2007 Yamaha YZF-R6S Motorcycle Service Manual

YZF-R6T 5SL-28197-12 SUPPLEMENTARY SERVICE MANUAL LIT-11616-18-45 YZF-R6TC

YZF-R6T / YZF-R6TC SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. First edition, September 2004 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-11616-18-45 EAS00001 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R6T / YZF-R6TC. For complete service information procedures it is necessary to use this Sup- plementary Service Manual together with the following manual. YZF-R6R / YZF-R6SR / YZF-R6RC / YZF-R6SRC SERVICE MANUAL: LIT-11616-16-45 (5SL-28197-10) YZF-R6S / YZF-R6SC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-17-46 (5SL-28197-11)

EAS00030 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers 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 deal- ers and will appear in future editions of this manual where applicable. NOTE: • This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • 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! 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. WARNING CAUTION: NOTE:

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. 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”. 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. Sub-section titles appear in smaller print than the section title. To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. 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 sequentially.

EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols to indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points. Engine oil Gear oil Molybdenum-disulfide oil Wheel-bearing grease Lithium-soap-based grease Molybdenum-disulfide grease Symbols to in the exploded diagrams indicate the following. Apply locking agent (LOCTITE ® ) Replace the part

CONTENTS GENERAL INFORMATION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 5 CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 5 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PERIODIC CHECKS AND ADJUSTMENTS BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . 20 ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . 22 CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . 24 FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 26 FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . 36 CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 37 ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . 38 SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ELECTRICAL SYSTEM ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 YZF-R6T / YZF-R6TC WIRING DIAGRAM

GEN INFO 1 EAS00027 GENERAL INFORMATION SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. • For others, use part number starting with “90890-”. Tool No. Tool name / Function Illustration 90890-01423 YM-01423 Damper rod holder This tool is used to hold the damper rod assembly when loosening or tightening the damper rod assembly bolt. 90890-01434 YM-01434 Rod holder This tool is used to support the damper adjusting rod. 90890-01441 YM-01441 Fork spring compressor This tool is used to disassemble or assemble the front fork legs. 90890-01442 YM-01442 Fork seal driver This tool is used to install the front fork’s oil seal and dust seal. SPECIAL TOOLS

SPEC 2 SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Model code 5SLR (USA except for CAL) • • • 5SLS (CAL) Dimensions Overall length 2,045 mm (80.5 in) • • • Overall width 690 mm (27.2 in) • • • Overall height 1,105 mm (43.5 in) • • • Seat height 830 mm (32.7 in) • • • Wheelbase 1,385 mm (54.5 in) • • • Minimum ground clearance 145 mm (5.7 in) • • • Minimum turning radius 3,800 mm (149.6 in) • • • Weight Wet (with oil and a full fuel tank) 183 kg (404 lb) (USA except for CAL) • • • 184 kg (406 lb) (CAL) • • • Maximum load (except motorcycle) 192 kg (423 lb) (USA except for CAL) • • • 191 kg (421 lb) (CAL) • • • Item Standard Limit Throttle bodies Model (manufacturer) × quantity 40EIS (MIKUNI) × 4 • • • ID mark 5SLM 30 (5SLR), 5SLS 40 (5SLS) • • • GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS

SPEC 3 CHASSIS SPECIFICATIONS Item Standard Limit Frame Caster angle 24.5° • • • Trail 95 mm (3.74 in) • • • Front tire Size 120 / 70 ZR17 M / C (55W) • • • Model (manufacturer) Pilot POWER C (MICHELIN) • • • D218FM (DUNLOP) Rear tire Model (manufacturer) Pilot POWER (MICHELIN) • • • D218M (DUNLOP) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 290 kPa (2.9 kgf / cm 2 , 2.9 bar, 41.3 psi) • • • 90 ~ 192 kg (198 ~ 426 lb) 290 kPa (2.9 kgf / cm 2 , 2.9 bar, 41.3 psi) • • • (USA except for CAL) 90 ~ 191 kg (198 ~ 423 lb) (CAL) 290 kPa (2.9 kgf / cm 2 , 2.9 bar, 41.3 psi) • • • High-speed riding 290 kPa (2.9 kgf / cm 2 , 2.9 bar, 41.3 psi) • • • Front brakes Brake lever free play 6.7 ~ 18.1 mm (0.26 ~ 0.71 in) • • • Brake discs Diameter × thickness 310 × 4.5 mm (12.20 × 0.18 in) • • • Min. thickness • • • 4.0 mm (0.16 in) Master cylinder inside diameter 16 mm (0.63 in) • • • Rear brake Brake pedal freeplay 4.3 ~ 9.0 mm (0.17 ~ 0.35 in) • • • CHASSIS SPECIFICATIONS

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2007 Yamaha YZF-R6S Motorcycle Service Manual

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