Download YZF-R6S(C) Supplementary Service Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the YZFR6S/YZF-R6SC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
YZF-R6R/YZF-R6SR/YZF-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
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended 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 dealers
and will appear in future editions of this manual where applicable.
NOTE:
S This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
S Designs and specifications are subject to change without notice.
EAS00040
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.
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 be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
2
1
3
4
5
8
6
7
EAS00008
1
2
GEN
INFO
SYMBOLS
SPEC
3
4
CHK
ADJ
CHAS
5
6
COOL
ENG
7
8
FI
ELEC
Symbols 10 to 17 indicate the following.
10
9
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
21
24
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Fuel injection system
8 Electrical system
9 Troubleshooting
22
23
25
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
3
PERIODIC CHECKS AND ADJUSTMENTS
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL INJECTION SYSTEM
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . 17
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
YZF-R6S/YZF-R6SC WIRING DIAGRAM
18
19
19
20
25
25
27
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Standard
5SLD (USA except for CAL)
5SLE (CAL)
Limit
SSS
ENGINE SPECIFICATIONS
Item
Throttle bodies
ID mark
Throttle valve size
Standard
5SL1 00 (5SLD),
5SL4 10 (5SLE)
#100
Limit
SSS
SSS
CHASSIS SPECIFICATIONS
Item
Front tire
Model (manufacturer)
Rear tire
Model (manufacturer)
Standard
Limit
Pilot SPORT N (MICHELIN)
D208 FJ (DUNLOP)
SSS
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
SSS
SSS
–1–
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Oil cooler
Cylinder identification sensor
Fastener
Bolt
Bolt
Thread
Q’ty
Q
ty
size
M20
M6
–2–
1
1
Tightening torque
Nm
mSkg
ftSlb
63
6.0
6.3
0.6
46
4.3
Remarks
Yamaha bond
No.1215
CABLE ROUTING
SPEC
CABLE ROUTING
1 Right handlebar switch lead
2 Clutch cable
3 Immobilizer unit lead, main switch lead and left han4
5
6
7
8
9
dlebar switch lead
Throttle cable (return side)
Throttle cable (pull side)
Front brake hoses
Throttle cables
Joint
Under bracket
A Pass the right handlebar switch lead inside the front
brake hoses and over the throttle cables.
B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward.
C Pass the clutch cable through the guide.
D Plastic locking tie shall be positioned at 10 mm
(0.39 in.) below 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.
–3–
CABLE ROUTING
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 face of the under bracket
with the plastic locking tie. Cut the surplus part of the
clamp tip leaving 2 (0.08 in.) to 4 mm (0.16 in.). Point
the tip of the clamp to the outside of vehicle.
H Pass the throttle cables inside the front brake
hoses.
SPEC
I Set in the coupler between the head light’s hollow
section and the duct.
J Install the relay to the rib of the head light.
(Location for the left and right relays is alternative.)
K To the wire harness
L To the front turn signal light (right)
M Set the sub wire harness in the joint.
N Do not catch the sub wire harness when the duct is
assembled.
O To the front turn signal light (left)
P Point the tip of the plastic locking tie to the front side
of the vehicle. Cut the tip leaving 2 X 10 mm (0.08
X 0.39 in).
Q Point the tip of the plastic locking tie under the under
bracket and rear side of the vehicle. Cut the tip leaving 2 X 10 mm (0.08 X 0.39 in).
–4–
CABLE ROUTING
1
2
3
4
5
6
7
8
9
Throttle stop screw
Coolant reservoir tank hose
Pickup coil lead
Rear brake light switch lead
Coolant hose
Clutch cable
Coolant hose protector
Hose clamp assembly
Hose clamp
A Pass the rear brake light switch lead outside of rear
engine mount bolt.
B Pass the ignition coil lead outside of the radiator
hose.
C Pass the coolant reservoir tank hose under the
frame and right side of the throttle body.
SPEC
D Pass the clutch cable inside of the coolant reservoir
tank hose and radiator return hoses.
E Assemble as “ a ” 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 the
clamp’s bottom end.
I Pass the clutch cable inside of the radiator hose.
J Clamp the clutch cable so that it is positioned in this
range.
K Put and apply the hose clamp to it.
–5–
CABLE ROUTING
L Clamp the clutch cable by routing the upper end of
the clamp along with the bottom end of the hose
clamp assembly.
