Yamaha 2007 R6 Service

							ELECTRICAL COMPONENTS
8-88



 
 
 








 
 



 
 



 
 







Charging method using a variable-current 
(voltage) charger
a. Measure the open-circuit voltage prior to 
charging.
NOTE:
Voltage should be measured 30 minutes after 
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
NOTE:
Set the charging voltage at 16–17 V. If the set-
ting is lower, charging will be insufficient. If too 
high, the battery will be over-charged.
c. Make sure that the current is higher than the 
standard charging current written on the bat-
tery.
NOTE:
If the current is lower than the standard charging 
current written on the battery, set the charging 
voltage adjust dial at 20–24 V and monitor the 
amperage for 3–5 minutes to check the battery.
d. Adjust the voltage so that the current is at the 
standard charging level.
e. Set the time according to the charging time 
suitable for the open-circuit voltage.
f. If charging requires more than 5 hours, it is 
advisable to check the charging current after 
a lapse of 5 hours. If there is any change in 
the amperage, readjust the voltage to obtain 
the standard charging current.
g. Measure the battery open-circuit voltage after 
leaving the battery unused for more than 30 
minutes.
         



 
 
 








 
 



 
 



 
 







Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to 
charging.
NOTE:
Voltage should be measured 30 minutes after 
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
c. Make sure that the current is higher than the 
standard charging current written on the bat-
tery.
NOTE:
If the current is lower than the standard charging 
current written on the battery, this type of battery 
charger cannot charge the MF battery. A vari-
able voltage charger is recommended.
d. Charge the battery until the battery’s charg-
ing voltage is 15 V.
NOTE:
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after 
leaving the battery unused for more than 30 
minutes.
          
6. Install:
•Battery
•Battery band
7. Connect:
•Battery leads
(to the battery terminals)
CAUTION:
ECA13630
First, connect the positive battery lead “1”, 
and then the negative battery lead “2”.
8. Check:
•Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
•Battery terminals •Standard charging current is reached
Battery is good.
•Standard charging current is not reached
Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
1
2 
						

							ELECTRICAL COMPONENTS
8-89
10.Install:
•Fuel tank bracket
•Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS28040
CHECKING THE RELAYS
Check each switch for continuity with the pocket 
tester. If the continuity reading is incorrect, re-
place the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery 
(12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification → Replace.
Starter relay
1.
Relay unit (starting circuit cut-off relay)
Relay unit (fuel pump relay)
Headlight relay (on/off)
 
Recommended lubricant
Dielectric grease
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
R
B
RR
R/W R/
21
43
W L/
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
2. Negative battery terminal 
						

							ELECTRICAL COMPONENTS
8-90
Headlight relay (dimmer)
Radiator fan motor relay
ET2C01021
CHECKING THE TURN SIGNAL RELAY
1. Check:
•Turn signal relay input voltage
Out of specification → The wiring circuit from 
the main switch to the turn signal relay cou-
pler is faulty and must be repaired.



 
 
 








 
 



 
 



 
 



 



a. Connect the pocket tester (DC 20 V) to the 
turn signal relay terminal as shown.
b. Turn the main switch to “ON”.
c. Measure the turn signal relay input voltage.
          
2. Check:
•Turn signal relay output voltage
Out of specification → Replace.



 
 
 








 
 



 
 



 
 



 



a. Connect the pocket tester (DC 20 V) to the 
turn signal relay terminal as shown.
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
 
Turn signal relay input voltage
DC 12 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
brown “1”
•Negative tester probe →
ground
 
Turn signal relay output voltage
DC 12 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C 
						

							ELECTRICAL COMPONENTS
8-91
b. Turn the main switch to “ON”.
c. Measure the turn signal relay output voltage.
         
EAS28050
CHECKING THE RELAY UNIT (DIODE)
1. Check:
•Relay unit (diode)
Out of specification → Replace.
NOTE:
The pocket tester or the analog pocket tester 
readings are shown in the following table.



 
 
 








 
 



 
 



 
 



 



a. Disconnect the relay unit coupler from the 
wire harness.
b. Connect the pocket tester (Ω × 1) to the relay 
unit terminal as shown. •Positive tester probe →
brown/white “1”
•Negative tester probe →
ground
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
 
Continuity
Positive tester probe → sky blue 
“1”
Negative tester probe → 
black/yellow “2”
No continuity
Positive tester probe → 
black/yellow “2”
Negative tester probe → sky 
blue “1”
Continuity
Positive tester probe → sky blue 
“1”
Negative tester probe → 
blue/yellow “3”
No continuity
Positive tester probe → 
blue/yellow “3”
Negative tester probe → sky 
blue “1”
Continuity
Positive tester probe → sky blue 
“1”
Negative tester probe → sky 
blue/white “4”
No continuity
Positive tester probe → sky 
blue/white “4”
Negative tester probe → sky 
blue “1”
Continuity
Positive tester probe → 
blue/black “5”
Negative tester probe → 
blue/yellow “3”
No continuity
Positive tester probe → 
blue/yellow “3”
Negative tester probe → 
blue/black “5” 
						

							ELECTRICAL COMPONENTS
8-92
c. Check the relay unit (diode) for continuity.
d. Check the relay unit (diode) for no continuity.
         
