Yamaha YZF-R6T Supplementary Service Manual Download

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CONTENTS

GENERAL INFORMATION

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS

GENERAL SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . .

ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . .

CHASSIS

FRONT WHEEL AND BRAKE DISCS

. . . . . . . . . . . . . . . . . . . . . . . . .

FRONT AND REAR BRAKES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . .

CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . .

SWINGARM AND DRIVE CHAIN

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM

RADIATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for YZF-R6T

Page 1: ...YZF R6T 5SL 28197 12 SUPPLEMENTARY SERVICE MANUAL LIT 11616 18 45 YZF R6TC ...

Page 2: ...d Printed in U S A P N LIT 11616 18 45 EAS00001 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF R6T YZF R6TC For complete service information procedures it is necessary to use this Sup plementary Service Manual together with the following manual YZF R6R YZF R6SR YZF R6RC YZF R6SRC SERVICE MANUAL LIT 11616 16 45 5SL 28197 10 YZF R6S YZF R6S...

Page 3: ...to provide the customer with the most 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE T...

Page 4: ...top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears Sub section titles appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a...

Page 5: ...ls to indicate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap based grease Molybdenum disulfide grease Symbols to in the expl...

Page 6: ...BLEEDING THE HYDRAULIC BRAKE SYSTEM 20 ADJUSTING THE FRONT FORK LEGS 22 CHASSIS FRONT WHEEL AND BRAKE DISCS 24 FRONT AND REAR BRAKES 25 FRONT BRAKE PADS 25 FRONT BRAKE MASTER CYLINDER 26 FRONT BRAKE CALIPERS 29 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 31 FRONT FORK 33 FRONT FORK LEGS 33 DISASSEMBLING THE FRONT FORK LEGS 36 CHECKING THE FRONT FORK LEGS 37 ASSEMBLING THE FRONT FORK ...

Page 7: ...ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM 47 CIRCUIT DIAGRAM 47 TROUBLESHOOTING 48 COOLING SYSTEM 51 CIRCUIT DIAGRAM 51 TROUBLESHOOTING 52 YZF R6T YZF R6TC WIRING DIAGRAM ...

Page 8: ...stakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool No Tool name Function Illustration 90890 01423 YM 01423 Damper rod holder This tool is used to hold the damper rod assembly when loosening or tightening the damper rod assembly bolt 90890 01434 YM 01434 Rod holder This tool is used to support the damper adjusting rod 9089...

Page 9: ...0 mm 32 7 in Wheelbase 1 385 mm 54 5 in Minimum ground clearance 145 mm 5 7 in Minimum turning radius 3 800 mm 149 6 in Weight Wet with oil and a full fuel tank 183 kg 404 lb USA except for CAL 184 kg 406 lb CAL Maximum load except motorcycle 192 kg 423 lb USA except for CAL 191 kg 421 lb CAL Item Standard Limit Throttle bodies Model manufacturer quantity 40EIS MIKUNI 4 ID mark 5SLM 30 5SLR 5SLS 4...

Page 10: ... 2 9 kgf cm2 2 9 bar 41 3 psi 90 192 kg 198 426 lb 290 kPa 2 9 kgf cm2 2 9 bar 41 3 psi USA except for CAL 90 191 kg 198 423 lb CAL 290 kPa 2 9 kgf cm2 2 9 bar 41 3 psi High speed riding 290 kPa 2 9 kgf cm2 2 9 bar 41 3 psi Front brakes Brake lever free play 6 7 18 1 mm 0 26 0 71 in Brake discs Diameter thickness 310 4 5 mm 12 20 0 18 in Min thickness 4 0 mm 0 16 in Master cylinder inside diameter...

Page 11: ...the fork spring 92 mm 3 62 in Spring preload adjusting positions Minimum 8 Standard 7 Maximum 0 Rebound damping adjusting positions Minimum 10 Standard 6 Maximum 1 Compression damping adjusting positions Minimum 13 Standard 6 Maximum 1 from the fully turned in position Rear suspension Spring Free length 167 5 mm 6 59 in Installed length 157 5 mm 6 2 in Spring rate K1 103 N mm 10 5 kg mm 587 83 lb ...

