Yamaha R6S Wartungshandbuch

YZF-R6T5SL-28197-12SUPPLEMENTARYSERVICE MANUALLIT-11616-18-45YZF-R6TC

SPEC3CHASSIS SPECIFICATIONSItem Standard LimitFrameCaster angle 24.5° • • •Trail 95 mm (3.74 in) • • •Front tireSize 120 / 70 ZR17 M / C (55W) • • •Mo

SPEC4ELECTRICAL SPECIFICATIONSItem Standard LimitFront suspensionSpringFree length 248.8 mm (9.80 in) 243.8 mm (9.60 in)Installed length 244.3 mm (9.6

SPEC5TIGHTENING TORQUESENGINE TIGHTENING TORQUESCHASSIS TIGHTENING TORQUESNOTE:NOTE:1. Insert the front wheel axle from the right side and tighten it

SPEC6CABLE ROUTINGRight handlebar switch leadClutch cableMain switch leadLeft handlebar switch leadThrottle cable (return side)Throttle cable (pull si

SPEC7Clamp it at the position of 50 mm (1.97 in) to 65 mm (2.56 in) from the upper face of the under bracket with the plastic locking tie. Cut the sur

SPEC8Throttle stop screwCoolant reservoir tank hoseCover 8Radiator fan motor lead (right)Pickup coil leadRear tail / brake light switch leadRadiator r

SPEC9Route the radiator fan motor lead (right) by the out-side of the clutch cable.Route the radiator fan motor lead (right) and clutch cable by the i

SPEC10Throttle cable (return side)Throttle cable (pull side)Starter motor leadCanister hose (for CAL)Canister (for CAL)Balance hose (for CAL)Coolant r

SPEC11Pass the fuel tank drain hose, fuel tank breather hose through the clamp of the coolant reservoir tank.Pass the coolant reservoir tank breather

SPEC12Right handlebar switch leadRadiator fan motor lead (right)Sub wire harnessHeadlight leadMeter leadCover 8Ignition coil leadThrottle position sen

YZF-R6T / YZF-R6TCSUPPLEMENTARYSERVICE MANUAL©2004 by Yamaha MotorCorporation, U.S.A.First edition, September 2004All rights reserved. Any reproductio

SPEC13Neutral switch lead coupler (connector 1 pole)Fuel hose (return side, for CAL)Canister hose (for CAL)Fuel hose (feed side, for CAL)Fuel tank dra

SPEC14Pass 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

SPEC15Upper or lower position relation between the left handlebar switch lead, right handlebar switch lead and radiator fan motor lead (right) is no o

SPEC16The 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

SPEC17Starter motor leadBatteryBattery positive leadStarter relayBoltTurn signal relayFuse boxPressure sensorTail / brake light Tool kitECUWire harne

SPEC18Insert it to the back end of the rib in the battery box assembly.The 20 mm (0.79 in) knob should be within this range.Pass the turn signal lead

SPEC19Connect the negative lead and the wire harness.Install the starting circuit cut-off relay to the deep-est position after placing the tail / brak

CHKADJ20EAS00135PERIODIC CHECKS AND ADJUSTMENTSBLEEDING THE HYDRAULIC BRAKE SYSTEMWARNINGBleed the hydraulic brake system when-ever:• the system is di

CHKADJ21f. Fully pull the brake lever or fully press down the brake pedal and hold it in posi-tion.g. Loosen the bleed screw.NOTE:NOTE:Loosening the b

CHKADJ22EAS00155ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.WARNING• Always adjust both front fork leg

EAS00030NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-ers and their qualified mechanics. It is not

CHKADJ231. Adjust:• rebound dampinga. Turn the adjusting screw in direction or .Compression dampingCAUTION:Never go beyond the maximum or minimum

CHAS24EAS00514CHASSISFRONT WHEEL AND BRAKE DISCSOrder Job / Part Q’ty RemarksRemoving the front wheel and brake discsRemove the parts in the order lis

CHAS25EAS00577FRONT AND REAR BRAKESFRONT BRAKE PADSOrder Job / Part Q’ty RemarksRemoving the front brake pads Remove the parts in the order listed.NOT

CHAS26EAS00584FRONT BRAKE MASTER CYLINDEROrder Job / Part Q’ty RemarksRemoving the front brake master cylinderRemove the parts in the order listed.Dra

CHAS27Order Job / Part Q’ty Remarks13 Brake master cylinder 114 Front brake switch 1For installation, reverse the removal procedure.13 Nm (1.3 m•kg, 9

CHAS28EAS00585Order Job / Part Q’ty RemarksDisassembling the front brake master cylinderDisassemble the parts in the order listed.Brake master cylind

CHAS29EAS00613FRONT BRAKE CALIPERSOrder Job / Part Q’ty RemarksRemoving the front brake calipers Remove the parts in the order listed.NOTE:NOTE:The fo

