Yamaha Moto matrix YZF-R6S Handbuch

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

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

email: [email protected]

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YZF-R6 (S) 2004. For complete service information procedures it is necessary to use this Supplemen-

tary Service Manual together 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

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

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NOTE:

WARNING

CAUTION:

EAS00002

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 manu-

al. 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 ve-

hicle unsafe and unfit for use.

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.

Designs and specifications are subject to change without notice.

EAS00004

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!

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 mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2Each 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) ap-

pears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

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24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate 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-disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

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CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TIGHTENING TORQUES 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

FUEL 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE LIGHTING SYSTEM 26. . . . . . . . . . . . . . . . . . . . . . . .

YZF-R6 (S) 2004 WIRING DIAGRAM

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–1–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5SLB (EUR), 5SLC (F), 5SLG/5SLL (AUS) SSS

ENGINE SPECIFICATIONS

Item Standard Limit

Throttle bodies

ID mark

Throttle valve size

5SL1 00 (5SLB/5SLG/5SLL),

5SL2 20 (5SLC)

#100

SSS

CHASSIS SPECIFICATIONS

Item Standard Limit

Front tire

Model (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) F8T814 (MITSUBISHI)

(5SLB/5SLG/5SLL)

F8T815 (MITSUBISHI) (5SLC)

SSS

Ignition coils

Model (manufacturer)

Primary coil resistance

Secondary coil resistance

F6T549 (MITSUBISHI)

0.24 X0.32 Ωat 20_C (68_F)

5.0 X6.8 kΩat 20_C (68_F)

SSS

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–2–

TIGHTENING TORQUES SPEC

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Item

Fastener

Thread

’

Tightening torque

Remarks

Item

Fastener

size

Qty

Nm mSkg ftSlb

Remarks

Oil cooler

Cylinder identification sensor

Bolt

M20

6.0

6.3

0.6

4.3 Yamaha bond

No.1215

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