R6 YEC Tech Info
Contents
1. hon EN GET ESO PIL BE BLACK BLACK BLACK BLACK HAN HARNESS WAE SUB LE4D 3 MAIN HARNESS WIRE SUB LEAD 2 MAIN HARNESS WIRE SUB LEAD 1 len 1 RI be eee ee RB RB IEE No COMPONENTS Su B Ltd Or 1 BTRY al 5 Os LACK 2 WIRE MINUS LEAD i 3 ACM2. TIP Regarding Assembly 1 Remove grease from the taper surfaces of both rotor and crank before assembling them 2 Apply engine oil on the thread and flange of mounting bolts before using them 2 Tightening torque 70 Tightening torque _ 29 21 Wire Harness Set 13S F2590 71 Parts List PART No PART NAME 135 82590 71 WIRE HARNESS ASSY 5GF 83976 00 SW HANDLE 1 14B 83976 70 SW HANDLE 1 2C0 2128A 70 BRKT REGULATOR 1 2C0 82509 70 WIRE SUB LEAD 4C8 82188 70 RESISTOR ASSY 90480 13003 GROMMET 90560 06201 SPACER 90111 06051 BOLT HEX SOCKET BUTTON 92907 06200 WASHER PLAIN o x REMARKS PIT ROAD LIMITER MAP SELECT Linked to wire harness N gt HK PO MO a Aa Aa sch 1 So CH NOTICE e Do not remove the AC generator but leave it to function Use on the battery alone will make the machine unable to run in a short time e wire harness will not function if it is not assembled with the ECU 2C0 8591A 90 of the kit The combination of this wire harness and ECU cannot be used with 07 models e Map select switches Map 1 and Map 2 of the YMS Comp FUEL NOTICE When switching to Map 1 or Map 2 using Map Select while riding check that proper riding is possible even when using either map e You can use Map Select and P
3. ice 4 STARTER RELAY kal tL jus d 5 STARTER MOTOR I SC IG2 1 R ie Gaa 6 Y 7 REC REGU l l 9 RELAY ASSY 1 10 1 1 11 IG COIL 1 Wy Ist west 106 ora OorG 2 I LACK 12 IG COIL 2 LT M84 2 I 13 IG COIL 3 i pe rt EE zm 14 IG COIL 4 3 15 MAIN FUSE 1 Bb ET 1 I i64 lag oan evel B 16 FUSE ETV I T 17 1 H 18 FUSE IGNITION ram we 1 oo 19 pb RST l EE 20 Ss E Wit E 21 Goes i r 4 Lj FWE2 22 iud MIO Su se 1 1 23 p 6189 0933 1 I ue per GRAY a 24 SW HANDLE R t C 25 FR STOP SW RUB 1 1 Ee BLACK L GA Je 26 6189 0934Dg 2 2 es G3 mr 27 G TP2 L4 28 nd vert TC 1 eri ju 29 FUEL PUMP ux as 30 METER una passen 31 INJECTOR 11 Ho Basa 32 INJECTOR 12 Pee 1 33 INJECTOR 13 8 3 EIS EE Jo E 34 14 00 BLACK un m 4 35 INJECTOR 21 TACHO e I I ries 36 INJECTOR 22 I RD eee 37 INJECTOR 23 Beleg ac qu emm BLACK BLACK 1 I Jaen s GRAY D INJECTOR 24 i I _ _ bon 1 FUEL I 1 40 tee o eer 1 x GA 1 Ima 41 3 OIL SEI l I B SGND1 23 Je
4. 47 30 Front Fork Spring ow 51 31 Steering Damper Stay Set 2 0 3495 80 57 32 Seat Cushion 13S 24713 70 58 33 Front Spare Wheel Assembly 2 0 25100 70 59 34 Rear Spare Wheel Assembly 260 25300 70 60 35 Throttle Set 260 6300 70 61 36 Throttle SeE 139 CO300 70 ee 62 3 Tightening Torque List 4 YZF R6 Wiring Diagram 1 Engine Specifications Spec SSP STK STD Displacement 599 cm 599 cm 599 cm Bore Storke 67 0 x 42 5 mm 67 0 x 42 5 mm 67 0 x 42 5 mm Maximum engine speed limiter controlled speed 15800 rpm 15800 rpm 15800 rpm Compression ratio recommended value 14 5 1 Depend of head gasket thickness and cylinder head surface grinding 13 7 1 Depending on the thickness of the head gasket 13 2 1 Valve timing event angle 110 105 105 115 110 110 Squish height minimum 0 60 mm 0 60 mm 0 70 mm Clearance between valve and piston minimum 1 05 mm ATDC 12 1 05 mm ATDC 12 1 15 mm ATDC 12 1 62 mm BTDC 12 1 62 mm BTDC 12 1 80 mm BTDC 12 valve tappet c
5. 4 42 H a Eum whe i SE al NEUTRAL sl I l 45 1 t I u24 Jae Be Gas la 28 1 1 1 LLL TACHO 47 J SHIFT 48 VTHM 49 m 1 1 ME 50 a 1 H 1 1 51 52 X af di 1 ane 5 u O 53 ET m BLACK 54 OIL LEVEL GAUGE d DARK GREEN haw 55 SS AMP 1 174374 4 1 Car 56 gt 1 1 1 57 S s SS me CD PW Pw 58 1 DARKBLUE T c Lia 50 I TURN 1 HI BEAM 54618958970 jai S us I NER pac HHA H Ex par i sud O aia 61 THROTTLE MOTOR Dia o mg Rei m 5 55 C ti mi i rime e 62 M P PA EXP WR i Se GA SENSOREEANARGIE 1 TURN R 6189 0970 MY 15 RFR A E poe 65 CRANK SHAFT SENSOR amp P ME Rd If ILLUMINATION I I BE LENG cone 1 66 vi un EDU I 1 CEDERE d 67 AIR TEMP SENSOR Se iQ qip I 68 WATER TEMP SENSOR 1 NU 69 PRESSURE SENSOR Pb I 1 L L DAOU 70 PRESSURE SENSOR Pa KC EES B iex 71 SHAFT SENSOR SEET Ke 19 e 72 SPEED SENSOR Eif E Eil O n h 4 73 E G EARTH MARK EXPLANATION CE d 74 STOP SW En Ter 75 _ SELECT S
6. To be tightened Part Name Screw dia Tightening Remarks x torque pitch kgf m HANDLE 91314 08030 BOLT 8 1 25 23 28 2 3 2 8 CROWN SOCKET OUTER TUBE HEAD HANDLE 90170 28419 NUT HEX M28x1 0 100 125 CROWN amp AGON 10 2 12 7 STEERING SHAFT HANDLE amp 91314 08030 BOLT 8 x 1 25 28 35 HEXAGON 2 8 3 6 OUTER TUBE SOCKET HEAD STEERING 90179 30691 NUT M30x1 0 12 15 SHAFT and Bees HINGNUT OUTER TUBE amp 91314 08030 BOLT M8x1 25 20 25 HEXAGON 2 0 2 5 UNDER SOCKET BRACKET HEAD E G BRACKET 95024 10040 BOLT M10x 1 25 35 45 FLANGE 3 6 4 6 FRONT SMALL HEAD E G BRACKET 90105 12228 BOLT M12 x 1 25 REAR UPPER FLANGE 90179 12248 NUT M12 1 25 58 70 5 9 7 1 E G BRACKET 90105 12228 BOLT M12 x 1 25 REAR UNDER FEANSE 90179 12248 NUT M12 1 25 58 70 5 9 7 1 MAIN FRAME amp 90149 10002 SCREW M10 x 1 25 33 40 REAR FRAME 3 3 4 1 PIVOT SHAFT amp 2C0 22141 SHAFT M32x1 5 12 19 FRAME 10 PIVOT 12 2 1 9 ARM RELAY 1 90109 10017 BOLT M10 x 1 25 SCREW IN FROM THE LEFT SIDE 95602 10200 NUT U M10 x 1 25 31 49 FLANGE 3 2 5 ARM RELAY 1 90109 12010 BOLT M12 x 1 25 SCREW IN FROM THE SARME LEFT SIDE 90185 12119 NUT SELF M12x 1 25 31 49 LOCKING 3 2 5 71 To be tightened ARM 1 amp REAR ARM 90109 12010 Part Name x pitch M12 x 1 25 Screw
