/WR/W R/W L/W G/Y 8 R G/Y L/W R/W 7 R R B L/Y W R/W G/Y 9 66 43 54 Y Dg B 187 55 B B/Y B B/Y H B/
LIGHTING SYSTEM 1 5 6 15 40 42 50 54 55 56 60 61 71 72 73 Main switch Battery Fuse (main) ECU High beam indicator light Meter light Fuse (headlight) Headlight relay (on / off) Headlight relay (dimmer) Fuse (park) Pass switch Dimmer switch Headlight License light Tail/ brake light –26– ELEC
LIGHTING SYSTEM ELEC EAS00788 Headlight Positive tester probe ! black/yellow 3 Negative tester probe ! black 4 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. B High beam 1. Headlight bulb and socket S Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” S Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both.
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. Refer to “CHECKING THE LEDs” S Are the meter light OK? S Check the tail/brake light for continuity. Refer to “CHECKING THE LEDs” S Are the tail/brake light OK? YES NO YES Replace the meter assembly. NO Replace the tail/brake light assembly. 2. Voltage 2.
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. Refer to “CHECKING THE BULBS AND BULB SOCKETS” S Are the license light bulb and socket OK? YES NO Replace the license light bulb, socket or both. 2. Voltage S Connect the pocket tester (DC 20 V) to the license light coupler (wire harness light side) as shown.
YZF-R6S/YZF-R6SC WIRING DIAGRAM
YZF-R6S/YZF-R6SC WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Main switch A.C.