–6–
SPEC
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Throttle cable (return side)
Throttle cable (pull side)
Starter motor lead
Coolant reservoir tank breather hose
Bracket 2
Sidestand switch lead
Oil level switch lead
A.C. magneto lead
Radiator fan motor lead
Fuel tank breather hose
Fuel tank drain hose
Coolant reservoir tank cover
Drive sprocket cover
Coolant reservoir tank
Canister hose (for CAL)
Canister (for CAL)
Balance hose (for CAL)
SPEC
A Pass the main switch lead under the left handlebar
switch 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 vehicle.
C Pass the fuel tank drain hose and fuel tank breather
hose inside of the reservoir tank breather hose, reservoir tank hose and wire harness and then route it
by the out side of the starter motor lead.
D Pass the coolant reservoir tank hose outside of the
fuel tank drain hose and fuel tank breather hose.
E Pass the fuel tank drain hose, fuel tank breather
hose through the clamp of the coolant reservoir
tank.
–7–
CABLE ROUTING
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.C. magneto lead, oil level switch lead
and sidestand switch lead.
L Pass the side stand switch lead, oil level switch lead
and A.C. magneto lead between the engine stay
and the engine.
M
N
O
P
Q
R
S
T
U
–8–
SPEC
To the throttle body
To the radiator fan motor relay and fuse box
Route it above the radiator hose.
Pass the throttle cable between the guide of the
cover 2 and the frame.
Pass the radiator fan motor lead through the hole of
the frame to the inner side of the vehicle.
Pass the coolant reservoir tank breather hose
through the hole of the coolant reservoir tank cover.
Order of ups and downs means no object.
Route it below the coolant reservoir thank.
To the horn
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
Right handlebar switch lead
Sub wire harness
Head light lead
Meter lead
Cover 8
Ignition coil lead
Throttle position sensor coupler
Coolant reservoir tank hose
Throttle stop cable
Speed sensor lead coupler
11 Crankshaft position sensor lead
12
13
14
15
16
17
coupler
Fuel tank breather hose (except
for CAL)
Fuel tank drain hose (except for
CAL)
Fuel hose (return side, except for
CAL)
Fuel pump 2 coupler
Fuel pump 1 coupler
Starter motor lead
–9–
SPEC
18 Fuel hose (feed side, except for
19
20
21
22
23
24
25
26
27
CAL)
Crankcase breather hose
Air vent hose
Fuse box
Cover 7
Radiator fan motor relay
Radiator fan motor lead
Left handlebar switch lead
Main switch lead
Wire harness
CABLE ROUTING
28 Throttle cables
29 Throttle sub-lead 1 (white 6
32 Sidestand switch lead coupler
(blue 2 poles)
poles)
33 A.C. magneto lead coupler
30 Throttle sub-lead 2 (black 6
(white 3 poles)
poles)
34 Rear brake light switch lead cou31 Oil level switch lead coupler
pler (brown 2 poles)
(white 1 pole)
–10–
35 Neutral
36
37
38
39
SPEC
switch lead coupler
(connector 1 pole)
Fuel hose (return side, for CAL)
Fuel hose (feed side, for CAL)
Fuel tank drain hose (for CAL)
Canister hose (for CAL)
CABLE ROUTING
A To the headlight
B Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it
when installing the side cowling.
C Clamp the plastic locking tie to the cover 8. Place
the coupler at the rear side of the vehicle against the
plastic locking tie. Point the tip of the plastic locking
tie to the downward in the inner side of the vehicle.
D Route the head light and meter leads under the
frame’s lower part from the hollow section of the
cover 2.
E Pass the left and right handlebar switch leads outside of the air filter case air vent hose.
SPEC
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 forward 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 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 clamp.
K To the rear brake light switch lead.
–11–
CABLE ROUTING
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 harness.
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 filter case)
R To the oil level switch, sidestand switch and A.C.
magneto
S Install the wire harness wrapping clamp to the stay
of the throttle body.
T Pass the wire harness over the throttle air vent
hose.
SPEC
U Pass the wire harness between frame and coolant
hose.
V Pass it through the frame hole.
W Do not catch the coupler when the air filter case is
assembled.
X Clamp the wire harness, left and right handlebar
switch leads and main switch lead. Align the tapping
positions of three leads except the wire harness.