7. 54 9 Press the rod downwards before adjusting the oil level Oil level in load state With the spring removed and the outer tube rod lowered 140mm from the top of the outer tube 10 Reassemble the parts after oil level adjustment by following the disassembly procedure in reverse Tightening torque 20N m 55 References Front and rear load changes and front and rear suspension movement in different scenarios Accelerating Load change The wider the throttle is opened the more the load is concentrated on the rear Front fork Reaches nearly maximum extended stroke Rear cushion Up to 20 to 30mm stroke displacement depending on conditions Braking Load change The harder the brake is applied the more the load is concentrated on the front Front fork Displaces until stroke has almost bottomed Rear cushion Reaches nearly maximum extended stroke Cornering Load change Increases the load on the front fork and rear cushion on both sides Front fork Up to 30 to 90mm stroke displacement depending on the size of the corner Rear cushion Up to 25 to 40mm stroke displacement depend ing on conditions 56 31 Steering Damper Stay Set 2C0 C3495 80 Parts List PART No 2C0 23495 80 PART NAME STAY DAMPER x REMARKS 91317 06025 BOLT HEX SOCKET HEAD 2C0 23488 80 SPACER 91317 08110 BOLT HEX SOCKET HEAD
8. Make sure that the pinion and wheel gear are combined for use according to the chart plan 22 YZF R6 Speed List Engine speed rpm 16000 Tire radius mm 315 perimeter m 1 979 Primary reduction ratio 41 85 2 073 e Values in the speed table may vary slightly according to tire manufacturer and size Select a The number of teeth P gt ter referring to the value the speed table reduction ratio Sprocket Speed km h 17 Mission Maintenance Set 2C0 A7000 70 Parts List PART No 90387 250R3 PART NAME COLLAR o x REMARKS 90209 21332 WASHER O w 93440 25186 CIRCLIP eo 90387 21003 COLLAR 90209 22352 WASHER 90209 21351 WASHER 90387 28011 COLLAR 90209 25011 WASHER GO O O 93440 28184 CIRCLIP 90387 25015 COLLAR 90214 25004 WASHER CLAW 90214 25003 WASHER CLAW 90387 21004 COLLAR 93102 35017 SEAL OIL 93440 52014 CIRCLIP 90201 20278 WASHER PLAIN 93306 20464 BRG 93306 20464 BRG 24 O O O 25 Transmission Assembly Th
9. is removed Parts List PART No PART NAME REMARKS 551 14821 70 PLATE 2 2 2 93608 16M16 PIN DOWEL 4 3 90336 10020 PLUG TAPER Installation 1 Remove the hose attached to the cylinder head cover and the air cut off valve assembly accompanying the hose Remove the cap fitted to the hose and remove the reed valve and plate from the inside Install the plate 5SL 1482L 70 in replacement of the cap Apply liquid gasket to the plate Remove the cylinder head cover and the four collars fitted to the cover Install the PIN 93608 16M16 After removing the hose connected to the air cleaner case from the air cut valve assembly open the upper case of the air cleaner case and insert the PLUG 90336 10020 into the hole where the hose was connected 13 STD A C ASSY KIT Insertion direction A C ASSY 14 13 Clutch Spring Set 2CO A6330 70 Parts List PARTNo PARTNAME QTY REMARKS 4 2 0 16334 70 SPRING CLUTCH 2 6 Identifying color Green The clutch spring should have a bigger mounting load than standard AR EER 45 14 Friction Plate Set 2CO A6321 70 Parts List PARTNo PARTNAME QTY REMARKS 5EB 632172 PLATE FRICTION 9 Compared to STD the friction plate enhances durability and operation Identification Paint Violet 16 15 Slipper Clutch Setting Set 4B1 A6377 7
10. 23 20 1 150 25 18 1 389 25 22 1 136 26 18 1 444 23 20 1 150 28 19 1 474 26 22 1 182 e No gear can be used for the kit transmission except for the specified STD gear e There is no compatibility with the 06 model transmission set 2C0 A7400 70 21 YZF R6 Mission ratio Part number The Part number The number number of teeth of teeth 1ST A 2 313 2C0 17411 80 A 16 A 2C0 17211 80 A 37 A B 2 471 2C0 17411 90 B 17 B 2C0 17211 90 B 42 B C 2 583 2C0 17411 00 12 2C0 17211 00 31 2ND A 1 857 2C0 17121 80 A 21 A 2C0 17221 81 A 39 A B 1 950 2C0 17121 90 B 20 B 2C0 17221 90 B 39 B C 12 000 2C0 17121 00 16 2C0 17221 00 32 3RD A 1 565 2 0 17131 80 23 2C0 17231 80 A 36 A B 1 611 2C0 17131 71 B 18 B 2C0 17231 70 B 29 B C 1 667 2C0 17131 90 C 18 2C0 17231 90 C 30 C 4TH 1 389 2C0 17131 80 A 18 2C0 17241 80 A 25 A B 1 444 2C0 17131 71 B 18 B 2C0 17241 70 B 26 B C 1 474 2C0 17131 90 C 19 C 2C0 17241 90 C 28 C 5TH 1 269 2C0 17151 71 A 26 2C0 17251 71 A 33 A B 1 304 2C0 17151 80 B 23 B 2C0 17251 80 B 30 B C 11 350 2C0 17151 90 C 20 2C0 17251 90 C 27 C 6TH A 1 136 2C0 17161 70 A 22 2C0 17261 71 A 25 A B 1 150 2 0 17161 00 20 2C0 17261 80 B 23 B 1 182 2C0 17161 90 C 22 2C0 17261 90 C 26 C
11. 13S 22210 71 SHOCK ABSORBER 98 Nmm Rear Suspension Performance Adjustment Method Low speed compression damping high speed compression damping rebound damping and preload can be adjusted Low speed compression damping adjustor bolt width 4mm hexagonal hole High speed compression damping adjustor bolt width 12mm hexagonal Rebound damping adjustor Preload adjustor Preload Adjustment Method Turn the adjustor clockwise to increase the preload and anticlockwise to reduce the preload The adjustment range is 8mm in steps of 1mm Shipping position Tightened 4 steps from the preload minimum position fifth step 43 Rebound Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force The adjustment range is between 3 to 20 steps back from the lightly tightened adjustor position Shipping position 15 steps back from the tightened adjustor position NOTICE When tightening the adjustor do it lightly Over tightening the adjustor can damage it Compression Damping Adjustment Method At Low Speeds Turn clockwise to increase the damping force and anticlockwise to reduce the damping force The adjustment range is 1 to 20 steps back from the lightly tightened adjustor position Shipping position 15 steps back from the tightened adjustor position NOTICE When tightening the adjustor do it lightly Over tightening the adjus
