YZF-R6S(C) Supplementary Service Manual
Contents
1. 500738 YES 5 1 Main and ignition fuses e Check the main and ignition fuses for conti Re gap or replace nuity the spark plug Refer to CHECKING THE FUSES in chap ter 3 e Are the main and ignition fuses OK 5 NO Replace the fuse s email info motomatrix co uk 20 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motoneyc aded Keyp d IGNITION SYSTEM 00743 4 Ignition spark gap The following procedure applies to all of the spark plugs eDisconnect the spark plug cap from the spark plug e Connect the ignition checker 1 and ignition coil 2 as shown e Set the main switch to ON Measure the ignition spark gap Measure the primary coil resistance eCrank the engine by pushing the starter switch and gradually increase the spark gap Primary coil resistance until a misfire occurs 0 24 0 32 at 20 C 68 F e Connect the pocket tester x 1k to the ignition coil as shown Negative tester probe ignition coil terminal 1 Positive tester probe spark plug terminal 2 18110202 Minimum ignition spark gap 6 mm 0 24 in els there a spark and is the spark gap within YES Measure the secondary coil resistance Secondary coil resistance Lm 5 0 6 8 at 20 C 68 F els the ignition coil OK YES y NO 5 Ignition coil resistance apace ntn Replace the ignition The fo2. 1 Coolant temperature sensor 9 Speed sensor 2 Intake air temperature sensor Crankshaft position sensor 8 Intake air pressure sensor 11 Cylinder identification sensor 4 Lean angle cut off switch 2 Radiator fan motor relay 5 Atmospheric pressure sensor 3 Headlight relay on off 6 ECU Headlight relay dimmer 7 Starting circuit cut off relay Turn signal relay email info motomatrix co uk 18 0 8 c Arce 9 5 2 Q O A 505 5 5 2 COBH GOS m Ox lxccco C g 5ggo 4 ES 5 PnZzoiwo XXX 5 oe gt 9 E OR MON 5 5 o 18 d 94 lt 5 2 gt Cel 955450 gt 19 X as i O P TI 4 O gt gt 2 U C 4 0 Za E SS3NHVH SHIM ENS LH NAYAH SS3NHVH SHIM 29 EER 206 info motomatrix co uk email Manuals by Motomatrix www motomatrix co uk The Solution For Lost aded KevE d IGNITION SYS
3. 1 18 1 97 in Pass the oil level switch lead and sidestand switch lead over the bracket 2 Pass the oil level switch lead and sidestand switch lead through the clamp 5 45 mm 0 20 1 77 in Clamp the A C magneto lead oil level switch lead and sidestand switch lead Pass the side stand switch lead oil level switch lead and A C magneto lead between the engine stay and the engine po gt SS NM 7 n Ui sess 422 i Ur di To the throttle body To the radiator fan motor relay and fuse box O Route it above the radiator hose P Pass the throttle cable between the guide of the cover 2 and the frame Q 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 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mote 2 d CABLE ROUTING SPECT 1 Right handlebar switch lead 11 Crankshaft position sensor lead Fuel hose feed side except for 2 Sub wire harness coupler CAL 3 Head light lead 12 Fuel tank breather hose except 19 Crankcase breather hose 4 Meter lead for CAL 60 Air vent hose 5 Cover 8 3 Fuel tank drain hose except for 1 Fuse box 6 Ignition coil lead CAL 62 C
4. CHECKING THE SWITCHES Replace the els the sidestand switch OK crankshaft position Sensor YES 5 Replace the side 500749 7 Main switch stand switch e Check the main switch for continuity ERSUUTD Refer to CHECKING THE SWITCHES 11 Clutch switch els the main switch OK YES e Check the clutch switch for continuity NO Refer to CHECKING THE SWITCHES els the clutch switch OK Replace the main YES NO switch Replace the clutch switch email info motomatrix co uk 22 IGNITION SYSTEM Manuals by Motomatrix www motomatrix co uk The Solution For Lost 500753 12 Starting circuit cut off relay e Disconnect the starting circuit cut off relay coupler from the wire harness e Connect the pocket tester Q x 1 to the starting circuit cut off relay coupler as shown eCheck the starting circuit cut off relay for continuity Positive tester probe sky blue 1 Negative tester probe black yellow 2 Positive tester probe sky blue 1 Negative tester probe blue yellow 3 Positive tester probe blue black Negative tester probe black yellow 2 Positive tester probe black yellow 2 Negative tester probe sky blue Positive tester probe blue yellow 3 N Negative tester probe dM sky blue continuity Positive tester probe blue yellow Negative tester probe blue black
