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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–3–
CABLE ROUTING SPEC
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 pull-
ing side of the throttle cables is routed downward.
C Pass the clutch cable through the guide.
D Plastic locking tie shall be positioned at 10 mm
(0.39 in.) below from the upper bracket.
E Clamp the left handlebar switch lead to the front fork
with the plastic locking tie and cut the tip of the tie.
Clamp it to the protector section.
1Right handlebar switch lead
2Clutch cable
3Immobilizer unit lead, main switch lead and left han-
dlebar switch lead
4Throttle cable (return side)
5Throttle cable (pull side)
6Front brake hoses
7Throttle cables
8Joint
9Under bracket
CABLE ROUTING
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–4–
I Set in the coupler between the head light’s hollow
section and the duct.
J Install the relay to the rib of the head light.
(Location for the left and right relays is alternative.)
K To the wire harness
L To the front turn signal light (right)
M Set the sub wire harness in the joint.
N Do not catch the sub wire harness when the duct is
assembled.
O To the front turn signal light (left)
P Point the tip of the plastic locking tie to the front side
of the vehicle. Cut the tip leaving 2 X10 mm (0.08
X0.39 in).
Q Point the tip of the plastic locking tie under the under
bracket and rear side of the vehicle. Cut the tip leav-
ing 2 X10 mm (0.08 X0.39 in).
CABLE ROUTING SPEC
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.
H Pass the throttle cables inside the front brake
hoses.
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–5–
CABLE ROUTING SPEC
1Throttle stop screw
2Coolant reservoir tank hose
3Pickup coil lead
4Rear brake light switch lead
5Coolant hose
6Clutch cable
7Coolant hose protector
8Hose clamp assembly
9Hose 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.
D Pass the clutch cable inside of the coolant reservoir
tank hose and radiator return hoses.
E Assemble as “ ” shown below when clamping.
F Pass the pickup coil lead over the throttle stop
cable.
G Tip of the plastic locking tie shall be pointed to the
inner side at the rear part of the vehicle.
H 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.
I Pass the clutch cable inside of the radiator hose.
J Clamp the clutch cable so that it is positioned in this
range.
K Put and apply the hose clamp to it.
a
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–6–
CABLE ROUTING SPEC
L Clamp the clutch cable by routing the upper end of
the clamp along with the bottom end of the hose
clamp assembly.
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–7–
CABLE ROUTING SPEC
1Throttle cable (return side)
2Throttle cable (pull side)
3Starter motor lead
4Coolant reservoir tank breather hose
5Bracket 2
6Sidestand switch lead
7Oil level switch lead
8A.C. magneto lead
9Radiator fan motor lead
10 Fuel tank breather hose
11 Fuel tank drain hose
12 Coolant reservoir tank cover
13 Drive sprocket cover
14 Coolant reservoir tank
A Pass the main switch lead under the left handlebar
switch lead and immobilizer unit lead and then to the
right side of the vehicle.
B 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 ve-
hicle.
C Pass the fuel tank drain hose and fuel tank breather
hose inside of the reservoir tank breather hose, res-
ervoir tank hose and wire harness and then route it
by the out side of the starter motor lead.
D Pass the coolant reservoir tank hose outside of the
fuel tank drain hose and fuel tank breather hose.
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–8–
L Pass the side stand switch lead, oil level switch lead
and A.C. magneto lead between the engine stay
and the engine.
M To the throttle body
N To the radiator fan motor relay and fuse box
O Route it above the radiator hose.
P Pass the throttle cable between the guide of the
cover 2 and the frame.
Q Pass the radiator fan motor lead through the hole of
the frame to the inner side of the vehicle.
R Pass the coolant reservoir tank breather hose
through the hole of the coolant reservoir tank cover.
S Order of ups and downs means no object.
T Route it below the coolant reservoir thank.
U To the horn
CABLE ROUTING SPEC
E Pass the fuel tank drain hose, fuel tank breather
hose through the clamp of the coolant reservoir
tank.
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 X1.97 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.