12. 29 Front Fork Parts List PART No PART NAME REMARKS 13S 23102 70 Fr FORK ASSY LH 9 5 2 13S 23103 70 Fr FORK ASSY RH 1 9 5 N mm Front Fork Performance Adjustment Method Compression low speed damping compression high speed damping rebound damping and preload can be adjusted Preload Adjustment Method Turn clockwise to increase the preload and anticlockwise to reduce the preload The adjustment range is 15mm 1mm turn Shipping position Tightened 6 turns from the preload minimum position Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force The adjustment range is Rebound 1 to 25 steps back from the adjustors clockwise lightly tightened position Compression low speeds 1 to 20 steps back from the adjustor s clockwise lightly tightened position Compression high speeds 4 turns back from the adjustor s clockwise lightly tightened position Shipping position Rebound 20 steps back from the tightened adjustor position Compression low speeds 10 steps back from the tightened adjustor position Compression high speeds 2 turns back from the tightened adjustor position NOTICE When tightening the adjustor do it lightly Over tightening the adjustor can damage it 47 Rebound damping adjustor Compression low speed Compression high speed damping adjustor damping adjustor 48 Performance and purpose of ki
13. 10 YZE RO 55 KIT MANUAL w PerformancejEdge RACING PARTS foriexcellentiriders Introduction e This manual is intended for persons with knowledge and experience of motorcycles Please refer to the YZF R6 service manual which shall be published from YAMAHA MOTOR CO LTD for information on part assembly and maintenance e The design of the YZF R6 racing kit is based on YZF R6 according to FIM racing rules but that does not mean the kit conforms to all competitions When used in races riders must mount the YZF R6 racing kit at their own discretion after checking the rules of competition issued by the sponsor About Warranty e Please understand that these parts are not covered by warranty e The Manufacturer does not take any responsibility for problems caused by these parts Request e These kit parts are intended exclusively for racing purposes You are strictly requested not to use them on public roads e The specifications and usage methods of these kit parts along with the contents of this manual are subject to change without notice for improvement Parts List Symbols e The star mark means that the part is included in the kit set and is a genuine Yamaha part Therefore you can easily purchase the part at any Yamaha part dealer when necessary e The circle mark means that when needed the individual part is sold separately to the kit set No PART No PART NAME REMARKS
14. 2 Glass plate 3 Oil 3 1 mixture of torque converter oil and white gasoline 4 Vaseline to seal the valve and glass plate Measurement method 1 Tighten a regulation spark plug to the regulation torque in the cylinder head to be measured 2 Set so that the alignment surface of the combustion chamber is level Apply a thin coat of Vaseline to the valve face and set the IN and EX valves 4 Apply a thin coat of Vaseline to the combustion chamber alignment surface and set the glass plate 5 Add drops of oil from the burette The total added amount minus the valve back clearance is the volume of the combustion chamber 4 Piston Set 13S 116A0 70 Parts List PART No 13S 11631 00 PART NAME PISTON REMARKS 2C0 11603 00 PISTON RING SET 2C0 11633 00 PIN PISTON 93450 16159 CIRCLIP Select four pistons so that the difference in their weights does not exceed 0 5g 5 Connecting Rod Set 13S 1165B 70 Parts List No Pr REMARKS 1 13S 11650 00 CONN RODASSY T 4 Select four connecting rod assemblies so that the difference in their weights does not exceed 2g and combine them so that the small end weights are uniform by Yamaha s measuring method 6 Crankshaft 2 0 11411 70 Parts List PART No PARTNAVE REMARKS T1 CRAWGHAFT Select a crankshaft with good balance 7 Cam Shaft and Cam Sprocket Part
15. 95607 08100 NUT U 2 0 2349 80 DAMPER 90201 07081 WASHER PLAIN N gt 90149 06302 SCREW 5VY 26398 00 WASHER SPECIAL 91317 08025 BOLT HEX SOCKET HEAD 2C0 23439 7 1 STOPPER STRG 2 90387 06084 COLLAR 90201 07081 WASHER PLAIN 90149 06302 SCREW 2C0 23429 70 STOPPER 90151 04002 SCREW CROSSRECESSED COUNTERSUNK 57 IO Po MI 32 Seat Cushion 13S 24713 70 Parts List No PARTNG PARTNAME REMARKS 1 esans CUSHONSEAT Anti slip seat Cut to any size for use 58 33 Front Spare Wheel Assembly 2C0 25100 70 Parts List mr pare ms 2C0 25160 00 CAST WHEEL ASSY ud 93900 00030 VALVE 1 This kit does not include a tire This part is an assembly of bearings spacers and an air valve in a STD wheel 59 34 Rear Spare Wheel Assembly 2C0 25300 70 Parts List mr ms 2 0 25370 00 CAST WHEEL ASSY ud 93900 00030 VALVE 1 This kit does not include a tire This part is an assembly of bearings spacers and an air valve in a STD wheel 60 35 Throttle Set 2C0 C6300 70 Parts List PART No PART NAME REMARKS 2C0 26281 70 CAP GRIP UPPER 5FL 26282 00 CAP GRIP UNDER 5SL 2624
