Yamaha YZF-R6 (2004), YZF-R6S (2004) Supplementary Service Manual

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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 Supplemen­tary 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

All rights reserved.

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 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.

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.

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 mo­torcycle.

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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12

4

8

3

5

6

7

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.

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22

1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GEN

INFO

SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

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

3

Periodic checks and adjustments

4

Chassis

5

Engine

6

Cooling system

7

Fuel injection system

8

Electrical system

9

Troubleshooting

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 indi­cate 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 indi­cate 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

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

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

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–2–

TIGHTENING TORQUES

SPEC

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Thread

’

Tightening torque

Item

Fastener

size

Qty

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

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–3–

CABLE ROUTING

SPEC

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 pull-

ing 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.

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 (pull side)
6 Front brake hoses
7 Throttle cables
8 Joint
9 Under bracket

CABLE ROUTING

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–4–

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 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 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.

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–5–

CABLE ROUTING

SPEC

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
8 Hose clamp assembly
9 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.

D Pass the clutch cable inside of the coolant reservoir

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 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.

a

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