Yamaha 2007 R6 Service
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COOLING SYSTEM 8-29 EAS27300 COOLING SYSTEM EAS27310 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 (RED) L/YL/B2 (RED)L/Y L/BR Br/LR Br/L LL
COOLING SYSTEM 8-30 3. Main switch 4. Ignition fuse 6. Main fuse 7. Battery 11.Engine ground 22.ECU (engine control unit) 42.Coolant temperature sensor 87.Radiator fan motor relay 88.Right radiator fan motor fuse 89.Left radiator fan motor fuse 90.Right radiator fan motor 91.Left radiator fan motor
COOLING SYSTEM 8-31 EAS27320 TROUBLESHOOTING NOTE: •Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank 3. Side cowlings NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check the fuses. (Main, ignition and radiator fan mo- tor) 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 main switch. Refer to “CHECKING THE SWITCHES” on page 8-81.Replace the main switch. 4. Check the radiator fan motors. Refer to “CHECKING THE RADIA- TOR FAN MOTORS” on page 8-96.Replace the radiator fan motor(s). 5. Check the radiator fan motor relay. Refer to “CHECKING THE RE- LAYS” on page 8-89.Replace the radiator fan motor relay. 6. Check the coolant temperature. Refer to “CHECKING THE COOL- ANT TEMPERATURE SENSOR” on page 8-97.Replace the coolant temperature sensor. 7. Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 8-29.Properly connect or repair the cooling sys- tem’s wiring. This circuit is OK.
FUEL INJECTION SYSTEM 8-33 EAS27330 FUEL INJECTION SYSTEM EAS27340 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 (RED) L/YL/B2 (RED)L/Y L/BR Br/LR Br/L LL
FUEL INJECTION SYSTEM 8-34 3. Main switch 4. Ignition fuse 5. Backup fuse (odometer and clock) 6. Main fuse 7. Battery 9. Fuel injection system fuse 11.Engine ground 12.ETV fuse 13.Relay unit 15.Fuel pump relay 16.Neutral switch 17.Sidestand switch 18.Fuel pump 20.Throttle position sensor (for throttle cable pulley) 21.Throttle position sensor (for throttle valves) 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 28.Primary injector #1 29.Primary injector #2 30.Primary injector #3 31.Primary injector #4 32.Secondary injector #1 33.Secondary injector #2 34.Secondary injector #3 35.Secondary injector #4 36.Throttle servo motor 37.Air induction system solenoid 38.EXUP servo motor 39.O 2 sensor 40.Crankshaft position sensor 41.Air temperature sensor 42.Coolant temperature sensor 43.Intake air pressure sensor 44.Atmospheric pressure sensor 45.Cylinder identification sensor 46.Speed sensor 47.Lean angle sensor 54.Multi-function meter 55.Engine trouble warning light 64.Engine stop switch
FUEL INJECTION SYSTEM 8-35 EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is stored in the memory of the ECU. •To inform the rider that the fuel injection system is not functioning, the engine trouble warning light flashes when the start switch is being pushed to start the engine. •If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro- priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat- ing the engine trouble warning light. •After the engine has been stopped, the lowest fault code number appears on the odometer/tripme- ter/fuel reserve tripmeter LCD. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is deleted. Engine trouble warning light indication and fuel injection system operation * The warning light flashes when any one of the conditions listed below is present and the start switch is pushed: Checking the engine trouble warning light The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to “ON” and it comes on while the start switch is being pushed. If the warning light does not come on under these conditions, the warning light (LED) may be defective.Warning light indica- tionECU operationFuel injection opera- tionVehicle operation Flashing*Warning provided when unable to start engineOperation stopped Cannot be operated Remains on Malfunction detectedOperated with substi- tute characteristics in accordance with the description of the mal- functionCan or cannot be oper- ated depending on the fault code 11: Cylinder identification sensor 30:Lean angle sensor (latch up detected) 12: Crankshaft position sensor 41:Lean angle sensor (open or short-circuit) 19:Sidestand switch (open circuit in the wire to the ECU)50:ECU internal malfunction (memory check error)
FUEL INJECTION SYSTEM 8-36 EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction. When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating, depending on the conditions. Self-Diagnostic Function table a b cc d a. Main switch “OFF” b. Main switch “ON” c. Engine trouble warning light offd. Engine trouble warning light on for 1.4 seconds Fault code No.Item SymptomAble/un- able to startAble/un- able to drive 11Cylinder identification sensorNo normal signals are received from the cylinder identification sensor when the engine is started or while the vehicle is being driv- en.Unable Able 12Crankshaft position sensorNo normal signals are received from the crankshaft position sen- sor.Unable Unable 13Intake air pressure sensor (open or short circuit)Intake air pressure sensor: open or short circuit detected.Able Able 14Intake air pressure sensor hose line (piping system)Intake air pressure sensor: hose system malfunction (clogged or detached hose).Able Able 15Throttle position sen- sor (for throttle valves) (open or short cir- cuit/loose connection)Throttle position sensor (for throt- tle valves): open or short circuit detected. Throttle position sensor (for throt- tle valves) coupler connection is loose.Able/Un- ableAble/Un- able 17EXUP servo motor circuit (open or short circuit)EXUP servo motor circuit: open or short circuit detected.Able Able
FUEL INJECTION SYSTEM 8-37 18EXUP servo motor (stuck)EXUP servo motor is stuck. Able Able 19Sidestand switch (open circuit in the wire to the ECU)Open circuit is detected in the in- put line from the sidestand switch to the ECU.Unable Unable 20Intake air pressure sensor or atmospher- ic pressure sensorWhen the main switch is turned to “ON”, the atmospheric pressure sensor voltage and intake air pres- sure sensor voltage differ greatly.Able Able 21Coolant temperature sensor (open or short circuit)Coolant temperature sensor: open or short circuit detected.Able Able 22Air temperature sen- sor (open or short circuit)Air temperature sensor: open or short circuit detected.Able Able 23Atmospheric pres- sure sensor (open or short circuit)Atmospheric pressure sensor: open or short circuit detected.Able Able 24O 2 sensorNo normal signal is received from the O2 sensor.Able Able 30 Lean angle sensorLatch up detected. No normal signal is received from the lean angle sensor.Unable Unable 33Cylinder-#1 ignition coil (open circuit)Primary lead of the cylinder-#1 ig- nition coil: open circuit detected.Able (depending on the number of faulty cylin- ders)Able (depending on the number of faulty cylin- ders) 34Cylinder-#2 ignition coil (open circuit)Primary lead of the cylinder-#2 ig- nition coil: open circuit detected.Able (depending on the number of faulty cylin- ders)Able (depending on the number of faulty cylin- ders) 35Cylinder-#3 ignition coil (open circuit)Primary lead of the cylinder-#3 ig- nition coil: open circuit detected.Able (depending on the number of faulty cylin- ders)Able (depending on the number of faulty cylin- ders) 36Cylinder-#4 ignition coil (open circuit)Primary lead of the cylinder-#4 ig- nition coil: open circuit detected.Able (depending on the number of faulty cylin- ders)Able (depending on the number of faulty cylin- ders) Fault code No.Item SymptomAble/un- able to startAble/un- able to drive