Page 12: ...ce is posi tioned on the end face of the fork At this stage it can be accepted if the end face of the axle becomes partially concave to the end face of the fork 4 In the order from the pinch bolt pinch bolt pinch bolt tighten each bolt to 21 Nm 2 1 m kg 15 ft lb without perform ing temporary tightening Item Fastener Thread size Q ty Tightening torque Remarks Nm m kg ft lb Clutch boss Nut M20 1 90 ...

Page 13: ...he throttle cables to the hook so that the pulling side of the throttle cables is routed down ward Pass the clutch cable through the guide Plastic locking tie shall be positioned at 15 mm 0 59 in below from the upper bracket 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 Clamping position should be 10...

Page 14: ... the wire harness To the front turn signal light right Set the sub wire harness in the joint Do not catch the sub wire harness when the duct is assembled To the front turn signal light left Install the relay to the rib of the headlight Location for the left and right relays is alternative Point the tip of the plastic locking tie to the front side of the vehicle Cut the tip leaving 2 10 mm 0 08 0 3...

Page 15: ...de of the radiator hose Pass the coolant reservoir tank hose under the frame and right side of the throttle body The tip of the clamp should be pointed to the inside above the vehicle Items to be clamped here are the radiator fan motor lead right coolant res ervoir tank hose and radiator return hoses 2 hoses Coupler should be placed within the shaded area of the cover 8 Extrusion below the shaded ...

Page 16: ...h mark starting point should be 5 mm 0 20 in below the clamp s bottom end Pass the clutch cable inside of the radiator hose Assemble as shown below when clamping Pass the pickup coil lead over the throttle stop cable Tip of the plastic locking tie shall be pointed to the inner side at the rear part of the vehicle Clamp the clutch cable so that it is positioned in this range Put and apply the hose ...

Page 17: ...then to the right side of the vehi cle 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 vehi cle Route the A C magneto lead sidestand switch lead and oil level switch lead so that they pass the inner side of the barance pipe 3 for CAL Pass the fuel tank drain hose and fuel tank breather hose inside ...

Page 18: ...eto lead oil level switch lead and sidestand switch lead Pass the sidestand switch lead oil level switch lead and A C magneto lead between the engine stay and the engine To the throttle body To the radiator fan motor relay and fuse box Route the radiator fan motor lead left by the out side of the radiator inlet hose Pass the throttle cable between the guide of the cover 2 and the frame Pass the ra...

Page 19: ...turn side except for CAL Fuel pump 2 coupler Fuel pump 1 coupler Starter motor lead Fuel hose feed side except for CAL Crankcase breather hose Throttle air vent hose Fuse box Cover 7 Radiator fan motor relay Radiator fan motor lead left Left handlebar switch lead Main switch lead Wire harness Throttle cables Throttle sub lead 1 white 6 poles Throttle sub lead 2 black 6 poles Oil level switch lead ...

Page 20: ...t the tip of the plastic locking tie to the downward in the inner side of the vehicle Route the headlight and meter leads under the frame s lower part from the hollow section of the cover 2 Pass the left and right handlebar switch leads out side of the air filter case air vent hose Connect the couplers 4 units at the frame side hole Do not catch each lead and wire harness when the cover 8 is attac...

Page 21: ...osition relation against the heat protector is no object There should be no interference between the wire harness and the tip of the rear frame attaching bolts To the coolant reservoir tank To the intake air temperature sensor air filter case To the oil level switch sidestand switch and A C magneto Install the wire harness wrapping clamp to the stay of the throttle body Pass the wire harness over ...

Page 22: ...e frame lower end However it should not be caught To the main switch lead coupler Point the tip of the plastic locking tie to the rear side of the vehicle To the fuse box and fan motor relay Pass the throttle cables over the cover 2 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 ...

Page 23: ...C 16 The clamp by the side of a hose comes below an attachment clamp Insert until it sets Poss the canister hose over fuel return hose and under the fuel hose Route it above the canister hose CABLE ROUTING ...