5. 4 Continuity email info motomatrix co uk When you switch the positive and negative tester probes the readings in the above chart will be reversed e Are the tester readings correct 13 Lean angle cut off switch voltage e Remove the lean angle cut off switch e Connect the pocket tester Q x 1 to the lean angle cut off switch terminals as shown Positive tester probe blue Negative tester probe yellow green Lean angle cut off switch voltage Less than 65 Approximately 1 V More than 65 b gt Approximately 4 V els the lean angle cut off switch OK Manuals by Motomatrix www motomatrix co uk The Solution For Lost aded Keyp d IGNITION SYSTEM YES y NO Replace the lean angle cut off switch EAS00754 14 Wiring e Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM els the ignition system s wiring properly con nected and without defects YES y NO Replace the ignitor Properly connect or unit repair the ignition system s wiring email info motomatrix co uk 24 Manuals by Motomatrix www motomatrix co uk 00780 LIGHTING SYSTEM CIRCUIT DIAGRAM a a 8 1 lt 1 1 lene WIRE HARNESS GylR B Pig o LGB uB B Lo L Y 4 YR R Py 7 HEADLIGHT SUB WIRE HARNESS TATA
6. 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 Jobs requiring more information such as special tools and technical data are described sequen tially Oo 11 4 caren an Ee 500273 500276 CLUTCH REMOVING THE CLUTCH CLUTCH COVER 1 Remove e clutch cover 1 gasket NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 2 Remove compression spring bolts 1 compression springs pressure plate rod 3 e friction plates clutch plates 3 Straighten the lock washer tab 4 Loosen e clutch bass nut 1 NOT E nr While holding the clutch boss 2 with the univer 2 i kp DA 1 GI gt 5 QD s OB Op S GOI YS fy sal clutch holder loosen the clutch boss nut gt x7 7 mM Sx 7 90890 04086 YM 91042 5 Remove clutch boss nut lock washer Removing the clutch cover Removing the parts in the order listed e clutch boss 3 Refer to COWLINGS chapter 3 thrust plate Engine oil Drain Refer to CHANGING TH
7. 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 the throttle air vent hose Pass the wire harness between frame and coolant hose Pass it through the frame hole Do not catch the coupler when the air filter case is assembled 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 ve hicle Sealing set of the cover can be either upper or lower against the frame lower end However it should not be caught Clamp the wire harness main switch lead branch section and radiator fan motor lead Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mote 2 d CABLE ROUTING SPEC YY Branching leads to the fuse box and radiator fan Tip of the plastic locking tie should point to the motor relay shall pass through the guide section downward outside of the vehicle of the cover 2 under the wire harness and then to Use the plastic locking tie to clamp the starter mo the outside of the frame tor lead at the protector section To the fuse box and fan motor relay Branching harness from the wire harness Pass the throttle cables over the cover 2 Poss the canister hose over fuel return hose and Point the tip of the plastic locking tie to the rear
8. headlight bulb and socket OK Replace the head High beam indicator light LEDs light bulb socket or Positive tester probe both black yellow 5 Negative tester probe black white 6 Meter assembly coupler wire harness side 2 Voltage e Connect the pocket tester DC 20 V to the headlight and meter assembly couplers as shown When the dimmer switch is set to When the dimmer switch is set to Headlight Positive tester probe black blue 1 Negative tester probe black 2 e Turn the main switch to ON e Start the engine e Set the dimmer switch to ZO e Measure the voltage DC 12 V of black blue CD or black yellow 3 on the headlight cou pler wire harness side els the voltage within specification i YES y NO This circuit is OK wiring circuit from the main switch Headlight coupler wire harness side Low beam 7 to the headlight cou pler is faulty and must be repaired email info motomatrix co uk 27 Manuals by Motomatrix www motomatrix co uk The Solution For Los C led Keys d LIGHTING SYSTEM 500789 500790 2 The meter light fails to come on 3 The tail brake light fails to come on 1 Meter light LEDs e Check the meter light for continuity 1 Tail brake light LEDs e Check the tail brake light for continuity Refer to CHECKING THE LEDs Are the tail brake light OK Refer to
