Yamaha Moto matrix YZF-R6S Manual

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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R6 (S) 2004. For complete service information procedures it is necessary to use this Supplemen-
tary 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.
is expressly prohibited.
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NOTE:
WARNING
CAUTION:
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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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12
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.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-
pears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
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22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
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 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10 Serviceable with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum-disulfide oil
21 Wheel-bearing grease
22 Lithium-soap- based grease
23 Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
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CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS AND ADJUSTMENTS
FUEL TANK 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION SYSTEM
AIR INDUCTION SYSTEM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS 16. . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
ELECTRICAL COMPONENTS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM 26. . . . . . . . . . . . . . . . . . . . . . . .
YZF-R6 (S) 2004 WIRING DIAGRAM
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–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5SLB (EUR), 5SLC (F), 5SLG/5SLL (AUS) SSS
ENGINE SPECIFICATIONS
Item Standard Limit
Throttle bodies
ID mark
Throttle valve size
5SL1 00 (5SLB/5SLG/5SLL),
5SL2 20 (5SLC)
#100
SSS
SSS
CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Model (manufacturer) Pilot SPORT N (MICHELIN)
D208 FJ (DUNLOP)
SSS
Rear tire
Model (manufacturer) Pilot SPORT B (MICHELIN)
D208 AJ (DUNLOP)
SSS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
CDI unit model (manufacturer) F8T814 (MITSUBISHI)
(5SLB/5SLG/5SLL)
F8T815 (MITSUBISHI) (5SLC)
SSS
SSS
Ignition coils
Model (manufacturer)
Primary coil resistance
Secondary coil resistance
F6T549 (MITSUBISHI)
0.24 X0.32 Ωat 20_C (68_F)
5.0 X6.8 kΩat 20_C (68_F)
SSS
SSS
SSS
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–2–
TIGHTENING TORQUES SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Fastener
Thread
Q
’
ty
Tightening torque
Remarks
Item
Fastener
size
Qty
Nm mSkg ftSlb
Remarks
Oil cooler
Cylinder identification sensor
Bolt
Bolt
M20
M6
1
1
63
6.0
6.3
0.6
46
4.3 Yamaha bond
No.1215
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