Page 24: ... and secure it Install to the deepest position of the rib of the bat tery box assembly Fit in the plastic cover of rivet to the main unit after assembly Make sure to clamp the wire harness Tighten it until the clamp latchet stops Insert the turn signal light relay to the back end of the rib in the battery box assembly Hook of the battery box assembly shall hook on the upper face of the fuse box It...

Page 25: ... the tail brake light left side attaching boss Route the tail brake light lead under the projection part Route the tail brake light lead above the projection part There should be no remarkable difference between the tension on right and left bands Point the tool kit opening to the rear side of the vehicle Connect the tail brake light lead coupler Make sure that the hooks four positions of the batt...

Page 26: ... Connect the negative lead and the wire harness Install the starting circuit cut off relay to the deep est position after placing the tail brake light lead and turn signal light lead in the guide CABLE ROUTING ...

Page 27: ...ening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake fluid reservoir to the proper level with the recommended brake fluid b Install the brake fluid reservoir diaphragm c Connect a clear plastic hose tight...

Page 28: ...m the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL WARNING After bleeding the hydraulic brake system check the brake operation NOTE NOTE After bleeding air the brake fluid may ooze around the thread section of each bleed screw This phenomenon d...

Page 29: ...lling over Spring preload CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt in direction or Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions Direction Spring preload is increased suspension is harder Direction Spring preload is decreased s...

Page 30: ...ping is decreased suspension is softer Adjusting positions Minimum 10 clicks in direction Standard 6 clicks in direction Maximum 1 clicks in direction with the adjusting screw fully turned in direction Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Minimum 13 clicks in direction Standard 6 clicks i...

Page 31: ...ft and right 2 2 Front brake caliper left and right 2 3 Front wheel axle pinch bolt 4 Loosen 4 Front wheel axle bolt 1 5 Front wheel axle 1 6 Collar left and right 2 7 Oil seal cover left and right 2 8 Front wheel 1 9 Front brake disc left and right 2 For installation reverse the removal procedure 21 Nm 2 1 m kg 15 ft lb 6 Nm 0 6 m kg 4 3 ft lb 91 Nm 9 1 m kg 66 ft lb 35 Nm 3 5 m kg 25 ft lb 18 Nm...

Page 32: ...NOTE NOTE The following procedure applies to both of the front brake calipers 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Bleed screw 1 For installation reverse the removal procedure 35 Nm 3 5 m kg 25 ft lb 5 Nm 0 5 m kg 3 6 ft lb 6 Nm 0 6 m kg 4 3 ft lb FRONT AND REAR BRAKES ...

Page 33: ...ake fluid 1 Stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake switch connector 2 Disconnect 9 Union bolt 1 10 Copper washer 2 11 Brake hose 1 12 Brake master cylinder bracket 1 13 Nm 1 3 m kg 9 4 ft lb 30 Nm 3 0 m kg 22 ft lb FRONT AND REA...

Page 34: ...HAS 27 Order Job Part Q ty Remarks 13 Brake master cylinder 1 14 Front brake switch 1 For installation reverse the removal procedure 13 Nm 1 3 m kg 9 4 ft lb 30 Nm 3 0 m kg 22 ft lb FRONT AND REAR BRAKES ...

Page 35: ...sassembling the front brake master cylinder Disassemble the parts in the order listed Brake master cylinder kit 1 Bleed screw 1 Brake master cylinder body 1 For assembly reverse the disassembly procedure 6 Nm 0 6 m kg 4 3 ft lb FRONT AND REAR BRAKES ...

Page 36: ... NOTE The following procedure applies to both of the front brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure 30 Nm 3 0 m kg 22 ft lb 6 Nm 0 6 m kg 4 3 ft lb 35 Nm 3 5 m kg 25 ft lb FRONT AND REAR BRAKES ...

Page 37: ... order listed NOTE NOTE The following procedure applies to both of the front brake calipers Brake pad clip 2 Brake pad pin 1 Brake pad spring 1 Brake pad 2 Brake caliper piston 4 Brake caliper piston seal 8 Bleed screw 1 For assembly reverse the disassembly procedure 5 Nm 0 5 m kg 3 6 ft lb FRONT AND REAR BRAKES ...