J5X45 mm (0.20 X1.77 in).
K Clamp the A.C. magneto lead, oil level switch lead
and sidestand switch lead.
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–9–
CABLE ROUTING SPEC
1Right handlebar switch lead
2Sub wire harness
3Head light lead
4Meter lead
5Cover 8
6Ignition coil lead
7Throttle position sensor coupler
8Coolant reservoir tank hose
9Throttle stop cable
10 Speed sensor lead coupler
11 Pickup coil lead coupler
12 Fuel tank breather hose
13 Fuel tank drain hose
14 Fuel hose (return side)
15 Fuel pump 2 coupler
16 Fuel pump 1 coupler
17 Starter motor lead
18 Fuel hose (feed side)
19 Crankcase breather hose
20 Air vent hose
21 Fuse box
22 Cover 7
23 Radiator fan motor relay
24 Radiator fan motor lead
25 Left handlebar switch lead
26 Immobilizer unit lead
27 Main switch lead
28 Wire harness
29 Throttle cables
30 Throttle sub-lead 1 (white 6
poles)
31 Throttle sub-lead 2 (black 6
poles)
32 Oil level switch lead coupler
(white 1 pole)
33 Sidestand switch lead coupler
(blue 2 poles)
34 A.C. magneto lead coupler
(white 3 poles)
35 Rear brake light switch lead cou-
pler (brown 2 poles)
36 Neutral switch lead coupler
(connector 1 pole)
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–10–
CABLE ROUTING SPEC
A To the headlight
B 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.
C Pass the left and right handlebar switch leads out-
side of the air filter case air vent hose.
D Connect the couplers (4 units) at the frame side
hole. Do not catch each lead and wire harness when
the cover 8 is attached.
E From the radiator
F Pass the coolant reservoir tank hose through for-
ward the starter motor lead and speed sensor lead.
G Pass the speed sensor lead coupler and crankshaft
position sensor lead coupler over the throttle stop
cable.
H To the rear brake light switch lead
I 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.
J To the neutral switch
K Pass the battery negative lead over the wire har-
ness.
L Insert the wire harness wrapping clamp to the frame
hole.
M There should be no interference between the wire
harness and the tip of the rear frame attaching bolts.
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–11–
W Clamp the wire harness, left and right handlebar
switch leads and main switch lead. Align the tapping
positions of three leads except the wire harness.
Point the tip of the clamp to the front side of the ve-
hicle.
X Route the head light and meter leads under the
frame’s lower part from the hollow section of the
cover 2.
Y To the main switch lead coupler
Z To the immobilizer unit coupler
AA To the fuse box and fan motor relay
AB Pass the throttle cables over the cover 2.
AC 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.
CABLE ROUTING SPEC
N To the coolant reservoir tank
O To the oil level switch, sidestand switch and A.C.
magneto
P To the intake temperature sensor (air filter case)
Q Install the wire harness wrapping clamp to the stay
of the throttle body.
R Pass the wire harness over the throttle air vent
hose.
S Pass the wire harness between frame and coolant
hose.
T Pass it through the frame hole.
U Pass the left handlebar switch lead and main switch
lead over the immobilizer unit lead.
V Do not catch the coupler when the air filter case is
assembled.
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–12–
AK Insert until it sets.
AL The clamp by the side of a hose comes below an
attachment clamp.
CABLE ROUTING SPEC
AD Clamp the wire harness, main switch lead branch
section, radiator fan motor lead and immobilizer
unit lead. Align the taping position of the immobi-
lizer unit lead.
AE Branching harness from the wire harness.
AF Use the plastic locking tie to clamp the starter mo-
tor lead at the protector section.
AG Tip of the plastic locking tie should point to the
downward outside of the vehicle.
AH Sealing set of the cover can be either upper or
lower against the frame lower end. However, it
should not be caught.
AI Make sure not to drop the headlight sub wire har-
ness beneath the projection of the duct. Check it
when installing the side cowling.
AJ Point the tip of the plastic locking tie to the rear
side of the vehicle.
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