9. in the coupler between the head light s hollow section and the duct Install the relay to the rib of the head light Location for the left and right relays is alternative To 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 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 10 mm 0 08 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 leav ing 2 10 mm 0 08 0 39 in 2 E FRY E SD CE DASS Med PEERS N Y a 2 e AY ALA email info motomatrix co uk email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mote d CABLE ROUTING SPECT 1 Throttle stop screw 2 Coolant reservoir tank hose 3 Pickup coil lead 4 Rear brake light switch lead 5 Coolant hose 6 Clutch cable 7 Coolant hose protector Hose clamp assembly 9 Hose clamp Pass the rear brake light switch lead outside of rear engine mount bolt Pass the ignition coil lead outside of the radiator hose Pass the coolant reservoir tank hose under the frame and right side of the throttle body D Pass the clutch cable inside
10. of the coolant reservoir tank hose and radiator return hoses Assemble as a 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 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 Pass the clutch cable inside of the radiator hose Clamp the clutch cable so that it is positioned in this range Put and apply the hose clamp to it Manuals by Motomatrix www motomatrix co uk Th Clamp the clutch cable by routing the upper end of the clamp along with the bottom end of the hose clamp assembly SIP 76 2 KASSAN 55 N 5 ORSON V Fg XN 2 Sp Vie US EN email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost d GABLE ROUTING SPEC 1 Throttle cable return side 2 Throttle cable pull side 3 Starter motor lead 4 Coolant reservoir tank breather hose 5 Bracket 2 6 Sidestand switch lead 7 Oil level switch lead A C magneto lead 9 Radiator fan motor lead Fuel tank breather hose 11 Fuel tank drain hose 12 Coolant reservoir tank cover 3 Drive sprocket cover Coolant reservoir tank 15 Canister hose for CAL Canister for CAL 17
11. Balance hose for CAL S NOT IN NM 7 ro v email info motomatrix co uk v EX 27 2 77 2124 75 EN 2 CN dun 555555 a 77752 SA 1 F are 5 X cie vo e ej IIIA gt CT ger 2 M 2 227 1 v LAZ EN C 4 2 Pass the main switch lead under the left handlebar switch lead and then to the right side of the vehicle 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 ve hicle Pass the fuel tank drain hose and fuel tank breather hose inside of the reservoir tank breather hose res ervoir tank hose and wire harness and then route it by the out side of the starter motor lead ID Pass the coolant reservoir tank hose outside of the fuel tank drain hose and fuel tank breather hose Pass the fuel tank drain hose fuel tank breather hose through the clamp of the coolant reservoir tank 1 lt NE 2 27 lt C bw A email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost d GABLE ROUTING SPEC Pass the coolant reservoir tank breather hose through the clamp of under the coolant reservoir tank Projection allowance from the coolant reservoir tank cover shall be 30 to 50 mm
12. CHECKING THE LEDs Are the meter light OK i YES NO I in the meter Replace the I in tail brake light as sembly 2 Voltage 2 Voltage Connect the pocket tester DC 20 V to the e Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side tail brake light coupler wire harness side as shown as shown 9 ow Br LA E e Turn the main switch to Measure the voltage DC 12 V of blue 1 on the meter assembly coupler wire harness side els the voltage within specification i YES This circuit is OK e Turn the main switch to e Measure the voltage DC 12 V of blue red D on the tail brake light coupler wire har ness side els the voltage within specification p YES This circuit is OK The wiring circuit l Wiring circuit from from the main switch the main switch to to the meter assem the tail brake light coupler is faulty and must be repaired bly coupler is faulty and must be re paired email info motomatrix co uk 28 Manuals by Motomatrix www motomatrix co uk 500792 4 The license light fails to come on 1 License light bulb and socket e Check the license light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the license light bulb and socket OK i YES Replace the license light bulb socket or both 2 Vo