Page 38: ...right handlebar First tighten the upper bolt then the lower bolt Attach the brake master cylinder to the vehicles inner side from a punch mark 3 Install copper washers brake hose union bolt tail brake light switch coupler WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING NOTE NOTE While holding the brake hose tighten the union bolt as shown T...

Page 39: ...not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM 6 Check brake fluid level Below the minimum level mark Add the recommended br...

Page 40: ...ers Refer to FRONT AND REAR BRAKES Front cowling inner panels Refer to COWLINGS in chapter 3 1 Front fender 1 2 Cap bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Upper bracket pinch bolt 1 Loosen 5 Under bracket pinch bolt 2 Loosen 6 Front fork leg 1 For installation reverse the removal procedure 6 Nm 0 6 m kg 4 3 ft lb 32 Nm 3 2 m kg 23 ft lb 26 Nm 2 6 m kg 19 ft lb 23 Nm 2 3 m kg 17 ft lb FRON...

Page 41: ...s in the order listed NOTE NOTE The following the procedure applies to both of the front fork legs Cap bolt 1 O ring 1 Damper adjusting rod 1 Nut 1 Washer 1 Spacer 1 Fork spring 1 Dust seal 1 Oil seal clip 1 Oil seal 1 23 Nm 2 3 m kg 17 ft lb 15 Nm 1 5 m kg 11 ft lb 23 Nm 2 3 m kg 17 ft lb FRONT FORK ...

Page 42: ...rks Washer 1 Damper rod assembly bolt 1 Copper washer 1 Damper rod assembly 1 Inner tube 1 Outer tube 1 For assembly reverse the disassembly procedure 23 Nm 2 3 m kg 17 ft lb 15 Nm 1 5 m kg 11 ft lb 23 Nm 2 3 m kg 17 ft lb FRONT FORK ...

Page 43: ... Use the side of the rod holder that is marked B c Loosen the nut d Remove the cap bolt e Remove the rod holder and fork spring compressor WARNING The fork spring is compressed f Remove the spacer and nut 2 Drain fork oil NOTE NOTE Stroke the damper rod several times while draining the fork oil 3 Remove dust seal oil seal clip oil seal washer with a flat head screwdriver CAUTION Do not scratch the...

Page 44: ...egs 1 Check inner tube outer tube Bends damage scratches Replace WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length Out of specification Replace 3 Check damper rod Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air damper rod adjusting rod Bends damage Replace Damper rod holder 90890 01423 YM 0142...

Page 45: ...S00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability NOTE NOTE When assembling the front fork leg be sure to replace the following parts outer tube bushing oil seal dust seal Before assembling the front fork leg ma...

Page 46: ...damage the inner tube 2 Lubricate inner tube s outer surface 3 Tighten damper rod assembly bolt LOCTITE NOTE NOTE While holding the damper rod assembly with the damper rod holder tighten the damper rod assembly bolt 4 Install dust seal oil seal clip oil seal washer Recommended lubricant Suspension oil 01 or equivalent 23 Nm 2 3 m kg 17 ft lb Damper rod holder 90890 01423 YM 01423 FRONT FORK ...

Page 47: ...l Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install oil seal with the fork seal driver 6 Install oil seal clip NOTE NOTE Adjust the oil seal clip so that it fits into the outer tube s groove 7 Install dust seal with the fork seal driver weight Fork seal driver 90890 01442 YM 01442 Fork seal driver 90890 01442...

Page 48: ...ting rod cap bolt a Remove the rod puller and adapter b Install the nut c Install the fork spring and spacer d Install the rod puller and adapter NOTE NOTE Install the spring with the smaller pitch fac ing up Rod puller 90890 01437 YM 01437 Rod puller attachment 90890 01436 YM 01436 Quantity each front fork leg 0 475 L 0 418 Imp qt 0 502 US qt Recommended oil Suspension oil 01 or equivalent Front ...

