Yamaha Moto matrix YZF-R6S, Supplementary Service Manual

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: ...gether 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 repr...

Page 4: ...anges 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 ch...

Page 5: ...D 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 diagram...

Page 6: ...he 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 ex...

Page 7: ...EL 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 TROUBLES...

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Page 9: ...lot 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...

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 Motomatri...

Page 11: ...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...

Page 12: ...der 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 forefr...

Page 13: ...ir 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 s...

Page 14: ...amp 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 e...

Page 15: ...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 ri...

Page 16: ...t 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 reservoi...

Page 17: ...kcase 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 ha...

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...

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...

Page 20: ...ter 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 fram...

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...

Page 22: ...p 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...

Page 23: ...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...

Page 24: ...er 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 Soluti...

Page 25: ...ight 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 r...

Page 26: ...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...

Page 27: ...s 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...

Page 28: ...ure applies to all of the ignition coils SDisconnect the ignition coil leads from the wire harness SConnect the pocket tester 1 to the ignition coil as shown Positive tester probe ignition coil termin...

Page 29: ...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...

Page 30: ...lack 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 blac...

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 uni...

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...

Page 33: ...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 Motomatr...

Page 34: ...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...

Page 35: ...in 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 tai...

Page 36: ...ket 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 pro...

Page 37: ...g 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...

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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...