Point the tip of the clamp to the front side of the vehicle.
Y Sealing set of the cover can be either upper or lower
against the frame lower end. However, it should not
be caught.
Z Clamp the wire harness, main switch lead branch
section and radiator fan motor lead.
–12–
CABLE ROUTING
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 To the main switch lead coupler
SPEC
AF Tip of the plastic locking tie should point to the
downward outside of the vehicle.
AG Use the plastic locking tie to clamp the starter motor lead at the protector section.
AH Branching harness from the wire harness.
AI Poss the canister hose over fuel return hose and
under the fuel hose.
AJ Insert until it sets.
AK The clamp by the side of a hose comes below an
attachment clamp.
–13–
CABLE ROUTING
Fuel pump assembly
Fuel tank drain hose
Fuel tank breather hose (except for CAL)
Clamp
Clip
Canister (for CAL)
Blance hose (for CAL)
Canister hose (for CAL)
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.
1
2
3
4
5
6
7
8
SPEC
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 contacts with the fuel
tank’s nipple.
I To injector
–14–
FUEL TANK
CHK
ADJ
EAS00040
PERIODIC CHECKS AND ADJUSTMENTS
FUEL TANK
7 Nm (0.7 mSkg, 5.1 ftSlb)
7 Nm (0.7 mSkg, 5.1 ftSlb)
4 Nm (0.4 mSkg, 2.9 ftSlb)
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the fuel tank
Rider seat
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Clamp
Fuel tank overflow hose
Fuel tank breather hose
Fuel tank
Fuel pump
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
1
1
1
1
1
1
1
1
1
1
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
Refer to the CABLE ROUTING for how to
attach a hose.
–15–
FUEL TANK
CHK
ADJ
INSTALLING THE FUEL PUMP
1. Install:
S fuel pump
4 Nm (0.4 mSkg, 2.9 ftSlb)
NOTE:
S Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
S Always use a new fuel pump gasket.
S Install the fuel pump as shown in the illustration.
S Tighten the fuel pump bolts in stages in a crisscross pattern and to the specified torque.
–16–
AIR INDUCTION SYSTEM
FUEL INJECTION SYSTEM
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1 Air cut-off valve
2 Reed valve
3 To air filter case
A To cylinder #1 and #2
B To cylinder #3 and #4
–17–
FI
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1
2
3
4
5
6
7
8
Coolant temperature sensor
Intake air temperature sensor
Intake air pressure sensor
Lean angle cut-off switch
Atmospheric pressure sensor
ECU
Starting circuit cut-off relay
Turn signal relay
9
10
11
12
13
14
–18–
Speed sensor
Crankshaft position sensor
Cylinder identification sensor
Radiator fan motor relay
Headlight relay (on / off)
Headlight relay (dimmer)
ON
OFF
1
W
R
W W
W
W W
L/B
-
L/Y L/B
L/B L/Y
10
R
Br/L
R
Br/L
Br/L
R
W W W
B
3
R/W
R
4
R
Br/L
Br/L
48
47
46
B
R/W
L
BrG
G/Y
49
BrG
R/Y
Br
L/B
B/L
R/Y
R
B
L
B
L
50
Y
B/L
B
YW
B/Y
52
51
B
Br Y
B
B
5
R
R
B
B
B
L/W
R/W
53
B B
67
Y
- Br/WR/Y
R
G/Y
B
Y L/R
Ch L/Y B B/Y Br
Dg Y
Br B R/B
L
6
R
R/B B Br
42
R R
L/WR/W
R/W L/W G/Y
8
R
G/Y L/W R/W
7
R
R
B
L/Y
W
W
9
66
43
54
Y Dg
B
187
55
B B/Y
B
B/Y H B/Y
B/L C B/L
RUN
OFF
44
Br B/Y B L/Y Ch
R/Y Br/W -
R
65
ON
57
OFF
L/W
LO
B
R/Y
HI
56
PUSH
FREE
45
