Yamaha 2007 R6 Service
Have a look at the manual Yamaha 2007 R6 Service online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
8 ELECTRICAL SYSTEM IGNITION SYSTEM......................................................................................... 8-1 CIRCUIT DIAGRAM .................................................................................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION....................... 8-3 TROUBLESHOOTING .............................................................................. 8-4 ELECTRIC STARTING SYSTEM.................................................................... 8-7 CIRCUIT DIAGRAM .................................................................................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-9 TROUBLESHOOTING ............................................................................ 8-11 CHARGING SYSTEM................................................................................... 8-13 CIRCUIT DIAGRAM ................................................................................ 8-13 TROUBLESHOOTING ............................................................................ 8-15 LIGHTING SYSTEM...................................................................................... 8-17 CIRCUIT DIAGRAM ................................................................................ 8-17 TROUBLESHOOTING ............................................................................ 8-19 SIGNALING SYSTEM................................................................................... 8-21 CIRCUIT DIAGRAM ................................................................................ 8-21 TROUBLESHOOTING ............................................................................ 8-23 COOLING SYSTEM...................................................................................... 8-29 CIRCUIT DIAGRAM ................................................................................ 8-29 TROUBLESHOOTING ............................................................................ 8-31 FUEL INJECTION SYSTEM......................................................................... 8-33 CIRCUIT DIAGRAM ................................................................................ 8-33 ECU SELF-DIAGNOSTIC FUNCTION.................................................... 8-35 SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 8-36 TROUBLESHOOTING METHOD............................................................ 8-39 DIAGNOSTIC MODE .............................................................................. 8-40 TROUBLESHOOTING DETAILS ............................................................ 8-48 FUEL PUMP SYSTEM.................................................................................. 8-73 CIRCUIT DIAGRAM ................................................................................ 8-73 TROUBLESHOOTING ............................................................................ 8-75