13. E ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Coolant hose Disconnect Clutch cable Disconnect Clutch cover Clutch cover gasket Dowel pin CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates For installation reverse the removal as a set procedure email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk 500008 SYMBOLS The following symbols are not relevant to every vehicle Symbols 1 to 9 indicate the subject of each chapter 1 General information 2 Specifications 8 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system Electrical system 9 Troubleshooting Symbols 9 to 47 indicate the following serviceable with engine mounted 17 Filling fluid 2 Lubricant 3 Special tool Tightening torque 5 Wear limit clearance Engine speed 17 Electrical data Symbols 8 to 3 in the exploded diagrams indi cate the types of lubricants and lubrication points Engine oil Gear oil 60 Molybdenum disulfide oil Wheel bearing grease 62 Lithium soap based grease 63 Molybdenum disulfide grease Symbols 62 to 65 in the exploded diagrams indi cate the following 64 Apply lo
14. Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys SIILI I MI 2 65 YZF R6SC SUPPLEMENTARY SERVICE MANUAL LIT 11616 17 46 5SL 28197 11 email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF R6S YZF R6SC For complete service information procedures it is necessary to use this Supplemen tary Service Manual together with the following manual YZF R6R YZF R6SR YZF ReRC YZF ReSRC SERVICE MANUAL LIT 11616 16 45 5SL 28197 10 500001 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 email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys 00030 NOTICE This manual was produced by the Yamaha Motor Company Ltd primarily for use by Yamaha dealers and their qualified mechanics Itis not possible to include all the knowl
15. O Perrin Pink BRETT TE Hed S o Sky blue W a n White gv Yellow B L Black Blue Black Red B W Black White B Y Black Yellow Br G Brown Green Br L Brown Blue Br R Brown Red Br W Brown White Br Y Brown Yellow G B Green Black G W Green White G Y Green Yellow Gy G Gray Green Gy R Gray Red L B Blue Black L R Blue Red L W Blue White Blue Yellow O B Orange Black O G Orange Green P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W Y White Yellow Y B Yellow Black Y G Yellow Green Y C errea Yellow Blue Y W Yellow White Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN email info motomatrix co uk
16. R eml e pafen WIRE HARNESS HEADLIGHT SUB WIRE HARNESS WIRE HARNESS Headlight c ar E ey 99 A EET Ee WIRE HARNESS SUB WIRE HARNESS 4 WIRE HARNESS SUB WIRE HARNESS 3 WIRE HARNESS SUB WIRE HARNESS 2 WIRE HARNESS SUB WIRE HARNESS 1 WIRE HARNESS Headlight couplet fog vT rder email info motomatrix co uk 25 Manuals by Motomatrix www motomatrix co uk EEEE 1 Main switch 5 Battery 6 Fuse main 15 ECU High beam indicator light 42 Meter light Fuse headlight Headlight relay on off 65 Headlight relay dimmer Fuse park Pass switch Dimmer switch 71 Headlight 72 License light 73 Tail brake light email info motomatrix co uk 26 Manuals by Motomatrix www motomatrix co uk 500788 CHECKING THE LIGHTING SYSTEM Headlight 1 The headlight and the high beam indicator Positive tester probe black yellow 3 light fail to come on Negative tester probe black 4 1 Headlight bulb and socket nigh e Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the