L/W
R/W
Br/L
W
R/Y A R/Y
L/B
R/Y
B/L
R/W
B/Y
B B/L
B
59
R/B
B/Y
W
L/W
B
W
L/W
B/W
W
R/W
G/Y
BrG
L
L
Br
Y
Y
R/B
187
R/G
Ignition coil
Spark plug
Neutral switch
Crankshaft position sensor
Lean angle cut-off switch
Engine stop switch
Clutch switch
B
B
Y
Y A Y
YW
B/L
B/Y
YW A YW
Y
B
B
L Ch
B
Ch
64
L
Br
L
12
60
R
L/W G/R
W
35
33
Y/B B/R -
32
31
30
13
37
36
34
B/W B B/W
Y/L B Y/L
Y/L
B/W
Y/B B Y/B
Sb/W A Sb/W
Y/B
Sb/W
B Gy/G O/G
O/G Gy/G B
L
B
Y
B/L
Y L
24
23
L
B
L Dg
B
Dg
63
Dg A Dg
B
B
Ch
Ch
-
B
B
Dg
Dg
-
Dg
L Ch Dg B/Y Sb/W - G/W Br
- Y/L - B/W R/G
40
40
39
39
38
-
-
-
28
B/L
B/L E B/L
L W/B
B/L
B/L
L E L
W/B E W/B
L Y/G B/L
B/L B
P
L
B/L
Y/G
B/L
L
-
B/L G B/L
-
- B/R Y/B
B/WR/G Y/L
HEADLIGHT SUB WIRE HARNESS
B
W L/Y
B/L
G/W B/L
Br/W B/L
B/L
22
21
L W/Y
B/L
B/L
- Sb
G/W
Br/W
Sb -
27
Y
W/B
L
B/L
Gy
L/Y
B/Y
Y/B
R/L
Lg
L/W
R/W
W/Y
P
Y/G
P/W G P/W P/W
G/W G G/W G/W
Br/W G Br/W Br/W
Y G Y
19
L - R/B G/B L/B O/B Y/B B O/G Gy/G
- B/L YW Lg G/W Gy Y/R R/L Y/R Br/R B O Gy/R
WIRE HARNESS
Y/B W
Y/L R/G B/W
Y W/Y P P/W R/W Br/W B/W W/B -
- L/B G/Y Y/G B/Y W Y/L -
- L/W -
L F L
25
B Gy
20
W L/Y
26
C
WIRE HARNESS Headlight coupler
B B/L
W/B
L
P B/L L
P/W B/L L
B/L
Y
L
Gy B/L
WIRE HARNESS SUB-WIRE HARNESS 1
Gy/R O R/B
D
R/B O Gy/R
P/W
61
G/W
Ch
B/R
W B B/R
R/G
Br
G/W A G/W
R/G B R/G
R/W A Br
29
R/L B
G/W B
L B/L
B/L L
WIRE HARNESS SUB-WIRE HARNESS 2
W/B Br/R
E
Br/R W/B
L
62
W
41
R/L
B/Y Sb/W
R/B L/W
B/W B/R L/W Lg R/W L/B L/Y Sb
L O/B L/B
WIRE HARNESS SUB-WIRE HARNESS 3
L/B O/B L
G/B R/B R/L
B/L
L
L/B B
11
- P/W B/L
F
N
R
R
B B
Br/W
58
Ch A Ch
L/Y
R/L R/B G/B
B/Y
G/W Br/W Y
L
B/L P/W -
W
2
B
Sb/W
B
L/B
L/B
B
WIRE HARNESS SUB-WIRE HARNESS 4
Ch
B
L/R
B
Br
B
R/L
B
Sb
Ch
B
L/R
Br/W
Br/W
G/W
B
WIRE HARNESS Headlight coupler
Dg
Lg
Ch
L
Br
L/R
B
L/Y
B/Y
B
B/L
B
B C B
187
B H B
Dg
Sb
Sb
Sb
G
14
WIRE HARNESS
O
G/Y
Y/L
Y/R
Y/R
Br/R
O/B
L/B
F O/B
G/B
Br/R
R/L O/B
O/B
R/L L/B
L/B
R/L G/B
Br/RR/B
Br/R E Br/R
O/B
L/B F L/B
G/B F G/B
G/B
R/L R/B
R/B
B
R/B F R/B
Gy/G
B
O/G
B D B
D O/G
B
Gy/R
B
O
Gy/G D Gy/G
O/G
Gy/R D Gy/R
D O
R/B
YW
Gy/G
O/G
Gy/R
O
17
17
17
17
Br Br/R
16
16
16
16
18
R/L
R/L
R/L
R/L
15
15
15
15
R/B
B Gy/G
B O/G
B Gy/R
B O
HEADLIGHT SUB WIRE HARNESS
- Ch G/W Y R/Y
Sb/W Dg B Y/W Br
R/W Y/W B Dg Sb/W
A
R/Y Y G/W Ch -
B
Y Br/W G/W
B
B/Y B
W
H
B/W
B B/Y
L
R/L
Dg
B
16
17
20
21
29
47
59
B
Main switch
Battery
Fuse (main)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand switch
ECU
B
Gy
B/L
–19–
B/L
1
5
6
11
12
13
15
W/Y
187
B A B
IGNITION SYSTEM
ELEC
EAS00735
IGNITION SYSTEM
CIRCUIT DIAGRAM
R/B D R/B
R/L F R/L
IGNITION SYSTEM
EAS00737
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
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 stop switch
9. Neutral switch
10. Sidestand switch
11. Clutch switch
12. Starting circuit cut-off relay
13. Lean angle cut-off switch
14. Wiring connections
(of the entire ignition system)
Minimum open-circuit voltage
12.8 V or more at 20_C (68_F)
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EAS00741
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. air filter case
4. bottom cowling
5. side cowlings
S Troubleshoot with the following special tool(s).