ELECTRICAL COMPONENTS..................................................................... 8-77 CHECKING THE SWITCHES ................................................................. 8-81 CHECKING THE BULBS AND BULB SOCKETS ................................... 8-84 CHECKING THE FUSES ........................................................................ 8-85 CHECKING AND CHARGING THE BATTERY....................................... 8-86 CHECKING THE RELAYS ...................................................................... 8-89 CHECKING THE TURN SIGNAL RELAY ............................................... 8-90 CHECKING THE RELAY UNIT (DIODE) ................................................ 8-91 CHECKING THE IGNITION COILS ........................................................ 8-92 CHECKING THE CRANKSHAFT POSITION SENSOR ......................... 8-93 CHECKING THE LEAN ANGLE SENSOR ............................................. 8-93 CHECKING THE STARTER MOTOR OPERATION ............................... 8-93 CHECKING THE STATOR COIL ............................................................ 8-94 CHECKING THE RECTIFIER/REGULATOR .......................................... 8-94 CHECKING THE HORN.......................................................................... 8-95 CHECKING THE OIL LEVEL SWITCH ................................................... 8-95 CHECKING THE FUEL SENDER ........................................................... 8-95 CHECKING THE SPEED SENSOR ........................................................ 8-96 CHECKING THE RADIATOR FAN MOTORS......................................... 8-96 CHECKING THE COOLANT TEMPERATURE SENSOR ...................... 8-97 CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE VALVES) .................................................................. 8-97 CHECKING THE THROTTLE POSITION SENSOR (FOR THROTTLE CABLE PULLEY) ...................................................... 8-98 CHECKING THE FUEL PUMP................................................................ 8-98 CHECKING THE AIR INDUCTION SYSTEM SOLENOID ...................... 8-99 CHECKING THE ATMOSPHERIC PRESSURE SENSOR ..................... 8-99 CHECKING THE CYLINDER IDENTIFICATION SENSOR .................. 8-100 CHECKING THE INTAKE AIR PRESSURE SENSOR ......................... 8-100 CHECKING THE AIR TEMPERATURE SENSOR ................................ 8-100
IGNITION SYSTEM 8-1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM Gy B Gy B/L B BL/BB ON OFF W W G/Y L/W R/W R/BB Br B L B LR RR RR/W L/WYL/RB Y L B Br YB BB R/LB G/W BrGRG/Y2R/W Ch ChB B B/L Y/GLP B/WO/R W B/LL/Y DgB L B/L W/Y L B/LW/B R/YB/GY/B2R/Y Ch ChB B Dg DgB BO BB B B B B/G B/YB Y Gy/R B/GB B/YBL/R L/RB Y/B1 B/W Y/L B/R R/G BrG/W L/W2Sb/W B/YDg Ch L B/L W/RL W B/LG/W O/G R/LR/BR/LL/BR/LW/L R/LG/BR/LO/BR/LSb/WR/LBr/B R/LBr/Y Gy/GBr/R R/W Br/R Br/R Br/W Br/W O O C C C C B B A B D D D CD A A B E C CBr/B FF F F D D DD C CF C O/G O/GGy/GGy/R Gy/RGy/G R/B R/B Lg/RY/BR/BR/BR/B R/BR/BR/B G/Y2Lg/R W/R W/RW/L W/L R/W R/W R/W Y/B2 B3B3BB L W/RB/R B/G LB/L B/LB/RB/G B/RB/G (BLACK)(BLACK) (BLACK) (GRAY) (BLACK)(GRAY) (GRAY) (GRAY)(GRAY) (GRAY) (GRAY) (GRAY) (GRAY) (GRAY)(BLACK) (BLACK) (BLACK) (BLACK)Y/R Lg/RY/R R/LR/LR/LR/LR/LR/LR/L L/BG/BR/B R/BG/BL/B R/LD R/LR/LR/LR/L Br/BBr/YSb/WO/B O/BSb/WBr/Y L L L YYB B B Y RLL BB B B BB L L LL BB LG L L L P P P B B B B P B/L B/L B/Y B/LB/L B/LGy Br WW Ch Ch Ch Ch Ch Br Br Y YB B Br Br Dg Dg DgDg Dg Dg Ch GyY/G LB/L B/L B/L B/L B/L B/L B/L B R R RR R B WWW WWW RR RR R R B B B B SbSbSbSb L/BL/BR/L B/Y Y/G W/Y W/B P/W P/W P/W B/W Y/B1L/W2 G/W L/W2L/W2 Sb/WSb/WSb/WY/B1 B/W R/WA A A A A AAAB BR/GG/W R/W L/W2 R/B G/Y B/Y R/Y B/YB/G L/R L/R L/RL/R L/R L/Y2 L/RL/R L/W Br/WBr/W G/WR/GB/R W/B W/YW/BP/WG/W G/W PB/LLB/LLP/W R/LR/BR/B L/YY/BY/LB/YP/B Lg P/B R LLLG LgR/WL/WW W W/R W/R B/L B/L R/L B/L B/L G L L (BLACK) (BLACK) Dg Y Br/WR/Y ChL/YBB/YBr (BLUE) (DARK GREEN) (BLUE)L/Y R/BL/W R/W L/W3 L/W2 R/W Sb/W L/Y2 Br/WBr DgB (BLACK) (BLACK) (GRAY) (GRAY) (BLACK)(BLACK) (BLACK) (BLACK)(BLACK) (DARK GREEN) (BLACK)(BLACK) Dg Y Br/WR/Y ChL/Y2BB/YBr (BROWN) (BLACK) (BLACK) (BLACK)(BLACK) (BLACK) (BLUE)(BLUE) (BLUE) (BLUE) (BLUE) (BLUE)(DARK BLUE) (BLACK) (BROWN) R/W R/G Br/L Br/L L/YL/B2 R/W G/YL/W2R/WR/BBBr WWW Br/LBr/L BrR/Y R/YR/Y R/W B/GB/GB/Y G/Y2 Y/B2Y/B2 Br/GBr/G Br/G R/YR/Y B L B L LL B/LR/L R/LL/W2R/B L/W R Sb/WB/Y Sb L/YL/BR/W L/W3 L/Y2 Gy/G Y/B1 Gy/R B BP/B W/YRO O/GBr/RR/L Lg B/Y L/B2Y/R G/Y2 Y/B2 Lg/R Lg L/W R/B L/B G/B L/YO/BB3 B3R/WY/GW/L Br/YSb/W Br/B LW B/G B/LB/LY/L G/W R/W P/W Br/W W/RW/RW/BGB/RGyLL PB/L R/LB L P/BGy/G2 Gy/G2 B W WWW Gy/G2 B Br/WB/L BR WWW L/B2 L/R L/R BY/L Y/L 24 25 26 27 23 2223 23 23 36 37 3835 34 33 32 31 30 29 28 46 42 4139 40 4320 21 44 45 60 60 59 58 57 56 55 54 61 76 75 74 7366 71 67 63 62 64 65 81 70 72 77 78 79 80 8268 6952 51 50 49 48 17 1615 13 14 12 6 2 5 4 31 89 7 10 11 85 83 84 90 88 89 9187 8618 19 53 47 W/L R/L R/L Sb/WSb/W W/L Sb Sb (BLACK) (BLACK) Br/Y Br/BBr/Y Br/B Gy/G2G/WB/W Y R/Y L/R B/WL/R Sb/W G/WSb/W DgDg Ch Ch BY B YB2 YB2R/W R/Y Br HEADLIGHT SUB-WIRE-HARNESS HEADLIGHT SUB- WIRE-HARNESS WIRE HARNESS B WIRE HARNESS SUB- WIRE-HARNESS1C WIRE HARNESS SUB- WIRE-HARNESS2D WIRE HARNESS NEUTRAL SWITCH SUB -WIRE-HARNESSE WIRE HARNESS SUB-WIRE-HARNESS3F WIRE HARNESS A W/BBr/R R/W O/GR/B B/LGy/R W/BB/LGy/R Gy/G O/GGy/G O Br/R R/WO LR/BL L/BB/LR/LR/B G/BP/WO/BLP L/BB/LR/BG/BP/WLR/LO/BP L/W2Br/WR/GY/L B/LB/RY/B1 Y/B1 Br/WR/G B/L Y/LWL/W2 LL (RED) L/YL/B2 (RED)L/Y L/BR Br/LR Br/L
IGNITION SYSTEM 8-2 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 13.Relay unit 16.Neutral switch 17.Sidestand switch 22.ECU (engine control unit) 23.Spark plug 24.Cylinder-#1 ignition coil 25.Cylinder-#2 ignition coil 26.Cylinder-#3 ignition coil 27.Cylinder-#4 ignition coil 40.Crankshaft position sensor 47.Lean angle sensor 64.Engine stop switch
IGNITION SYSTEM 8-3 ET2C01023 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark. However, the engine continues to run under the following conditions: •The transmission is in gear (the neutral switch circuit is open) and the sidestand is up (the sidestand switch circuit is closed). •The transmission is in neutral (the neutral switch circuit is closed) and the sidestand is down (the sid- estand switch circuit is open). 1 4 5 1012 11 9 7 2 6 3 8 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10. Relay unit (diode) 11. Neutral switch 12. Engine ground
IGNITION SYSTEM 8-4 EAS27150 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: •Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Air filter case 4. Canister (for California only) 5. Side cowlings 6. Bottom cowlings NG → OK ↓ NG → OK ↓ NG → OK ↓ OK → NG ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check the fuses. (Main and ignition) Refer to “CHECKING THE FUS- ES” on page 8-85.Replace the fuse(s). 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-86.•Clean the battery terminals. •Recharge or replace the battery. 3. Check the spark plugs. Refer to “CHECKING THE SPARK PLUGS” on page 3-8.Re-gap or replace the spark plug(s). 4. Check the ignition spark gap. Refer to “CHECKING THE IGNI- TION COILS” on page 8-92.Ignition system is OK. 5. Check the ignition coils. Refer to “CHECKING THE IGNI- TION COILS” on page 8-92.Replace the ignition coil(s). 6. Check the crankshaft position sen- sor. Refer to “CHECKING THE CRANK- SHAFT POSITION SENSOR” on page 8-93.Replace the crankshaft position sensor. 7. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-81.Replace the main switch.