16. 70 8 9 Qu Pumpt260 T3300 0 a a 8 10 Air Funnel Set MGC A300908 10 sss nennen nnn 9 11 Throttle Body Clamp Assembly 2 0 1351 70 12 12 Plug Set 13S A46 90 70 due deste tee ub engen 13 13 Clutch Spring Set 2CO A6330 70 tiae e teet 15 14 Friction Plate Set 2CO A6321 70 16 15 Slipper Clutch Setting Set 481 6377 70 17 16 SEPANSMISSION vidente petes E E S 20 17 Mission Maintenance Set 2CO A7000 70 24 18 DriVe SprocKet codec t ra se 27 19 Sprocket Nut Set 2 0 7463 70 28 20 ACM Set 2C0 F1400 7 1 n 29 21 Wire Harness Set 13S F2590 71 30 22 ECU Set 2C0 8591A 91 ace Ne desley 35 23 Cable Interface 13S 8533A 70 36 2 2 Vehicle Accessories ER 39 24 Engine Protector Set 2C0 A549 1270 39 25 Chassis Protector Set 2C0 C117G 70 40 26 Oil Catch Tank Set 2 0 1707 81 42 20 Rear SUuspenslorn Ea 43 28 Rear Shock Opg unas 46 29 Front Fork
17. BRI WwW M 2C0 17402 70 DRIVE AXLE ASSY 2C0 17421 00 AXLE DRIVE 93305 20509 BRG 90387 25016 COLLAR 2C0 17221 81 A GEAR 2ND WHEEL 2C0 17221 90 B GEAR 2ND WHEEL 2C0 17221 00 GEAR 2ND WHEEL 2C0 17261 71 A GEAR 6TH WHEEL 2C0 17261 80 B GEAR 6TH WHEEL 2C0 17261 90 C GEAR 6TH WHEEL 2C0 17241 80 A GEAR 4TH WHEEL 2C0 17241 70 B GEAR 4TH WHEEL 2C0 17241 90 C GEAR 4TH WHEEL 2C0 17231 80 A GEAR 3RD WHEEL 2C0 17231 70 B GEAR 3RD WHEEL 2C0 17231 90 C GEAR 3RD WHEEL 2C0 17251 71 A GEAR 5TH WHEEL 2C0 17251 80 B GEAR 5TH WHEEL 2C0 17251 90 C GEAR 5TH WHEEL 2C0 17211 80 A GEAR 1ST WHEEL 2C0 17211 90 B GEAR 1ST WHEEL 20 e sesch 1 sch 1 sech sch gt O gt O BD O UD O O gt Parts List e PARTNe PARTNE QTY REMARKS e Gear Ratio 31 12 2 583 37 16 2 313 42 17 2 471 31 12 2 583 32 16 2 000 39 21 1 857 39 20 1 950 32 16 2 000 30 18 1 667 36 23 1 565 29 18 1 611 30 18 1 667 26 18 1 444 27 21 1 286 33 26 1 269 30 23 1 304 27 20 1 350 NOTICE
18. REMARKS OLPUMPASSY 1 e This pump is capable of a larger discharge than the STD counterpart 10 Air Funnel Set MGC A300908 10 Parts List PART No PART NAME REMARKS PRIMARY FUNNEL SUPPORT L SUPPORT R EXTENSION FUNNEL R EXTENSION FUNNEL L e This set is capable of higher intake efficiency than the STD counterpart Fitting Method 1 Installing the Primary Funnel Screw on the plates on the throttle body Put only the 2 lower screw like on the schema Use standard screw 2 Assemble Support and Axle The axles are the standards ones don t forget to put the small ring into the hole Use the lever and bushing intended for a STD machine Lever wa Bush Bush Support R Support L Lever assembly 3 Mount the Assembly Secure the lever assembly to the primary funnel Secure using standard screws in the places illustrated Then put the screw on the superior part of the supports shown by a red arrow on the photo Below Make sure that the axle can easily turn without friction 4 Connecting Rod Use standard connecting rod Begin by clipping white prismatic side to the motor axle then clip other side to the tong of the inferior axle SHAFTASSY A C LEVER ASSY Motor side Lever side PRIMARY FUNNEL 10 5 Fitting the Extention Funnel Attach the extension funnel t
19. TOA Electronics Inc Vendor ID 6837 Product ID 9001 36 e Use of the ECU in the kit and the harness allows functioning of the following codes in the STD diagnosis YMS Monitor YEC FI Matching System also allows functioning of the code shown below lt Diagnosis Functions gt Contents Throttle sensor YMS Monitor TPS 1 deg Atmospheric pressure sensor Atmospheric kPa Intake pressure sensor 1 Intake Air kPa Intake temperature sensor Air Temp C Water temperature sensor Water Temp C Vehicle speed sensor Speed Signal Overturn sensor Lean Angle Signal V Monitor voltage System Voltage V Throttle sensor 2 TPS 2 deg Accelerator sensor 1 APS 1 deg Accelerator sensor 2 APS 2 deg Neutral switch Neutral SW Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Injector primary 1 Injector primary 2 Injector primary 3 Injector primary 4 Injector secondary 2 Injector secondary 1 Injector secondary 3 Injector secondary 4 Intake funnel Main relay Program version Self Diagnosis Functions e The ECU and harness in the kit provide the functions for the following codes of standard self diagnosis 00 All fu
20. and 9 to a turn of nut angle of 75 5 Retighten the bolt in the sequence of 10 to a turn of nut angle of 50 5 Tighten the bolts in the tightening sequence of 11 and 12 to 24x2N m 2 4x0 2kgf m Tighten the bolts in the tightening sequence of 13 to 29 to 10x2N m 1 0x0 2kgf m The numbers 1 to 29 show the sequence in which the bolts are tightened Apply engine oil to the bolt threads and both sides of the washers These numbers indicate the tightening sequence 75 4 YZF R6 Wiring Diagram
21. 0 Parts List PART PART QTY REMARKS 1 4B1 16377 70 NUT LOCK 2 4B1 16391 70 SHIM cd 17 Setting of back torque limiter of clutch A clutch with a back torque limiter mechanism is installed in the YZF R6 engines The operation of the back torque limiter be adjusted through adjusting the number of SHIMs set up for the kit the number of springs b the whole thickness of the clutch plate and the strength of C spring set up for the kit of the slipper clutch setting set Recommended setting method To begin with the dimensions of the clutch are re set to the standard values For details please refer to the service manual published from YAMAHA MOTOR CO LTD If you attach the slipper clutch setting of kit 2 make it the same as the standard setting When decreasing the number of SHIMs standard setting is three of slipper clutch setting set the back torque limiter tends to be effective Engine braking becomes less effective Standard 3 2 1 0 lt effective Engine braking becomes less effective Further when decreasing the number of 8 spring the number of standard setting is three to two the back torque limiter becomes effective Engine braking becomes less effective clutch spring can be either the kit item or the standard item If you mount the clu