EAS28100
CHECKING THE IGNITION COILS
The following procedure applies to all of the igni-
tion coils.
1. Check:
•Primary coil resistance
Out of specification → Replace.



 
 
 








 
 



 
 



 
 







a. Remove the ignition coil from the spark plug.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown.
c. Measure the primary coil resistance.
         
2. Check:
•Secondary coil resistance
Out of specification → Replace.



 
 
 








 
 



 
 



 
 







a. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.b. Measure the secondary coil resistance.
          
3. Check:
•Ignition spark gap
Out of specification → Replace.



 
 
 








 
 



 
 



 
 



 



a. Connect the ignition checker “1” as shown.
b. Turn the main switch to “ON” and engine stop 
switch to “”.
c. Measure the ignition spark gap “a”.
 
Primary coil resistance
1.19–1.61 Ω
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
red/black “1”
•Negative tester probe →
orange or gray/red or orange/green or 
gray/green “2”
 
Secondary coil resistance
8.5–11.5 kΩ
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Negative tester probe →
red/black “1”
•Positive tester probe →
spark plug terminal “2”
 
Minimum ignition spark gap
6.0 mm (0.24 in)
 
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
2. Ignition coil 
						

							ELECTRICAL COMPONENTS
8-93
d. Crank the engine by pushing the start switch 
“” and gradually increase the spark gap un-
til a misfire occurs.
         
EAS28120
CHECKING THE CRANKSHAFT POSITION 
SENSOR
1. Disconnect:
•Crankshaft position sensor coupler
(from the wire harness)
2. Check:
•Crankshaft position sensor resistance
Out of specification → Replace the crank-
shaft position sensor.



 
 
 








 
 



 
 



 
 







a. Connect the pocket tester (Ω × 100) to the 
crankshaft position sensor coupler as shown.
b. Measure the crankshaft position sensor re-
sistance.
         
EAS28130
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
•Lean angle sensor
(from the bracket)
2. Check:
•Lean angle sensor output voltage
Out of specification → Replace.



 
 
 








 
 



 
 



 
 



 



a. Connect the lean angle sensor coupler to the 
lean angle sensor.
b. Connect the pocket tester (DC 20 V) to the 
lean angle sensor coupler as shown.
c. Turn the main switch to “ON”.
d. Turn the lean angle sensor to 65°.
e. Measure the lean angle sensor output volt-
age.
          
ET2C01012
CHECKING THE STARTER MOTOR 
OPERATION
1. Check:
•Starter motor operation
Does not operate → Perform the electric 
starting system troubleshooting, starting with 
step 4.
Refer to “TROUBLESHOOTING” on page 
8-11.



 
 
 








 
 



 
 



 
 



 



a. Connect the positive battery terminal “1” and 
starter motor lead “2” with a jumper lead “3”.
WARNING
EWA13810
A wire that is used as a jumper lead must 
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may 
burn.
 
Crankshaft position sensor resis-
tance
248–372 Ω at 20 °C (68 °F)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
gray “1”
•Negative tester probe →
black “2”
Gy
B
1 2
 
Lean angle sensor output voltage
Less than 65°: 0.4–1.4 V
More than 65°: 3.7–4.4 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
yellow/green “1”
•Negative tester probe →
black/blue “2” 
						

							ELECTRICAL COMPONENTS
8-94
This check is likely to produce sparks, 
therefore, make sure no flammable gas or 
fluid is in the vicinity.
b. Check the starter motor operation.
         
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
•Stator coil coupler
(from the wire harness)
2. Check:
•Stator coil resistance
Out of specification → Replace the stator coil.



 
 
 








 
 



 
 



 
 







a. Connect the pocket tester (Ω × 1) to the stator 
coil coupler as shown.b. Measure the stator coil resistance.
          
EAS28170
CHECKING THE RECTIFIER/REGULATOR
1. Check:
•Charging voltage
Out of specification → Replace the rectifi-
er/regulator.



 
 
 








 
 



 
 



 
 



 



a. Set the engine tachometer to the cylinder-#1 
ignition coil.
b. Connect the pocket tester (DC 20 V) to the 
rectifier/regulator coupler as shown.
c. Start the engine and let it run at approximate-
ly 5000 r/min.
d. Measure the charging voltage.
          
 
Stator coil resistance
0.12–0.18 Ω at 20 °C (68 °F)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
white “1”
•Negative tester probe →
white “2”
•Positive tester probe →
white “1”
•Negative tester probe →
white “3”
•Positive tester probe →
white “2”
•Negative tester probe →
white “3”
 
Charging voltage
14 V at 5000 r/min
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
red “1”
•Negative tester probe →
black “2”
W
WW
123
B R WW
W
2 1 
						

							ELECTRICAL COMPONENTS
8-95
EAS28180
CHECKING THE HORN
1. Check:
•Horn resistance
Out of specification → Replace.