17. TEM EAS00737 500739 The ignition system fails to operate no e Check the condition of the battery spark or intermittent spark Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Check mini 1 antium 2 Battery 12 8 V or more at 20 C 68 F bee ess 4 Ignition spark gap 5 Ignition coil resistance YES 5 6 Crankshaft position sensor 7 Main switch 8 Engine stop switch Clean the battery 9 Neutral switch terminals 10 Sidestand switch Recharge re 11 Clutch switch place the battery 12 Starting circuit cut off relay 13 Lean angle cut off switch 14 Wiring connections of the entire ignition system 3 Spark plugs e Before troubleshooting remove the following 500741 part s The following procedure applies to all of the 1 seat spark plugs 2 fuel tank e Check the condition of the spark plug 3 air filter case e Check the spark plug type 4 bottom cowling Measure the spark plug gap 5 side cowlings Refer to CHECKING THE SPARK PLUGS Troubleshoot with the following special tool s in chapter 3 Standard spark plug Dynamic spark tester CR9EK or CR10EK NGK Spark plug gap YM 34487 0 6 0 7 mm 0 0236 0 0276 in Ignition checker 90890 06754 15 the spark plug in good condition is it of the Pocket tester correct type and is its gap within specifica 90890 03112 YU 3112 tion
18. cking agent LOCTITE 65 Replace the part Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys 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 FUEC TANG MMC 15 INSTALLING THE FUEL iugo onaee vs 16 FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM 17 AIR INDUCTION SYSTEM DIAGRAMS 17 ELECTRICAL ELECTRICAL COMPONENTS 18 IGNITION SYSTEM 19 CIRCUIT DIAGRAM 19 TROUBLESHOOTING ER Ere cece 20 LIGHTING SYSTEM Rape m dare A 25 CIRCUIT DIAGRAM i cx hx reda Ran WR UR mex m ans 25 CHECKING THE LIGHTING SYSTEM 27 YZF R6S YZF R6SC WIRING DIAGRAM email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys email info motomatrix co uk M Is by Mot trix mot trix co uk The Sol
19. edge 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 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 ve hicle 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 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 NOTE e This Service Manual contains information regarding periodic maintenance to the emission control system Please read this material carefully e Designs and specifications are subject to change without notice EAS00040 IMPORTANT MANUAL INFORMATION Particularly important informatio
20. er 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 Route the head light 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 CABLE ROUTING Connect the couplers 4 units at the frame side hole Do notcatch each lead and wire harness when the cover 8 is attached From the radiator Pass the coolant reservoir tank hose through for ward the starter motor lead and speed sensor lead Pass the speed sensor lead coupler and crankshaft position sensor lead coupler over the throttle stop cable 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 To the rear brake light switch lead email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mote d CABLE ROUTING SPECT To the neutral switch Insert the wire harness wrapping clamp to the frame hole Pass the battery negative lead over the wire har ness O There should be no interference between the wire harness and the tip of the rear frame attaching bolts To the coolant reservoir tank Q To the intake air temperature sensor air
21. er to SEATS 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 Disconnect Disconnect ll For installation reverse the removal procedure Refer to the CABLE ROUTING for how to attach a hose email info motomatrix co uk 15 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mott yE FUEL TANK ADJ INSTALLING THE FUEL PUMP 1 Install sfuel pump Sa 4Nm 0 4 m kg 2 9 ftelb _ NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump e Always use a new fuel pump gasket e Install the fuel pump as shown in the illustra tion e Tighten the fuel pump bolts in stages in a criss cross pattern and to the specified torque for CAL email info motomatrix co uk 16 Manuals by Motomatrix www motomatrix co I INBE Solution For Lost Motorc Co 2 d AIR INDUCTION SYSTEM FUEL INJECTION SYSTEM AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut off valve To cylinder 1 and 2 2 Reed valve To cylinder 3 and 4 3 To air filter case 12 5 Gc 9 email info motomatrix co uk 17 Manuals by Motomatrix www motomatrix co uk DIENC aded KevE ELECTRI ELECTRICAL ELECTRICAL COMPONENTS