22. 1 90149 06082 SCREW 12 042 1 2 0 2 COVER CRANKCASE 1 x STATOR ASSY 90149 06080 10 042 1 00 2 PLUG WITH COMMUNICATION HOLE x CRANKCASE 1 90149 06082 12 042 1 2 0 2 Install COVER CHAIN CASE 90110 06060 BOLT HEXAGON SOCKET HEAD 10 042 1 0 0 2 Install M GALLERY PLUG 36Y 15189 00 PLUG M16 x 1 5 8 0 2 0 8 0 2 TAKE CARE NOT TO OVER TIGHTEN COVER CRANKCASE 1 x CLAMP 90149 06082 10 042 1 00 2 STATOR LEAD Install COVER 90109 06015 BOLT 12 042 1 2 0 2 Install OIL PIPE OUTSIDE 90110 06161 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 CRANKCASE 2 x PICKUP 90110 06168 BOLT HEXAGON SOCKET HEAD 10 042 1 0 0 2 Embedded in CRANKCASE x STUD EMBEDDED 90116 1002 BOLT STUD M10 x 1 25 HEIGHT 68 241 Install PRESSURE PLATE 90159 06024 8 0 2 0 8 0 2 BOSS CLUTCH x MAIN AXLE 4B1 16377 70 NUT LOCK M20 x 1 0 68 115 0 5 11 5 0 5 APPLY OIL BOTH TO THREAD AND BEARING SUR FACE To be tightened BOSS PRESSURE PLATE x BOLT STUD 2C0 16374 00 Part Name x pitch M8 x 1 25 Screw dia Tightening torque Nem kgf m 25 042 2 5 0 2 Remarks Install SPROCKET DRIVE 90179 20005 M20 x 1 0 85 045 8 5 0 5 WITH LOCK WASHER HOUSING BEARING 90151 06024 SCRE
23. 1 4C8 11181 70 GASKET CYLINDER t 0 30mm HEAD 1 2 5VY 11351 00 GASKET CYLINDER 1 3 8 4C8 11603 00 PISTON RING SET 12 4 5VY 1165A 01 BOLT CONNECTING ROD 24 SPECIAL La 24 Symbol Marks Particularly important information is distinguished in this manual by the following notations A This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property TIP A TIP provides key information to make procedures easier or clearer CONTENTS 1 Engine U u 1 2 et E a um I DUI 2 2 1 Engine Parts 2 1 Maintenance Set 2CO MAINT 71 2 2 Spark Plug Set SFL R045Q 70 13S R373A 70 3 3 saan atin tian Rieti seen 4 4 Piston Set 1 39 116A0 E 6 5 Connecting Rod 5 135 1165 70 6 6 Crankshaft 200 1141 197 0 6 7 Shaft and Cam Sprocket 7 8 Valve Spring Set 2 0 2110
24. 117G 70 Parts List PART No PART NAME REMARKS 2C0 2117G 70 PROTECTOR LH LONG 2C0 2117G 90 PROTECTOR RH SHORT 2C0 21472 70 COLLAR PROTECTOR 91317 10060 BOLT HEX SOCKET HEAD 91314 10065 BOLT HEX SOCKET HEAD 90201 10136 WASHER PLAIN Tightening torque 40 Nem 4 0 mekg ENGINE Tightening torque A 40 Nem 4 0 mekg FWD Ww Tightening torque Nb R SIDE L SIDE FRAME FRAME 65 1 ENGINE ENGINE FES p 40 Before mounting the protector cut the cowling so that the protector can fit against the chassis As a rough guide cut by 60 centered on the engine mount See the figures below 41 26 Oil Catch Tank Set 2C0 C1707 81 Parts List PART No 2C0 21707 70 PART NAME OIL TANK COMP x REMARKS 90450 25037 HOSE CLAMP ASSY 135 15373 70 2 0 15393 70 2 2 0 2419 00 91317 06020 BOLT HEX SOCKET HEAD 90480 13018 GROMMET 90119 06044 BOLT HEX W WASHER o O N 2C0 15373 70 PIPE BREATHER This oil tank has the effective capacity of 540 cc 42 N DI N aj BR For 2006 and 2007 models 27 Rear Suspension Parts List PARTNo PARTNAME QTY REMARKS
25. 2 APPLY GREASE TO O RING HOLDER x CRANKCASE 2 90110 06161 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 PIPE OIL x CRANKCASE 2 90110 06161 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 OIL COOLER x CARNKCASE 2 12822 00 BOLT UNION M20 x 1 5 63 043 6 3 0 3 APPLY OIL TO THREAD AND BEARING SUR FACE UPPER CASE x CAP CASE ASSY 92012 06020 BOLT BUTTON HEAD 5 0 0 5 0 5 0 05 UPPER CASE x LOWER CASE 98902 05020 SCREW CROSS RECESS BINDING 2 0 0 5 0 2 0 05 ELEMENT x UPPER CASE 98902 05020 SCREW CROSS RECESS BINDING 2 0 0 5 0 2 0 05 JOINT CARBURETOR 1x THROTTLE 90450 56007 HOSE CLAMP ASSY 20 2 5 0 2 0 25 CONTACT FIT COLLAR OR TORQUE CON TROL THROTTLE x FUNNEL 90109 05011 BOLT 34 5 0 34 0 5 LOWER FILTER CASE x FUNNEL SUPPORT UNIT 90159 05035 SCREW WITH WASHER 2 5 0 5 0 25 0 05 Install THROTTLE WIRE 13S 26302 00 THROT TLE WIRE ASSY 65 3 5 5 5 0 35 0 55 To be tightened Part Name Screw dia Tightening Remarks x torque Nem pitch kgf m NUT RING x 90179 08410 NUT M8x1 25 20 0 2 2 0 0 2 TIGHTEN EXHAUST PIPE MEAD amp HEAD STAY 91314 08035 BOLT M8 x 1 25 20 0 2 2 0 0 2 INSTALL HEXAGON EXHAUST PIPE MUFFLER 1 2 SOCKET MUFFLER HEAD STAY
26. 3 71 TUBE GUIDE 2C0 26391 70 CLIP WIRE 1 2C0 26311 70 WIRE THROTTLE 1 Grip side Retracting sharing 2C0 26313 70 WIRE THROTTLE 3 Engine side Retracting sharing 2C0 26261 70 CYLINDER 5FL 26244 70 SLIDER 2C0 2639E 70 PROTECTOR 90201 261L1 WASHER PLAIN 91314 05020 BOLT HEX SOCKET HEAD 91314 05008 BOLT HEX SOCKET HEAD e Hi Machining off the boss Scrape away CAP GRIP UPPER of the kit as shown above 61 36 Throttle Set 13S C6300 70 Parts List PART No 2C0 26281 70 PART NAME CAP GRIP UPPER REMARKS 5FL 26282 00 CAP GRIP UNDER 5SL 26243 71 TUBE GUIDE 2C0 26391 70 CLIP WIRE 1 13S 26302 70 THROTTLE WIRE ASSY Common use for pulling back 90201 261L1 WASHER PLAIN 91314 05020 BOLT HEX SOCKET HEAD 91314 05008 BOLT HEX SOCKET HEAD In this throttle set the working angle of the throttle grip turning is made smaller for quicker response to the throttle openning Machining off the boss Scrape away CAP GRIP UPPER of the kit as shown above 62 3 Tightening Torque List Engine To be tightened CAP CAMSHAFT x HEAD 90105 06027 Part Name Screw dia x pitch Tightening torque Nem kgf m 10 042 1 00 2 Remarks CAM SHAFT SHALL TURN LIGHTLY Embedd
