Yamaha 2004 Moto Matrix Supplementary Service Manual Download Page 21 | Manualshive

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–13–

CABLE ROUTING

SPEC

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.

C Direction of which is sufficient as the knob of a clip.
D Air opening

1

Fuel pump assembly

2

Fuel tank drain hose

3

Fuel tank breather hose

4

Clamp

5

Clip

Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys

email: [email protected]

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Summary of Contents for 2004 Moto Matrix

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: ...ogether 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email...

Page 4: ...hanges 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...

Page 5: ...ND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a disassembly step 6 Symbols indicate parts to b...

Page 6: ...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 disul...

Page 7: ...UEL 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys em...

Page 8: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 9: ...ot 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 X 0 32 Ω at 20_C 68_F 5 0 X 6...

Page 10: ... ty Tightening torque Remarks Item Fastener size Q ty 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 11: ...w 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 1 Right handlebar switch lead 2 Clutch cable 3 Immobilizer unit lead main switch lead and left han dlebar switch lead 4 Throttle cable return side 5 Throttle cable pull side 6 Front brake hoses 7 Throttle cables 8 Joint 9 Under ...

Page 12: ...nder the under bracket and rear side of the vehicle Cut the tip leav ing 2 X 10 mm 0 08 X 0 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 fa...

Page 13: ...oir 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 ...

Page 14: ...lamp the clutch cable by routing the upper end of the clamp along with the bottom end of the hose clamp assembly Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 15: ...d 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...

Page 16: ...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 X 1 97 in H Pass the oil level switch...

Page 17: ...nkcase 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 m...

Page 18: ... 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 clam...

Page 19: ... 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...

Page 20: ...rter 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 t...

Page 21: ... crookedness in fuel tank drain hose and fuel tank breather hose between fuel tank s nipple and clamp C Direction of which is sufficient as the knob of a clip D Air opening 1 Fuel pump assembly 2 Fuel tank drain hose 3 Fuel tank breather hose 4 Clamp 5 Clip Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 22: ...mp 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS Disconnect Disconnect For installation reverse the removal procedure Refer to the CABLE ROUTING for how to attach a hose 7 Nm 0 7 mSkg 5 1 ftSlb 7 Nm 0 7 mSkg 5 1 ftSlb 4 Nm 0 4 mSkg 2 9 ftSlb FUEL TANK CHK ADJ EAS00040 PERIODIC CHECKS AND ADJUSTMENTS FUEL TANK Manuals by Motomatrix www motomatrix co uk The Solution For Los...

Page 23: ...f the fuel tank when installing the fuel pump SAlways use a new fuel pump gasket SInstall the fuel pump as shown in the illustra tion STighten the fuel pump bolts in stages in a criss cross pattern and to the specified torque Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 24: ...der 3 and 4 1 Air cut off valve 2 Reed valve 3 To air filter case FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 25: ...light relay dimmer 1 Coolant temperature sensor 2 Intake air temperature sensor 3 Intake air pressure sensor 4 Lean angle cut off switch 5 Atmospheric pressure sensor 6 ECU 7 Starting circuit cut off relay 8 Turn signal relay ELECTRICAL ELECTRICAL COMPONENTS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 26: ...r R Br R B3 R B R B G B G B L B L B O B O B B Dg B B3 Dg B W Y W Y R R B B W R G Y L Lg W Y B 14 Lg Lg R G HEADLIGHT SUB WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS 1 B 17 E 38 22 B Y B L R B R B F 24 B L B L B L E W B W B G B G B E 55 70 54 R Y B L YW L B B Y B Ch B Ch B 69 Dg B Dg B B O 17 B B B 27 O O B B L B L Dg Ch F B L B Y B Y L L B B Gy R 17 L B L B Lg Lg F O B O B F 25 P W B L L L Y B L L ...

Page 27: ...es SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK Replace the fuse s EAS00737 TROUBLESHOOTING 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 ...

Page 28: ... applies to all of the ignition coils SDisconnect the ignition coil leads from the wire harness SConnect the pocket tester Ω 1 to the ignition coil as shown Positive tester probe ignition coil terminal Negative tester probe ignition coil terminal SConnect the pocket tester Ω 1k to the ignition coil as shown SMeasure the primary coil resistance Primary coil resistance 0 24 X 0 32 Ω at 20_C 68_F Neg...

Page 29: ...K YES NO Replace the main switch EAS00748 EAS00750 8 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES NO Replace the right handlebar switch EAS00751 9 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK YES NO Replace the neutral switch EAS00752 10 Sidestand ...

Page 30: ...black 1 2 3 4 EAS00753 Positive tester probe sky blue Negative tester probe blue yellow Continuity 1 3 Positive tester probe blue black Negative tester probe black yellow 4 2 Positive tester probe black yellow Negative tester probe sky blue 2 1 Positive tester probe blue yellow Negative tester probe sky blue No continuity 3 1 13 Lean angle cut off switch voltage SRemove the lean angle cut off swit...

Page 31: ... system s wiring Refer to CIRCUIT DIAGRAM SIs the ignition system s wiring properly con nected and without defects YES NO Properly connect or repair the ignition system s wiring Replace the ignitor unit Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 32: ... W P W P W Y Y L W B B2 R G Y L Lg R W O G Gy G B Br R R L Gy G W Lg YW B L Y L W B Y Y G G Y L Y B BB R G Y L Lg R W L W L W B W Br R Br R B3 R B R B G B G B L B L B O B O B B Dg B B3 Dg B W Y W Y R R B B W R G Y L Lg W Y B 14 Lg Lg R G HEADLIGHT SUB WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS 1 B 17 E 38 22 B Y B L R B R B F 24 B L B B L B L E W B W B G B G B E 55 70 54 R Y B L YW L B B Y B L B C...

Page 33: ...t 42 Meter light 50 Fuse headlight 54 Headlight relay on off 55 Headlight relay dimmer 56 Fuse park 60 Pass switch 61 Dimmer switch 71 Headlight 72 License light 73 Tail brake light Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 34: ...e dimmer switch is set to Headlight coupler wire harness side Low beam Headlight Positive tester probe black blue Negative tester probe black 1 2 Meter assembly coupler wire harness side STurn the main switch to ON SStart the engine SSet the dimmer switch to or SMeasure the voltage DC 12 V of black blue or black yellow on the headlight cou pler wire harness side SIs the voltage within specificatio...

Page 35: ...hin specification 1 This circuit is OK EAS00790 3 The tail brake light fails to come on YES NO 1 Tail brake light LEDs SCheck the tail brake light for continuity Refer to CHECKING THE LEDs SAre the tail brake light OK Replace the tail brake light as sembly YES NO 2 Voltage SConnect the pocket tester DC 20 V to the tail brake light coupler wire harness side as shown Wiring circuit from the main swi...

Page 36: ...cket tester DC 20 V to the license light coupler wire harness light side as shown The wiring circuit from the main switch to the license light coupler is faulty and must be repaired Positive tester probe blue red Negative tester probe black 1 2 STurn the main switch to ON SMeasure the voltage DC 12 V of blue red on the license light coupler wire harness side SIs the voltage within specification 1 ...

Page 37: ...ng circuit cut off relay Sidestand switch Fuel pump ECU Ignition coil Spark plug Injector AI system solenoid Neutral switch Crankshaft position sensor Intake air temperature sensor Coolant temperature sensor Throttle position sensor Intake air pressure sensor Atmospheric pressure sensor Cylinder identification sensor Speed sensor Lean angle cut off switch Meter assembly Immobilizer indicator light...

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: ...YZF R6 S 2004 WIRING DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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