22. gnition coil Spark plug 1 Fuel injector Air induction system solenoid Neutral switch 60 Crankshaft position sensor 61 Intake air temperature sensor 62 Coolant temperature sensor 63 Throttle position sensor 62 Intake air pressure sensor 65 Atmospheric pressure sensor 66 Cylinder identification sensor 67 Speed sensor Lean angle cut off switch 69 Meter assembly Fuel level warning light 31 Oil level warning light 62 Neutral indicator light 63 Tachometer Shift timing indicator light 65 Multi function meter Engine trouble warning light 67 Coolant temperature indicator light High beam indicator light Turn signal indicator light Meter light Oil level switch 42 Right handlebar switch Front brake light switch Engine stop switch Start switch Fuse signal 47 Fuse headlight Fuse radiator fan motor Radiator fan motor relay Radiator fan motor 61 Headlight relay on off 62 Headlight relay dimmer 63 Rear brake light switch Left handlebar switch 65 Clutch switch Dimmer switch 67 Horn switch Turn signal switch Horn Turn signal relay email info motomatrix co uk Rear turn signal light right 62 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 ucro Black Brown OR 2522 Chocolate Dg Dark green Green GY 2 2 Gray eee Blue Light green
23. ll side 6 Front brake hoses 7 Throttle cables Joint 9 Under bracket Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables Install the throttle cables to the hook so that the pull ing side of the throttle cables is routed downward 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 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 B 2 E FRY 4 Gy ES eR RS a q Sa NN ESSO KAN email info motomatrix co uk 0 XS ISS Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mote d CABLE ROUTING SPEC ue 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 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 Pass the throttle cables inside the front brake hoses LI Set
24. llowing procedure applies to all of the Sell ignition coils e Disconnect the ignition coil leads from the wire harness e Connect the pocket tester x 1 to the ignition coil as shown Positive tester probe ignition coil terminal Negative tester probe ignition coil terminal email info motomatrix co uk 21 Manuals by Motomatrix www motomatrix co uk The Solution For Lost aded Keyp d IGNITION SYSTEM 50 500748 5007 S 6 Crankshaft position sensor resistance 8 Engine stop switch e Check the engine stop switch for continuity Refer to CHECKING THE SWITCHES e Disconnect the crankshaft position sensor coupler from the wire harness e Connect the pocket tester Q x 100 to the crankshaft position sensor coupler as shown Positive tester probe gray 1 i Pes 5 NS Negative tester probe black 2 Replace the right handlebar switch els the engine stop switch OK 500751 9 Neutral switch e Check the neutral switch for continuity B Refer to CHECKING THE SWITCHES els the neutral switch OK e Measure the crankshaft position sensor resistance p YES 5 Crankshaft position sensor resistance Replace the neutral 248 372Q at 20 C 68 F switch between gray and black 15 the crankshaft position sensor OK i YES 4 500752 10 Sidestand switch e Check the sidestand switch for continuity Refer to
25. ltage e 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 e Turn the main switch to e Measure the voltage DC 12 V of blue red 1 on the license light coupler wire harness side els the voltage within specification i YES This circuit is OK wiring circuit from the main switch to the license light coupler is faulty and must be repaired email info motomatrix co uk _29 A A A A AL pulam ME P o T Ev view pwp D ore 0 cya 3t EE AOR Bo CE ow mon els jns a Ee B Re fog v vba cuve Be 1 vice 69 AWB we we BA 1 ve A St email info motomatrix co uk gar 6 Solution For Lost Motorcycle Coded Keys 1 Main switch 2 A C magneto 8 Rectifier regulator 4 Fuse backup 5 Battery 6 Fuse main 7 Starter relay Starter motor 9 Fuse fuel injection Fuse ignition 11 Starting circuit cut off relay 12 Sidestand switch 3 Fuel pump ECU 15 I