27. 7 x 0 75 Screw dia Tightening torque Nem kgf m Remarks APPLY MOLYB DENUM DISULFIDE OIL TO THREAD 2C0 1165A 00 M7 x 0 75 APPLY MOLYB DENUM DISULFIDE OIL TO THREAD 90179 07001 M7 x 0 75 14 7 1 47 1 5 0 15 180 5 DENUM DISULFIDE OIL TO BEARING SURFACE ACM ROTOR x CRANKSHAFT M12 x 1 25 70346 7 0 0 5 DEGREASE TAPERED SUR FACE APPLY OIL BOTH TO BOLT BEARING SURFACE AND THREAD AND TO BOTH SIDES OF WASHER USE MORI COATED WASHER TENSIONER ASSY x CYLINDER 90110 06106 12 042 1 2 0 2 INSTALL TEN SIONER ASSY Install COVER THERMOSTAT 91312 06020 12 042 1 2 0 2 Install JOINT 90105 06082 10 042 1 0 0 2 Install WATER PUMP 90110 06140 12 042 1 2 0 2 OIL PUMP ASSY x CRANKCASE 2 95812 06030 12 042 1 2 0 2 OIL PUMP ASSY x CRANKCASE 2 95812 06080 12 042 1 2 0 2 COVER STRAINER x CRANKCASE 2 90109 06015 64 12 0 2 1 2 0 2 To be tightened DRAIN BOLT for COVER STRAINER 90340 14132 Part Name PLUG STRAIGHT SCREW Screw dia x pitch M14 x 1 5 Tightening torque Nem kgf m 43 044 4 3 0 4 Remarks DRAIN BOLT Tighten UNION BOLT for FILTER 90401 20145 BOLT UNION M20 x 1 5 70 045 7 0 0 5 ELEMENT OIL FILTER 5GH 13440 20 OIL CLEANER ASSY M20 x 1 5 17 042 1 7 0
28. 90105 08054 BOLT M8 x 1 25 34 0 4 3 40 4 INSTALL FLANGE DAMPER MUFFLER 2 x SMALL BRACKET HEAD MUFFLER 1 Tighten BAND 91314 06030 BOLT M6 x 1 0 10 0 2 1 0 0 2 HEXAGON MUFFLER SOCKET HEAD SILENCER x 90105 08063 BOLT M8 x 1 25 20 0 2 2 00 2 FOOT REST Install WIRE 13S 1133E WIRE M6 x 1 0 5 7 0 5 0 7 00 PULLEY 1 PULLEY 13S 1133F WIRE 00 PULLEY 2 PULLEY x 90110 05028 BOLT M5 x 0 8 6 5 1 5 HEXAGON 0 65 0 15 SOCKET MOTOR HEAD BRACKET 7 x 95827 06014 BOLT M6 x 1 0 6 10 0 6 1 0 FLANGE FRAME SMALL HEAD BRACKET 7 x 95027 06025 BOLT M6 x 1 0 5 8 0 5 0 8 FLANGE SERVOMOTOR SMALL HEAD Install 90111 06071 BOLT M6 x 1 0 8 0 1 5 HEXAGON 0 8 0 15 MUFFLER SOCKET PROTECTOR BUTTON Install 90111 06099 BOLT M6 x 1 0 6 5 1 5 HEXAGON 0 65 0 15 MUFFLER SOCKET PROTECTOR BUTTON EXHAUST 90179 06063 NUT M6 x 1 0 6 5 1 5 VALVE 0 65 0 15 SUBASSY CRANKCASE 1 90119 08083 BOLT M8x1 25 See page 75 for APPLY OIL HEXAGON details BOTH TO x CRANKCASE WITH THREAD AND 2 WASHER TO BEARING SURFACE 66 To be tightened Part Name Screw da Tightening Remarks x torque pitch kgf m CRANKCASE 1 90119 08084 BOLT M8x1 25 See page 75 for APPLY OIL HEXAGON details BOTH TO x CRANKCASE WITH THREAD AND 2 WASHER TO BEARING SURFACE CRANKCASE 1 90109 06100 BOLT M6 x 1 0 10 0 2 1 0 0 2 APPLY OIL BOTH TO x CRA
29. IAL TOOL are supplied with the front fork 13S 23102 70 e Use Yamaha M1 suspension oil 54 Front Fork Spring Replacement Method 1 Turn the damping adjustor and preload adjustor anticlockwise to set to the weakest position 2 After fixing the axle bracket in a vice turn the fork bolt anticlockwise to lower the outer tube until the dust seal touches the upper surface of the axle bracket Rebound damping adjustor Preload adjustor Fork bolt 3 Insert the spanner SPECIAL TOOL into the notch of the spring seat upper and clamp the 14mm special nut 4 Use a 14mm box spanner on the preload adjustor to remove the cap bolt assembly Do not remove the spanner SPECIAL TOOL while doing this Spanner A SPECIAL TOOL Spring seat upper Preload tube 52 5 Remove the push rod and fit the rod SPECIAL TOOL to the piston rod Push rod Rod SPECIAL TOOL k g 6 Grip the rod SPECIAL TOOL firmly and remove the spanner SPECIAL TOOL Be very careful to apply downward pressure on the rod SPECIAL TOOL when you remove the spanner SPECIAL TOOL 53 7 Remove the spring seat upper and preload tube before removing the rod SPECIAL TOOL 8 Remove the washer special nut and spring guide and replace the spring When replacing the spring fit the new spring with the tapered closed end upwards E Washer A T Special nut gt x Spring guide
30. NKCASE THREAD AND 2 TO BEARING SURFACE CRANKCASE 1 95812 06055 BOLT M6 x 1 0 10 0 2 1 0 0 2 APPLY OIL FLANGE BOTH TO x CRANKCASE THREAD AND 2 TO BEARING SURFACE CRANKCASE 1 95812 08065 BOLT 8 1 25 24 2 2 4 0 2 APPLY OIL FLANGE BOTH TO x CRANKCASE THREAD AND 2 TO BEARING SURFACE CRANKCASE 1 95812 06065 BOLT M6 x 1 0 10 0 2 1 0 0 2 APPLY OIL FLANGE BOTH TO x CRANKCASE THREAD AND 2 TO BEARING SURFACE CRANKCASE 1 95812 06045 BOLT M6 x 1 0 10 0 2 1 0 0 2 APPLY OIL FLANGE BOTH TO x CRANKCASE THREAD AND 2 TO BEARING SURFACE CRANKCASE 1 95812 06030 BOLT M6 x 1 0 10 0 2 1 0 0 2 APPLY OIL FLANGE BOTH TO x CRANKCASE THREAD AND 2 TO BEARING SURFACE Install COVER 90109 06015 BOLT M6 x 1 0 12 0 2 1 2 0 2 CRANKCASE 1 Install COVER 90109 06031 BOLT M6 x 1 0 12 0 2 1 2 0 2 CRANKCASE 2 Install COVER 90110 06156 BOLT M6 x 1 0 12 022 1 2 0 2 HEXAGON CRANKCASE 2 SOCKET HEAD Install COVER 90110 06303 BOLT M6 x 1 0 12 022 1 2 0 2 1 HEXAGON SOCKET HEAD COVER 1 x 90109 06015 BOLT M6x1 0 12 042 1 2 0 2 HOLDER CLUTCH COVER 1 x 92014 08014 BOLT M8 x 1 25 15 0 2 1 5 0 2 BUTTON BOLT HEAD 67 To be tightened COVER 1 x PLUG STRAIGHT 90340 32004 Part Name PLUG STRAIGHT SCREW Screw dia x pitch M32 x 1 5 Tightening torque Nem kgf m CLOSE CON TACT WITH BEARING SUR FACE Remarks PLATE BREATHER x C C
31. W COLOR CORD I N 76 MEASUREMENT TOOL I Gs 77 POWER SUPPLY 1 CONNECTING WITH GND WIRE 75 PCIE E L a sol 79 MAIN SW ND I 80 SW HANDLE x 81 SUB LD OAO CONNECTOR MARK BETWEEN MAIN amp SUB HARNESS 1 PIT ROAD LIMIT SW 83 VI MOTOR 84 ECU m irs CONNECTOR SYMBOL 85 RESISTOR ASSY 86 MAP SELECT SW 76 Published by YAMAHA MOTOR ENGINEERING co LTD