3. Spark plugs
The following procedure applies to all of the
spark plugs.
S Check the condition of the spark plug.
S Check the spark plug type.
S Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR9EK or CR10EK (NGK)
Spark plug gap
0.6 X 0.7 mm (0.0236 X 0.0276 in)
Dynamic spark tester
YM-34487
Ignition checker
90890-06754
Pocket tester
90890-03112, YU-3112
S Is the spark plug in good condition, is it of the
correct type, and is its gap within specification?
YES
EAS00738
NO
1. Main and ignition fuses
S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main and ignition fuses OK?
YES
Re-gap or replace
the spark plug.
NO
Replace the fuse(s).
–20–
IGNITION SYSTEM
ELEC
EAS00743
4. Ignition spark gap
The following procedure applies to all of the
spark plugs.
S Disconnect the spark plug cap from the
spark plug.
S Connect the ignition checker 1 and ignition
coil 2 as shown.
S Set the main switch to “ON”.
S Measure the ignition spark gap a .
S Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
S Measure the primary coil resistance.
Primary coil resistance
0.24 X 0.32 Ω at 20_C (68_F)
S Connect the pocket tester (Ω
ignition coil as shown.
1k) to the
Negative tester probe !
ignition coil terminal 1
Positive tester probe !
spark plug terminal 2
Minimum ignition spark gap
6 mm (0.24 in)
S Is there a spark and is the spark gap within
specification?
NO
YES
S Measure the secondary coil resistance.
Secondary coil resistance
5.0 X 6.8 kΩ at 20_C (68_F)
The ignition system
is OK.
S Is the ignition coil OK?
YES
NO
EAS00747
5. Ignition coil resistance
Replace the ignition
coil.
The following procedure applies to all of the
ignition coils.
S Disconnect the ignition coil leads from the
wire harness.
S Connect the pocket tester (Ω
1) to the
ignition coil as shown.
Positive tester probe !
ignition coil terminal
Negative tester probe !
ignition coil terminal
–21–
IGNITION SYSTEM
EAS00748
ELEC
EAS00750
6. Crankshaft position sensor resistance
8. Engine stop switch
S Disconnect the crankshaft position sensor
coupler from the wire harness.
S Connect the pocket tester (Ω
100) to the
crankshaft position sensor coupler as shown.
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
YES
Positive tester probe ! gray 1
Negative tester probe ! black 2
NO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
S Measure the crankshaft position sensor
resistance.
YES
Crankshaft position sensor
resistance
248 X 372Ω at 20_C (68_F)
(between gray and black)
NO
Replace the neutral
switch.
S Is the crankshaft position sensor OK?
EAS00752
10. Sidestand switch
YES
NO
S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the sidestand switch OK?
Replace the
crankshaft position
sensor.
YES
Replace the sidestand switch.
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
EAS00763
11. Clutch switch
S Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the clutch switch OK?
NO
Replace the main
switch.
YES
NO
Replace the clutch
switch.
–22–
IGNITION SYSTEM
ELEC
EAS00753
12. Starting circuit cut-off relay
NOTE:
When you switch the positive and negative
tester probes, the readings in the above chart
will be reversed.