26. n is distinguished in this manual by the following AN The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING 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 CAUTION 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 email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Motorcycle Coded Keys 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 CD 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 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 diagrams at the start of each removal
27. over 7 7 Throttle position sensor coupler Fuel hose return side exceptfor 03 Radiator fan motor relay Coolant reservoir tank hose CAL 64 Radiator fan motor lead 9 Throttle stop cable 15 Fuel pump 2 coupler 65 Left handlebar switch lead Speed sensor lead coupler Fuel pump 1 coupler 66 Main switch lead 17 Starter motor lead 67 Wire harness 2 9 DA 8 94017 42 3 4 email info motomatrix co uk _9 Manuals by Motomatrix www motomatrix co uk Th 333 1 lt lt ug Qe o 0 j5 co 5 2d 0 0 6 4 gt o Oo 0 c wo o 555556 LL LL O brown 2 poles blue 2 poles white 3 poles Rear brake light switch lead cou pler 82 Sidestand switch lead coupler 65 Neutral switch lead coupler 63 A C magneto lead coupler 6 Fuel hose co co ow Eas v 5 d Y N 9 uc 29 9 Do 5 5 D o oo o 220840 0 white 1 pole DA 8 94017 42 3 4 2 9 10 email info motomatrix co uk email info motomatrix co uk Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mot To the headlight Make sure not to drop the headlight sub wire har ness beneath the projection of the duct Check it when installing the side cowling Clamp the plastic locking tie to the cover 8 Place the coupl
28. under the fuel hose side of the vehicle Insert until it sets To the main switch lead coupler The clamp by the side of a hose comes below an attachment clamp email info motomatrix co uk 13 Manuals by Motomatrix www motomatrix co uk Th 1 Fuel pump assembly Direction of which is sufficient as the knob of a clip 2 Fuel tank drain hose D Air opening 3 Fuel tank breather hose except for CAL Install the breather hose without projecting canister 4 Clamp nipple out of the breather hose 5 Clip Install the clip with its tab pointed in the downward 6 Canister for CAL direction 7 Blance hose for CAL Install the clip with its tab pointed in the upward Canister hose for CAL direction Install the O ring with its lip pointed upward Install the roll over valve until it contacts with the fuel Pass the fuel tank drain hose and fuel tank breather tank s nipple hose through the clamp LI To injector There needs to be no crookedness in fuel tank drain hose and fuel tank breather hose between fuel tank s nipple and clamp SSS lt H ID UN o je om 1 1 1 1 1 1 Q4 7 e 7 vai Oo Si email info motomatrix co uk 14 Manuals by Motomatrix www motomatrix co uk The Solution For Lost Mot FUEL TANK EAS00040 PERIODIC CHECKS AND ADJUSTMENTS FUEL TANK Removing the fuel tank Remove the parts in the order listed Rider seat Ref
29. ution For Lost Mot d 5 anuals by Motomatrix www motoma CEB AL SBECIEICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Sandara Model code 5SLD USA except for CAL 5SLE CAL ENGINE SPECIFICATIONS Throttle bodies ID mark 5SL1 00 5510 5514 10 5SLE Throttle valve size 100 CHASSIS SPECIFICATIONS Item Standard Front tire Model manufacturer Pilot SPORT N MICHELIN D208 FJ DUNLOP Rear tire Model manufacturer Pilot SPORT B MICHELIN D208 AJ DUNLOP ELECTRICAL SPECIFICATIONS Ignition system CDI unit model manufacturer F8T816 MITSUBISHI Ignition coils Model manufacturer F6T549 MITSUBISHI Primary coil resistance 0 24 0 32 Q at 20 C 68 F Secondary coil resistance 5 0 6 8 kQ at 20 C 68 F email info motomatrix co uk 1 M Is by Motomatrix tomat k The Solution For Lost Mot d anuals by Motomatrix www motomatrix Soliton ged SPECT TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Thread Tightening torque torque Item Fastener 8 Q ty Remarks Oil cooler Bolt M20 63 6 3 46 Cylinder identification sensor Bolt M6 6 0 0 6 4 3 a email info motomatrix co uk 9 Manuals by Motomatrix www motomatrix co uk Th CABLE ROUTING 1 Right handlebar switch lead 2 Clutch cable 3 Immobilizer unit lead main switch lead and left han dlebar switch lead 4 Throttle cable return side 5 Throttle cable pu
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