 
 
 








 
 



 
 



 
 







a. Disconnect the horn leads from the horn ter-
minals.
b. Connect the pocket tester (Ω × 1) to the horn 
terminals.
c. Measure the horn resistance.
         
2. Check:
•Horn sound
Faulty sound → Adjust or replace.



 
 
 








 
 



 
 



 
 







a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or “b” 
until the horn sound is obtained.
         
EAS28190
CHECKING THE OIL LEVEL SWITCH
1. Drain:
•Engine oil
2. Remove:
•Oil level switch
(from the oil pan)
3. Check:
•Oil level switch resistance
Out of specification → Replace the oil level 
switch.



 
 
 








 
 



 
 



 
 



 



a. Connect the pocket tester (Ω × 100) to the oil 
level switch terminal as shown.
b. Measure the oil level switch resistance.
          
EAS28230
CHECKING THE FUEL SENDER
1. Disconnect:
•Fuel pump coupler
 
Coil resistance
1.15–1.25 Ω at 20 °C (68 °F)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
horn terminal “1”
•Negative tester probe →
horn terminal “2”
1
2
ab
 
Oil level switch resistance
Maximum level position
484–536 Ω
Minimum level position
114–126 Ω
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Minimum level position “A”
•Positive tester probe →
connector (white) “1”
•Negative tester probe →
body earth “2”
Maximum level position “B”
•Positive tester probe →
connector (white) “1”
•Negative tester probe →
body earth “2” 
						

							ELECTRICAL COMPONENTS
8-96
•Fuel sender coupler
(from the wire harness)
2. Remove:
•Fuel tank
3. Remove:
•Fuel pump
(from the fuel tank)
4. Check:
•Fuel sender resistance



 
 
 








 
 



 
 



 
 







a. Connect the pocket tester (Ω × 1) to the fuel 
sender terminal as shown.
b. Measure the fuel sender resistance.
         
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
•Speed sensor output voltage
Out of specification → Replace.



 
 
 








 
 



 
 



 
 







a. Connect the pocket tester (DC 20 V) to the 
speed sensor coupler (wire harness side) as 
shown.b. Turn the main switch to “ON”.
c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage of white/yellow and 
black/blue. With each full rotation of the rear 
wheel, the voltage reading should cycle from 
0.6 V to 4.8 V to 0.6 V to 4.8 V.
          
EAS28250
CHECKING THE RADIATOR FAN MOTORS
1. Check:
•Radiator fan motor
Faulty/rough movement → Replace.



 
 
 








 
 



 
 



 
 



 



a. Disconnect the radiator fan motor coupler 
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
c. Measure the radiator fan motor movement.
          
 
Fuel sender resistance
900–1050 Ω at 25 °C (77 °F)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
green/white “1”
•Negative tester probe →
black “2”
 
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
white/yellow “1”
•Negative tester probe →
black/blue “2”
•Positive tester probe →
blue “1”
•Negative tester probe →
black “2”
L P
B/
W/Y
L
1
2
B/W
O/R 
						

							ELECTRICAL COMPONENTS
8-97
EAS28260
CHECKING THE COOLANT TEMPERATURE 
SENSOR
1. Remove:
•Coolant temperature sensor
Refer to “THERMOSTAT” on page 6-7.
WARNING
EWA14130
Handle the coolant temperature sensor 
with special care.
Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
2. Check:
•Coolant temperature sensor resistance
Out of specification → Replace.



 
 
 








 
 



 
 



 
 







a. Connect the pocket tester (Ω × 100) to the 
coolant temperature sensor as shown.
b. Immerse the coolant temperature sensor “1” 
in a container filled with coolant “2”.
NOTE:
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer “3” in the coolant.
d. Slowly heat the coolant, then let it cool down 
to the specified temperature.
e. Measure the coolant temperature sensor re-
sistance.
          
EAS28300
CHECKING THE THROTTLE POSITION 
SENSOR (FOR THROTTLE VALVES)
1. Remove:
•Throttle position sensor (for throttle valves)
(from the throttle body)
2. Check:
•Throttle position sensor (for throttle valves) 
maximum resistance
Out of specification → Replace the throttle 
position sensor (for throttle valves).



 
 
 








 
 



 
 



 
 



 



a. Connect the pocket tester (Ω × 1k) to the 
throttle position sensor (for throttle valves) 
terminal as shown.
b. Measure the throttle position sensor (for 
throttle valves) maximum resistance.
          
3. Install:
•Throttle position sensor (for throttle valves)
 
Resistance at 80 °C
290–354 Ω
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C 
Resistance
2.0–3.0 kΩ
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
•Positive tester probe →
blue “1”
•Negative tester probe →
black/blue “2”
B/LG
L L
2
1