S Disconnect the starting circuit cut-off relay
coupler from the wire harness.
S Connect the pocket tester (Ω
1) to the
starting circuit cut-off relay coupler as
shown.
S Check the starting circuit cut-off relay for
continuity.
S Are the tester readings correct?
YES
Positive tester probe !
sky blue 1
Negative tester probe !
black/yellow 2
Positive tester probe !
sky blue 1
Negative tester probe !
blue/yellow 3
Replace the starting
circuit cut-off relay.
13. Lean angle cut-off switch voltage
Continuity
S Remove the lean angle cut-off switch.
S Connect the pocket tester (Ω
1) to the
lean angle cut-off switch terminals as
shown.
Positive tester probe !
blue/black 4
Negative tester probe !
black/yellow 2
Positive tester probe ! blue
Negative tester probe ! yellow/green
Positive tester probe !
black/yellow 2
Negative tester probe !
sky blue 1
Positive tester probe !
blue/yellow 3
Negative tester probe !
sky blue 1
NO
No
continuity
Positive tester probe !
blue/yellow 3
Negative tester probe !
blue/black 4
Lean angle cut-off switch voltage
Less than 65_ a !
Approximately 1 V
More than 65_ b !
Approximately 4 V
S Is the lean angle cut-off switch OK?
–23–
IGNITION SYSTEM
YES
NO
Replace the lean
angle cut-off switch.
EAS00754
14. Wiring
S Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the ignition system’s wiring properly connected and without defects?
YES
Replace the ignitor
unit.
NO
Properly connect or
repair the ignition
system’s wiring.
–24–
ELEC
ON
OFF
1
W
R
W W
W
W W
L/B
R
Br/L
Br/L
R
L
G/Y
B
L
BrG
L
R/W
B
48
47
10
L/Y L/B
L/B L/Y
Br/L
R
Br/L
R
Br/L
46
-
W W W
B
3
B
49
BrG
R/Y
Br
50
R/W
R
Y
L/B
B/Y
B/L
B/L
R/Y
4
R
B
YW
R/G
52
51
B
Br Y
B
B
5
R
R
B
B
B
L/W
R/W
53
B B
67
Y
- Br/WR/Y
R
G/Y
B
Y L/R
Ch L/Y B B/Y Br
Dg Y
Br B R/B
L
6
R
R/B B Br
42
R R
L/WR/W
R/W L/W G/Y
8
R
G/Y L/W R/W
7
R
R
B
L/Y
W
R/W
G/Y
9
66
43
54
Y Dg
B
187
55
B B/Y
B
B/Y H B/Y
B/L C B/L
RUN
OFF
44
Br B/Y B L/Y Ch
R/Y Br/W -
R
R/W
B/Y
L/W
65
LO
HI
56
PUSH
FREE
45
B
R/Y
B B/L
B
L/W
R/W
W
R/B
187
ON
OFF
57
59
R/B
B/Y
Br/L
W
L/W
B
W
L/W
B/W
W
L/B
YW
BrG
L
L
B
Br
Y
Y
R/Y A R/Y
R/Y
B/L
B/L
B/Y
YW A YW
Y
B
B
Y
Y A Y
Br
B
B
L/R
B
B
L Ch
B
Ch
64
L
Br
L
N
R
R
60
B
L Dg
B
L
L/B B
11
Dg
63
Dg A Dg
12
B B
Br/W
58
Ch A Ch
L/Y
L
L/W G/R
B
B
Ch
Ch
-
62
W
41
W
R/L
B
B
Dg
Dg
-
61
G/W
Dg
Ch
B/R
W B B/R
R/G
Br
29
G/W A G/W
R/G B R/G
R/W A Br
F
L O/B L/B
G/B R/B R/L
35
33
34
40
40
39
39
38
37
36
L B/L
B/L L
L Ch Dg B/Y Sb/W - G/W Br
B/W B B/W
Y/L B Y/L
Y/L
B/W
Y/B B Y/B