32. W CROSS RECESSED COUNTER SUNK 12 042 1 2 0 2 Install STOPPER SHAFT BAR 90110 06182 BOLT HEXAGON 10 042 1 0 0 2 STOPPER embedded in CRANKCASE 1D7 18127 00 STOPPER SCREW 8 x 1 25 22 042 2 2 0 2 Install ARM SHIFT 95822 06020 10 042 1 0 0 2 CHECK FOR SERRATION TIGHTENING UP Install ROTOR PICKUP 90105 08113 BOLT FLANGE M8 x 1 25 35 045 3 5 0 5 Install STARTER MOTOR 90105 06083 BOLT FLANGE SMALL HEAD 10 042 1 0 0 2 NEUTRAL SWITCH ASSY 3GB 82540 01 NEUTRAL S W ASSY M10 x 1 25 19 612 2 0 0 2 OVERTIGHTEN ING LEADS TO DAMAGE Install OIL LEVEL SENSOR 95022 06016 BOLT FLANGE SMALL HEAD 10 042 1 0 0 2 APPLY GREASE TO O RING SPEED SENSOR x C C 91312 06016 BOLT HEXAGON SOCKET HEAD 10 042 1 0 0 2 CAM SENSOR x COVER H C 90110 06175 BOLT HEXAGON SOCKET HEAD 7 5 1 5 0 75 0 15 WIRE HARNESS NEGATIVE LEAD WIRE 91380 06012 BOLT HEXAGON SOCKET HEAD 69 10 0 2 1 0 0 2 To be tightened Screw dia Tightening Remarks X torque Nem pitch kgf m Install O2 135 8592 2 SEN M18 x 1 5 45 045 4 5 0 5 SENSOR S SOR Install 8CC 85790 THERMO M12 x 1 5 17 642 1 8 0 2 01 SENSOR THERMOSENSOR ASSY 70 Body
33. dia Tightening torque Nem kgf m Remarks SCREW IN FROM THE LEFT SIDE 90185 12119 NUT SELF LOCKING M12 x 1 25 REAR CUSHION amp ARM RELAY 1 90109 12011 BOLT M12 x 1 25 SCREW IN FROM THE LEFT SIDE 90185 12119 NUT SELF LOCKING M12 x 1 25 CHAIN PULLER ADJUST NUT 95604 08200 NUT U FLANGE 8 x 1 25 SHAFT PIVOT amp LOCK NUT 2 0 22252 00 NUT 2 M32 x 1 5 SHAFT PIVOT amp U NUT 90185 22002 NUT SELF LOCKING M22 x 1 5 FUEL PUMP amp FUEL TANK 90110 05028 BOLT HEXAGON SOCKET HEAD FRONT STAY for FUEL TANK amp FRAME 90110 06233 BOLT HEXAGON SOCKET HEAD Mid portion of FUEL TANK amp STAY 91312 06016 BOLT HEXAGON SOCKET HEAD BRACKET TANK rear amp FUEL TANK 91312 06090 BOLT HEXAGON SOCKET HEAD BRACKET TANK rear amp REAR FRAME 90111 06071 BOLT HEXAGON SOCKET BUTTON FRONT WHEEL SHAFT amp FR FORK 90105 14002 BOLT FLANGE M14 x 1 5 REAR WHEEL SHAFT amp NUT 90185 24007 NUT SELF LOCKING M24 x 1 5 FR CALIPER amp FR FORK 90401 10012 BOLT UNION M10 x 1 25 DISC BRAKE amp FR WHEEL 90149 06043 SCREW APPLY LOCK ING AGENT LOCKTITE DISC BRAKE amp RR WHEEL 90149 08009 M8 x 1 25 72 APPLY LOCK ING AGENT LOCKTITE To be tightened Part Name Scr
34. e seal side should face outward one side 3 seal bearing press the bearing all the way into the case until it touches bottom EN d Apply molybdenum oil to inside diameter After assembly it should rotate smoothly Apply molybdenum oil to the inside diameter and end After assembly it should rotate smoothly Apply molybdenum oil to teeth of spline After assembly it should slide smoothly Points to be careful of the oil seal assembly The convex part on the oil seal should be put into the case groove vertically so that the oil seal does not fall over and is tightly 2 3 2 2 3 2 fit into the bearing cup of the bearing Apply grease to the lip TIP G D e Always use a new circlip e Do not mistake the washer and circlip directions See drawing below Matching mark Matching mark Portion R Circlip Washer Portion R Position the abutment joint of the circlip right between the splines A Detail of installation of washer washer s claw their matching mark Assemble washer with putting together Rotate washer so that its teeth meet axle spline teeth on the axle and then lock with Detail of installation of circlip Circlip Washer Matching mark Matching mark Washer G Detail of installation of washer Direction not applicable Gear Shaft Position the abutment joint of the circlip righ
35. ed in HEAD 95612 08625 M8 x 1 25 15 0 2 1 5 0 2 Tighten HEAD 90179 10006 M10 x 1 25 TURN OF NUT METHOD AXIAL FORCE 41kN 2kN SNUG TORQUE 28 2 8 ROTA TION ANGLE 55 APPLY OIL BOTH TO THREAD AND BEARING SUR FACE SEE page 74 FOR DETAILS Tighten HEAD 90176 10075 M10 x 1 25 TURN OF NUT METHOD AXIAL FORCE 41kN 2kN SNUG TORQUE 36 3 6 ROTA TION ANGLE 55 APPLY OIL BOTH TO THREAD AND BEARING SUR FACE SEE page 74 FOR DETAILS Tighten HEAD on side of CAM CHAIN compartment 90110 06094 BOLT HEXAGON SOCKET HEAD 12 0 2 1 2 0 2 WITH WASHER SPARK PLUG 5FL 1119C 70 13S 1119C 70 PLUG SPARK M10S x 1 0 12 15 1 2 1 5 SEE page 3 FOR DETAILS HEAD COVER x HEAD 90109 066F0 12 0 2 1 2 0 2 Plug for sand drain hole 90340 18002 PLUG STRAIGHT SCREW M18 x 1 5 42 4 4 3 0 4 APPLY LOCK ING AGENT LOCKTITE Check bolt for oil passage 95022 08012 BOLT FLANGE SMALL HEAD 8 x 1 25 15 042 1 5 0 2 Tighten Al CAP 90110 06175 BOLT HEX AGON SOCKET HEAD 10 042 1 0 0 2 CAMSHAFT x SPROCKET 90105 07004 BOLT FLANGE 24 042 2 4 0 2 JOINT CARBURETOR 1 x HEAD 91312 06016 BOLT HEXAGON SOCKET HEAD 63 10 0 2 1 0 0 2 To be tightened CON ROD X CAP CON ROD 2C0 11654 00 BOLT CON ROD x pitch
36. en accelerating passing over a gap etc Reduces turning performance stroke volume is excessive and the rear of the machine is lower than the front Kit suspension specs Limits excessive dipping by increasing the damping force on the compression side Others Kit suspension specs Change in total length Being assembled with a rebound spring the kit suspension raises the road holding property of the rear tire when braking The total length is changed according to the rebound spring setting Spring load Depends on the stroke Damping force Depends on the stroke speed Commercially available machine 1G Kit Spring load N Stroke mm Commercially available machine Damping load N Stroke speed m s R1 293mm STD 290mm R6 287mm STD 290mm 28 Rear Shock Spring Parts List PART No PART NAME REMARKS 13S 22222 70 SPRG Rr SHOCK 103 N mm Identifying stamp 165 55 103 135 22222 75 SPRG Rr SHOCK 98 N mm Identifying stamp 165 55 98 135 22222 80 SPRG Rr SHOCK 93 N mm Identifying stamp 165 55 93 e These springs can be used with the standard or kit shock absorbers e There is a stamp on the side of the springs for rate identification e The stamp number indicates the length diameter and rate e For spring replacement see the 13S STD Service Manual e The spring rate of the standard rear suspension is 103 N mm 46