IGNITION SYSTEM 8-5 NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 8. Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 8-81.Replace the right handlebar switch. 9. Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 8-81.Replace the neutral switch. 10.Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-81.Replace the sidestand switch. 11.Check the relay unit (diode). Refer to “CHECKING THE RELAY UNIT (DIODE)” on page 8-91.Replace the relay unit. 12.Check the lean angle sensor. Refer to “CHECKING THE LEAN ANGLE SENSOR” on page 8-93.Replace the lean angle sensor. 13.Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-1.Properly connect or repair the ignition sys- tem’s wiring. Replace the ECU.
ELECTRIC STARTING SYSTEM 8-7 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM B BL/BB ON OFF WW G/Y L/W R/W R/BB Br B L B L R RR RR/W L/W YL/RBY L B Br Y B B B R/L BG/W BrGR G/Y2R/W Ch ChB B DgB R/YB/GY/B2R/Y Ch ChB B DgL L Dg B B BBB B B B/G B/Y B YB/GBB/YB L/R L/R B B/WR/GBrG/WB/YDg Ch L A E (BLACK) (GRAY) (GRAY) L Y Y B B B Y R LL B B BB BB BB BBBB B/Y Br WW Ch Ch ChCh Ch Br Br Y Y B B Br Br Dg Dg DgDg Dg DgCh B RRR R R B WWWWWWR RRRR RB BBB Sb Sb SbSbL/BL/BR/LB/Y G/W R/W A A A A A A AA BBR/GG/W R/WL/W2R/B G/Y B/YR/Y B/YB/GL/RL/R L/RL/R L/R L/Y2 L/RL/R L/W Br/WBr/WG/WR/GB/R R/L (BLACK) Dg YBr/WR/YChL/YBB/YBr (BLUE) (DARK GREEN) (BLUE) L/Y R/BL/W R/W L/W3 L/W2R/W Sb/W L/Y2 Br/WBr DgB (BLACK) (BLACK) (GRAY) (GRAY) (BLACK) Dg YBr/WR/YChL/Y2BB/YBr (BROWN) (BLACK) (BLACK) (BLACK)(BLACK) (BLACK) (BLUE)(BLUE) (BLUE) (BLUE) (BLUE) (BLUE) (BLACK) (BROWN) R/W R/GBr/L Br/L L/YL/B2(RED) L/YL/B2(RED)L/Y L/B R/W G/YL/W2R/WR/BBBr WWW Br/L Br/L Br R/YR/Y R/YR/W B/G B/G B/Y G/Y2Y/B2 Y/B2 Br/G Br/GBr/G R/Y R/Y B L B L LL R/LL/W2R/B L/WRSb/WB/Y SbL/YL/BR/WL/W3 L/Y2 WWW B BR WWW R Br/LR Br/L L/RL/R60 60 59 58 57 56 55 54 61 76757473 66 71 67 63626465 81 70 72 77787980 82 6869 52 51 50 4948 1716 151314 12 62 5 4 3 1 8 97 10 11 85 83 84 90 8889 91 87 86 18 53 W/LR/L R/LSb/WSb/WW/LSb Sb(BLACK) (BLACK) Br/Y Br/BBr/Y Br/B SUB- WIRE-HARNESS2 D WIRE HARNESSNEUTRAL SWITCH SUB -WIRE-HARNESS E WIRE HARNESSSUB-WIRE-HARNESS3 F WIRE HARNESSL/B B/LR/LR/B G/B P/WO/BLPL/BB/LR/BG/B P/WL R/LO/BP