Yamaha 2006 YZFR6V, Service Manual

Page: 81 / 444

CABLE ROUTING
2-50
1. EXUP servo motor lead
2. Crankshaft position sensor lead
3. Ignition coil lead
4. Wire harness
5. Right radiator fan motor lead
6. Front brake fluid reservoir hose
7. Right handlebar switch lead
8. Throttle cable (accelerator cable)
9. Throttle cable (decelerator cable)
10. Front brake hose
11. Headlight sub-wire-harness
12. Coolant reservoir hose
13. Front right turn signal light lead
14. Coolant reservoir breather hose
15. Clutch cable
16. Radiator outlet hose
17. Water pump outlet hose
18. Water pump breather hose
19. EXUP cables
20. O
2
sensor lead
21. Rear brake light switch lead
22. Rear brake fluid reservoir hose
23. Rear brake hose
24. Headlight sub-wire-harness 2
25. Headlight sub-wire-harness 1
26. Right radiator fan motor sub-wire-harness
27. Right handlebar switch lead
A. Fasten the EXUP cables, EXUP servo motor lead,
and rear brake light switch lead with a plastic
locking tie, making sure to fasten the tie on the
metal tubes around the cables, 0
–
20 mm (0
–
0.79
in) from the ends of the tubes. Face the end of the
plastic locking tie rearward, and then cut off the
excess end of the tie to 2
–
4 mm (0.08
–
0.16 in).
B. Route the wire harness on top of the heat
protector, making sure to push the harness inward
so that it does not protrude past the frame.
C. To the front right turn signal light
D. Route the coolant reservoir breather hose between
the radiator and the coolant reservoir, then to the
outside of the damper on the radiator.
E. Fasten the clutch cable with the holder, making
sure that the metal band around the cable is above
the holder.
F. Cross the coolant reservoir breather hose and
clutch cable, and then fasten them with the holder,
making sure to align the top of the holder with the
bottom edge of the white paint mark on the cable.
G. Fasten the clutch cable to the radiator outlet hose
with the plastic band, making sure to position the
band between the screw clamp and the hose
protector. Install the plastic band with its buckle
positioned toward the rear of the vehicle and its
end facing inward.
H. Fasten the coolant reservoir breather hose with the
holder, making sure that the white paint mark on
the hose is positioned to the rear of the holder.
I. Pass the clutch cable through the guide on the
engine.
J. Make sure that the O
2
sensor lead and EXUP
cables are not twisted or crossed between the
plastic locking ties.
K. Fasten the EXUP cables and O
2
sensor lead with a
plastic locking tie. Face the end of the plastic
locking tie rearward, and then cut off the excess
end of the tie to 2
–
4 mm (0.08
–
0.16 in).
L. Be sure to position the plastic locking tie 0
–
20 mm
(0
–
0.78 in) below the plastic locking tie fastened
around the O
2
sensor lead.
M. Pass a plastic locking tie through the bottom hole
in the bracket, and then fasten the wire harness at
the positioning tape with the tie. Face the end of
the plastic locking tie downward, and then cut off
the excess end of the tie to 2
–
10 mm (0.08
–
0.39
in).
N. Fasten the clutch cable with the plastic band,
making sure that the cable is positioned within the
60
°
angle shown in the illustration.
O. Front
P. Bend back the right radiator fan motor sub-wire-
harness as shown in the illustration, and then
insert the projection on the coupler into the hole in
the right coupler holder, making sure to route the
lead to the inside of the coupler.
Q. Route the right radiator fan motor sub-wire-
harness to the inside of the clutch cable.