Page 49: ... speci fied i Set the cap bolt distance to specifica tion j Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt k Hold the cap bolt and tighten the nut to specification l Remove the rod holder and fork spring compressor WARNING The fork spring is compressed Always use a new cap bolt O ring Fork spring compressor 90890 01441 YM 01441 Rod holder 90890 01434 YM 01434 Di...

Page 50: ...ain front drive sprocket and rear drive sprocket as a set NOTE NOTE While measuring the 15 link section push down on the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining d...

Page 51: ...chain 4 Check O rings Damage Replace the drive chain drive chain rollers Damage wear Replace the drive chain drive chain side plates Damage wear Replace the drive chain Cracks Replace the drive chain and make sure that the battery breather hose is properly routed away from the drive chain and below the swingarm 5 Lubricate drive chain 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth ...

Page 52: ... case Refer to AIR FILTER CASE in chapter 3 Side cowlings and bottom cowling Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Coolant reservoir hose 1 2 Throttle body hose 2 3 Radiator outlet hose 1 4 Coolant pipe 1 5 Radiator inlet hose 1 6 Oil cooler outlet hose 1 7 Radiator 1 8 Radiator fan 2 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 12 Nm 1 2 m k...

Page 53: ...COOL 46 Order Job Part Q ty Remarks 9 Radiator cap 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 12 Nm 1 2 m kg 8 7 ft lb RADIATOR ...

Page 54: ...RIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse main Starter relay Starter motor Fuse ignition Starting circuit cut off relay Sidestand switch Neutral switch Engine stop switch Start switch Clutch switch ELECTRIC STARTING SYSTEM ...

Page 55: ... FUSES in chap ter 3 Are the main and ignition fuses OK YES NO Replace the fuse s Pocket tester 90890 03112 YU 3112 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK YES NO Clean the battery terminals Recharge or replace the battery 3 Starter motor Connect the positive batt...

Page 56: ...r from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the starter relay coupler as shown Positive battery terminal red white Negative battery terminal blue white Positive tester probe red Negative tester probe black Does the starter relay have continuity between red and black YES NO Replace the starter relay 6 Main switch Check the main switch for continuity Refer to CHECKING THE S...

Page 57: ...TCHES Is the clutch switch OK YES NO Replace the clutch switch 11 Start switch Check the start switch for continuity Refer to CHECKING THE SWITCHES Is the start switch OK YES NO Replace the right handlebar switch 12 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly con nected and without defects YES NO The starting system circuit is ...

Page 58: ...RCUIT DIAGRAM Main switch Battery Fuse main Fuse ignition ECU Coolant temperature sensor Radiator fan motor relay Fuse radiator fan motor left Fuse radiator fan motor right Radiator fan motor left Radiator fan motor right COOLING SYSTEM ...

Page 59: ...ails to light when the engine is warm 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 Are the main ignition and radiator fan motor fuses OK YES NO Replace the fuse s Pocket tester 90890 03112 YU 3112 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in ch...

Page 60: ...eplaced 5 Radiator fan motor relay Disconnect the radiator fan motor relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor terminal as shown Check the radiator fan motor of continuity Battery positive terminal red white Battery negative terminal green yellow Tester positive probe black Tester negative probe black Does the radiator fan motor relay hav...

Page 61: ...peratures indicated in the table Coolant temperature sensor resistance 0 C 32 F 5 21 6 37 kΩ 80 C 176 F 0 29 0 35 kΩ WARNING Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it Coolant temperature sensor 20 Nm 2 0 m kg 14 ft lb Three bond sealock 10 Does the coolant temperature...

Page 62: ...YZF R6T YZF R6TC WIRING DIAGRAM ...

Page 63: ...adlight Radiator fan motor relay Fuse radiator fan motor left Fuse radiator fan motor right Radiator fan motor left Radiator fan motor right Headlight relay on off Headlight relay dimmer Rear brake light switch Left handlebar switch Clutch switch Dimmer switch Horn switch Turn signal switch Horn Turn signal relay Rear turn signal light right Rear turn signal light left Front turn signal position l...

Page 64: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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