CHAS30EAS00615Order Job / Part Q’ty RemarksDisassembling the front brake calipersDisassemble the parts in the order listed.NOTE:NOTE:The following pro

CHAS31EAS00607ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDERWARNING• Before installation, all internal brake com-ponents should be cleaned

CHAS324. Fill:• brake fluid reservoir (with the specified amount of the recom-mended brake fluid)WARNING• Use only the designated brake fluid. Other b

EAS00007HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all inst

CHAS33EAS00647FRONT FORKFRONT FORK LEGSOrder Job / Part Q’ty RemarksRemoving the front fork legs Remove the parts in the order listed.Front wheel Refe

CHAS34EAS00648Order Job / Part Q’ty RemarksDisassembling the front fork legs Disassemble the parts in the order listed.NOTE:NOTE:The following the pro

CHAS35Order Job / Part Q’ty RemarksWasher 1Damper rod assembly bolt 1Copper washer 1Damper rod assembly 1Inner tube 1Outer tube 1For assembly, reverse

CHAS36EAS00652DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of the front fork legs.1. Remove:• cap bolt (from the damper

CHAS374. Remove:• damper rod assembly bolt• damper rod assemblyNOTE:NOTE:While holding the damper rod assembly with the damper rod holder , loosen th

CHAS38CAUTION:• The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu-larly sensiti

CHAS39WARNINGAlways use new copper washer.CAUTION:Allow the damper rod assembly to slide slowly down the inner tube until it pro-trudes from the bot

CHAS40CAUTION:Make sure the numbered side of the oil seal faces up.NOTE:NOTE:• Before installing the oil seal, lubricate its lips with lithium-soap-ba

CHAS418. Install:• rod puller • rod puller attachment (onto the damper rod )9. Fill:•front fork leg (with the specified amount of the recom-mended

CHAS42e. Press down on the spacer with the fork spring compressor .f. Pull up the rod puller and install the rod holder between the nut and the s

EAS00008SYMBOLSThe following symbols are not relevant to every vehicle.Symbols to indicate the subject of each chapter.General informationSpecific

CHAS43EAS00709SWINGARM AND DRIVE CHAINCHECKING THE DRIVE CHAIN1. Measure:• Measure the dimension between 15-links on the inner side and outer side

CHAS44CAUTION:This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air,

COOL45EAS00454COOLING SYSTEMRADIATOROrder Job / Part Q’ty RemarksRemoving the radiator Remove the parts in the order listed.Rider seat Refer to “SEATS

COOL46Order Job / Part Q’ty Remarks9 Radiator cap 1For installation, reverse the removal procedure.10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•

ELEC47EAS00755ELECTRICAL SYSTEMELECTRIC STARTING SYSTEMCIRCUIT DIAGRAMMain switchBatteryFuse (main)Starter relayStarter motorFuse (ignition)Starting c

ELEC48EAS00757TROUBLESHOOTINGCheck:1. main and ignition fuses2. battery3. starter motor4. starting circuit cut-off relay5. starter relay6. main switch

ELEC49EAS00759EAS00761EAS00749EAS00750EAS007514. Starting circuit cut-off relay• Disconnect the starting circuit cut-off relay coupler from the wire h

ELEC50EAS00752EAS00763EAS00764EAS007669. Sidestand switch• Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”.• Is the sidest

ELEC51EAS00807COOLING SYSTEMCIRCUIT DIAGRAMMain switchBatteryFuse (main)Fuse (ignition)ECUCoolant temperature sensorRadiator fan motor relayFuse (radi

ELEC52EAS00808TROUBLESHOOTINGCheck:1. main, ignition, and radiator fan motor fuses2. battery3. main switch4. radiator fan motor5. radiator fan motor r

CONTENTSGENERAL INFORMATIONSPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1SPECIFICATIONSGENERAL SPECI

ELEC53EAS008094. Radiator fan motor (left and right)• Disconnect the radiator fan motor coupler from the wire harness.• Connect the battery (DC 12 V)

ELEC54EAS00812EAS008136. Coolant temperature sensor• Remove the coolant temperature sensor.• Connect the pocket tester (Ω × 1k) to the coolant temper

YZF-R6T/YZF-R6TC WIRING DIAGRAM

YZF-R6T / YZF-R6TC WIRING DIAGRAMMain switchA.C. magnetoRectifier / regulatorFuse (backup)BatteryFuse (main)Starter relayStarter motorFuse (fuel injec

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

ELECTRICAL SYSTEMELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . .

GENINFO1EAS00027GENERAL INFORMATIONSPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use only the

SPEC2SPECIFICATIONSGENERAL SPECIFICATIONSENGINE SPECIFICATIONSItem Standard LimitModel code 5SLR (USA except for CAL) • • •5SLS (CAL)DimensionsOverall