Sb/W A Sb/W
Y/B
Sb/W
WIRE HARNESS SUB-WIRE HARNESS 2
W/B Br/R
E
Br/R W/B
- Y/L - B/W R/G
13
Y/B B/R -
32
31
30
R/L B
G/W B
WIRE HARNESS SUB-WIRE HARNESS 3
B/Y Sb/W
R/B L/W
B/W B/R L/W Lg R/W L/B L/Y Sb
R
WIRE HARNESS SUB-WIRE HARNESS 4
L/B O/B L
B/Y
- P/W B/L
R/L R/B G/B
L
B/L P/W -
W
W
B
Sb/W
B
L/B
L/B
B
Sb
Ch
B
L/R
Br/W
Br/W
Lg
Ch
L
R/L
B
2
Dg
R/L
Dg
B
G/W
B
WIRE HARNESS Headlight coupler
Ch
B
Br
L/R
B
L/Y
B/Y
B
B/L
B
B C B
187
B H B
Dg
B
B Gy/G O/G
O/G Gy/G B
L
B
Y
B/L
Y L
-
-
28
B/L
B/L E B/L
L W/B
B/L
L E L
P
L
B/L
Y/G
B/L
L
L F L
25
B Gy
20
B/L
-
B/L B
-
B/L G B/L
-
- B/R Y/B
B/WR/G Y/L
- R/B G/B L/B O/B Y/B B O/G Gy/G
HEADLIGHT SUB WIRE HARNESS
B
W L/Y
B/L
G/W B/L
Br/W B/L
B/L
22
21
L W/Y
B/L
B/L
- Sb
27
W/Y
P
Y/G
P/W G P/W P/W
G/W G G/W G/W
G/W
Y
W/B
L
B/L
Gy
Br/W G Br/W Br/W
Y G Y
19
L/Y
B/Y
Y/B
R/L
Lg
L/W
R/W
Br/W
Sb -
- B/L YW Lg G/W Gy Y/R R/L Y/R Br/R B O Gy/R
L
WIRE HARNESS
Y/B W
Y/L R/G B/W
Y W/Y P P/W R/W Br/W B/W W/B -
- L/B G/Y Y/G B/Y W Y/L -
W/B E W/B
L Y/G B/L
C
- L/W -
W/B
L
P B/L L
P/W B/L L
P/W
Y
L
B/L
B B/L
WIRE HARNESS Headlight coupler
W L/Y
26
24
L
B/L
23
Gy B/L
WIRE HARNESS SUB-WIRE HARNESS 1
Gy/R O R/B
D
R/B O Gy/R
Gy
B/L
Sb
Sb
Sb
G/W Br/W Y
L
G
14
WIRE HARNESS
O
G/Y
Y/L
Y/R
Y/R
Br/R
O/B
L/B
F O/B
G/B
Br/R
R/L O/B
O/B
R/L L/B
L/B
R/L G/B
Br/RR/B
Br/R E Br/R
O/B
L/B F L/B
G/B F G/B
G/B
R/L R/B
R/B
B
R/B F R/B
Gy/G
B
O/G
B D B
D O/G
B
Gy/R
B
O
Gy/G D Gy/G
O/G
Gy/R D Gy/R
D O
R/B
YW
Gy/G
O/G
Gy/R
O
17
17
17
17
Br Br/R
16
16
16
16
18
R/L
R/L
R/L
R/L
15
15
15
15
R/B
B Gy/G
B O/G
B Gy/R
B O
HEADLIGHT SUB WIRE HARNESS
- Ch G/W Y R/Y
Sb/W Dg B Y/W Br
R/W Y/W B Dg Sb/W
A
R/Y Y G/W Ch -
B
Y Br/W G/W
W
B/Y B
B
H
B/W
B B/Y
B/L
–25–
W/Y
187
B A B
LIGHTING SYSTEM
ELEC
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
R/B D R/B
R/L F R/L
LIGHTING SYSTEM
1
5
6
15
40
42
50
54
55
56
60
61
71
72
73
Main switch
Battery
Fuse (main)
ECU
High beam indicator light
Meter light
Fuse (headlight)
Headlight relay (on / off)
Headlight relay (dimmer)
Fuse (park)
Pass switch
Dimmer switch
Headlight
License light
Tail/ brake light
–26–
ELEC
LIGHTING SYSTEM
ELEC
EAS00788
Headlight
Positive tester probe ! black/yellow 3
Negative tester probe ! black 4
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
B High beam
1. Headlight bulb and socket
S Check the headlight bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
S Are the headlight bulb and socket OK?
YES
NO
Replace the headlight bulb, socket or
both.
