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Yamaha Moto matrix YZF-R6S Service Manual Download Page 18

–10–

35

Neutral switch lead coupler
(connector 1 pole)

36

Fuel hose (return side, for CAL)

37

Fuel hose (feed side, for CAL)

38

Fuel tank drain hose (for CAL)

39

Canister hose (for CAL)

32

Sidestand switch lead coupler
(blue 2 poles)

33

A.C. magneto lead coupler
(white 3 poles)

34

Rear brake light switch lead cou-
pler (brown 2 poles)

CABLE ROUTING

SPEC

28

Throttle cables

29

Throttle sub-lead 1 (white 6
poles)

30

Throttle sub-lead 2 (black 6
poles)

31

Oil level switch lead coupler
(white 1 pole)

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

email: [email protected]

Summary of Contents for Moto matrix YZF-R6S

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: ...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 Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 17 46 Manuals by Motomatrix www motomatri...

Page 4: ...t satisfaction from his vehicle and to conform to federal environmental quality objectives 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 SThis Service Manual contains information ...

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: ...EL TANK 15 INSTALLING THE FUEL PUMP 16 FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM 17 AIR INDUCTION SYSTEM DIAGRAMS 17 ELECTRICAL ELECTRICAL COMPONENTS 18 IGNITION SYSTEM 19 CIRCUIT DIAGRAM 19 TROUBLESHOOTING 20 LIGHTING SYSTEM 25 CIRCUIT DIAGRAM 25 CHECKING THE LIGHTING SYSTEM 27 YZF R6S YZF R6SC WIRING DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys ...

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

Page 9: ...l 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 F8T816 MITSUBISHI 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 8 kΩ at 20_C 68_F SSS S...

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: ...en 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 P...

Page 16: ... SPEC 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...

Page 17: ...her hose except for CAL 13 Fuel tank drain hose except for CAL 14 Fuel hose return side except for CAL 15 Fuel pump 2 coupler 16 Fuel pump 1 coupler 17 Starter motor lead 18 Fuel hose feed side except for CAL 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 Main switch lead 27 Wire harness Man...

Page 18: ...lead coupler blue 2 poles 33 A C magneto lead coupler white 3 poles 34 Rear brake light switch lead cou pler brown 2 poles CABLE ROUTING SPEC 28 Throttle cables 29 Throttle sub lead 1 white 6 poles 30 Throttle sub lead 2 black 6 poles 31 Oil level switch lead coupler white 1 pole Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 19: ...de of the air filter case air vent hose F Connect the couplers 4 units at the frame side hole Do not catch each lead and wire harness when the cover 8 is attached G From the radiator H Pass the coolant reservoir tank hose through for ward the starter motor lead and speed sensor lead I Pass the speed sensor lead coupler and crankshaft position sensor lead coupler over the throttle stop cable J Pass...

Page 20: ...ain switch lead branch section and radiator fan motor lead CABLE ROUTING SPEC 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 har ness 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 fil...

Page 21: ...f a hose comes below an attachment clamp CABLE ROUTING SPEC 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 T...

Page 22: ...in 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 E Install the breather hose without projecting canister nipple out of the breather hose F Install the clip with its tab pointed in the downward direction G Install the clip with its tab pointed in the upward direction H Install the roll over valve until it...

Page 23: ...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 24: ...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 25: ...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 26: ...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 27: ...RE HARNESS SUB WIRE HARNESS 1 B 16 E 36 21 B Y B L R B R B F 23 B L B L B L E W B W B G B G B E 52 64 51 R Y B L YW L B B Y B L B L Ch B L Ch B 63 L Dg B L Dg B B O 16 B B B B 26 O O B B L B L Dg Ch F B L B Y B Y L L B B Gy R 16 L B L B F O B O B F 24 P W B L L L Y B L L Y B W L Y B L W B L B L R G B W Y L B R Y B Br G W Sb W B Y Dg Ch L Br W B L G B L B L R L R L 22 B L G W B W B W B B L L B F L ...

Page 28: ...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 29: ... 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 30: ...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 31: ...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 32: ... 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 33: ...L W B W Br R Br R B R B R B G B G B L B L B O B O B B Dg B B Dg B W Y W Y R R B B W R G Y L W Y B 13 HEADLIGHT SUB WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS 1 B 16 E 36 21 B Y B L R B R B F 23 B L B L B L E W B W B G B G B E 52 64 51 R Y B L YW L B B Y B L B L Ch B L Ch B 63 L Dg B L Dg B B O 16 B B B B 26 O O B B L B L Dg Ch F B L B Y B Y L L B B Gy R 16 L B L B F O B O B F 24 P W B L L L Y B L ...

Page 34: ...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 35: ...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 36: ...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 37: ...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 38: ...YZF R6S YZF R6SC WIRING DIAGRAM Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

Page 39: ... switch Fuel pump ECU Ignition coil Spark plug Fuel injector Air induction 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 Fuel level warning light Oil level warning li...

Page 40: ...Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk ...

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