High beam indicator light (LEDs)
Positive tester probe !
black/yellow 5
Negative tester probe !
black/white 6
Meter assembly coupler (wire harness side)
2. Voltage
S Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
A When the dimmer switch is set to “
B When the dimmer switch is set to “
”
”
Headlight
Positive tester probe ! black/blue 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Start the engine.
S Set the dimmer switch to “
” or “
”.
S Measure the voltage (DC 12 V) of black/blue
1 or black/yellow 3 on the headlight coupler (wire harness side).
S Is the voltage within specification?
Headlight coupler (wire harness side)
A Low beam
YES
This circuit is OK.
–27–
NO
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
ELEC
LIGHTING SYSTEM
EAS00789
EAS00790
2. The meter light fails to come on.
3. The tail/brake light fails to come on.
1. Meter light (LEDs)
1. Tail/brake light (LEDs)
S Check the meter light for continuity.
Refer to “CHECKING THE LEDs”
S Are the meter light OK?
S Check the tail/brake light for continuity.
Refer to “CHECKING THE LEDs”
S Are the tail/brake light OK?
YES
NO
YES
Replace the meter
assembly.
NO
Replace
the
tail/brake light assembly.
2. Voltage
2. Voltage
S Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
S Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Positive tester probe ! blue 1
Negative tester probe ! black/white 2
Positive tester probe ! blue/red 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of blue 1 on
the meter assembly coupler (wire harness
side).
S Is the voltage within specification?
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of blue/red
1 on the tail/brake light coupler (wire harness side).
S Is the voltage within specification?
YES
This circuit is OK.
NO
YES
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
This circuit is OK.
–28–
NO
Wiring circuit from
the main switch to
the tail/brake light
coupler is faulty and
must be repaired.
LIGHTING SYSTEM
EAS00792
4. The license light fails to come on.
1. License light bulb and socket
S Check the license light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
S Are the license light bulb and socket OK?
YES
NO
Replace the license
light bulb, socket or
both.
2. Voltage
S Connect the pocket tester (DC 20 V) to the
license light coupler (wire harness light side)
as shown.
Positive tester probe ! blue/red 1
Negative tester probe ! black 2
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) of blue/red
1 on the license light coupler (wire harness
side).
S Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the main switch
to the license light
coupler is faulty and
must be repaired.
–29–
ELEC
YZF-R6S/YZF-R6SC WIRING DIAGRAM
YZF-R6S/YZF-R6SC WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Main switch
A.C. magneto
Rectifier/ regulator
Fuse (backup)
Battery
Fuse (main)
Starter relay
Starter motor
Fuse (fuel injection)
Fuse (ignition)
Starting circuit cut-off relay
Sidestand 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 light
Neutral indicator light
Tachometer
Shift timing indicator light
Multi-function meter
Engine trouble warning light
Coolant temperature indicator light
High beam indicator light
Turn signal indicator light
Meter light
Oil level switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Fuse (signal)
Fuse (headlight)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
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
61
62
63
64
65
66
67
Rear turn signal light (right)
Rear turn signal light (left)
Front turn signal / position light (right)
Front turn signal / position light (left)
Headlight
License light
Tail/ brake light
COLOR CODE
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ L . . . . .
B/ R . . . .
B/ W . . . .
B/ Y . . . .
Br/ G . . .
Br/ L . . . .
Br/ R . . . .
Br/ W . . .
Br/ Y . . . .
G/B . . . .
G/W . . . .
G/Y . . . .
Gy/ G . . .
Gy/ R . . .
L/B . . . . .
L/R . . . .
L/W . . . .
L/Y . . . . .
O/B . . . .
O/G . . . .
P/ W . . . .
R/ B . . . .
R/ G . . . .
R/ L . . . .
R/ W . . . .
R/ Y . . . .
Sb/ W . . .
W/ B . . . .
W/ Y . . . .
Y/ B . . . .
Y/ G . . . .
Y/ L . . . . .
Y/ W . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ Red
Black/ White
Black/ Yellow
Brown/ Green
Brown/ Blue
Brown/ Red
Brown/ White
Brown/ Yellow
Green / Black
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue/ Black
Blue/ Red
Blue/ White
Blue/ Yellow
Orange / Black
Orange / Green
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red White
Red/ Yellow
Sky blue / White
White/ Black
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue
Yellow/ White