37. ew dia x pitch Tightening torque kgf m Remarks REAR WHEEL 90185 10009 NUT SELF M10x 1 25 90 109 SPROCKET amp LOCKING 9 2 11 1 CLUTCH HUB SPLIT BOLT for 91314 08040 BOLT 8 x 1 25 18 23 1 8 2 3 FRONT AXLE SOCKET HEAD 73 Tightening the Cylinder Head Tightening the Cylinder Head Turn of Nut Method 1 2 3 4 TIP Tighten the bolts in the tightening sequence of 1 to 7 to a snug torque of 28N m 2 8kgf m Tighten the bolts in the tightening sequence of 8 and 9 to a snug torque of 36Nem 3 6kgfem Tighten the bolt in the tightening sequence of 10 to a snug torque of 28N m 2 8kgf m Retighten the bolts in the tightening sequence of 1 to 10 to a turn of nut angle of 55 The numbers 1 to 10 show the sequence in which the bolts are tightened Apply engine oil to the bolt threads contact surfaces and washers These numbers indicate the tightening sequence AJNA ERA GE EE JE GAG Nor ooo 74 Installing the Crankcase Tightening the bolts 1 2 TIP Tighten the bolts in the tightening sequence of 1 to 10 to 20N m 2 0kg m After loosening the bolts once in the tightening sequence of 1 to 10 retighten them one by one to 12Nem 1 2kg m Retighten the bolts in the tightening sequence of 1 to 7 to a turn of nut angle of 50 5 Retighten the bolts in the tightening sequence of 8
38. ing installation on the following points 1 The tightening torque is 12 15 Nem 1 2 1 5 kgf m 2 When not checking the torque tighten by rotating through 30 after manual tightening in the case of new plugs When reusing plugs tighten by rotating through 15 Reused 15 New gasket 30 3 Head Gasket Parts List PART No 2C0 11181 71 PART NAME GASKET CYLINDER HEAD REMARKS t 0 40mm 2C0 11181 76 GASKET CYLINDER HEAD t 0 45mm 2C0 11181 81 GASKET CYLINDER HEAD t 0 50mm 2C0 11181 86 GASKET CYLINDER HEAD The thickness of the standard parts is 0 60mm These parts are used to adjust the squish height In normal cases use the one with 76 0 45mm After processing the cylinder upper case make sure to check the squish height and use the gasket so that the squish height becomes 0 60mm or above TIP t 0 55mm Squish height means the gap between the flat portion of the piston and the head cylinder Stamping location Measuring the volume of the cylinder head combustion chamber obtain the highest performance for use the four cylinders should be uniform If you modify the head cylinder always measure the combustion chamber volume and do the work based on the measured value Measure the volume of the combustion chamber of the cylinder head commonly called the dome volume as follows Measuring equipment 1 Burette
39. it Road Limiter with the switches 2 types included with this set See diagram 1 Diagram 1 Main switch Map select 1 2 Map 1 2 Map 2 Engine stop switch Pit road M limiter Starter switch 30 e Use the 3 prong coupler in front with the red wire attached as the main switch See diagram 2 Fitting it turns the power on and removing it turns the power off NOTICE Be careful not to pull the wire too strongly Diagram 2 Main switch Diagram 3 Main switch Pit road limiter Je E Engine stop p T 2 ki switch Not used s gt Hi Map 2 Pa j Pit road limiter e ON ON PUSH OFF Starter switch Ignition cut switch 31 e The ignition cut switch function can be used by combining the harness and kit ECU To use the STD switch left side to function as the ignition cut switch connect the wire sub lead that was packaged with this set to the terminal that is normally connected to the left side horn See diagram 4 If you remove the resistor assy at the tail side the ignition cut switch may malfunction in wet weather See diagram 5 NOTICE Do not bend the resistor assembly It will cease to function if it is bent 2 Install the switch to the 2 pin black coupler underneath the fuel tank Turning the switch ON cuts the ignition Diagram 4 Diagram 5 NOTICE Do not connect the coupler for resist
40. learance 0 15 0 19 mm 0 18 0 22 mm 0 18 0 22 mm 0 23 0 27 mm 0 23 0 27 mm 0 23 0 27 mm 2 Kit Parts 2 1 Engine Parts 1 Maintenance Set 2CO MAINT 71 Parts List PART No 2C0 11181 76 PART NAME GASKET CYLINDER HEAD REMARKS 2C0 11603 00 PISTON RING SET 93450 16159 CIRCLIP 2C0 1165A 00 BOLT CONNECTING ROD 90179 07001 NUT 4SV 12119 00 SEAL VALVE STEM OIL 2 0 12213 00 GASKET TENSIONER 2C0 13414 70 GASKET STRAINER ANTI STICK TYPE 1 2 3 4 5 6 7 8 9 2C0 15451 70 GASKET CRANKCASE COVER 1 ANTI STICK TYPE eo 2C0 15461 70 GASKET CRANKCASE COVER 2 ANTI STICK TYPE 2C0 15456 70 GSKT 1 ANTI STICK TYPE 93102 35017 SEAL OIL FOR DRIVE AXLE 90151 06024 SCREW CROSSRECESSED COUNTERSUNK FOR BEARING HOUSING 2 Spark Plug Set 5FL R045Q 70 13S R373A 70 Parts List Semi surface discharge Type 5FL R045Q 70 No REMARKS 5FL 1119C 70 PLUG SPARK R0045Q 10 Parts List Angled ground strap Type 13S R373A 70 No PART No PARTNAVE REMARKS 13S 1119C 70 PLUG SPARK NGK R0373A 10 TIP Since these spark plugs have a copper gasket caution is needed dur
41. nctions normally 11 Cam angle sensor malfunctions 12 Crank angle sensor malfunctions 13 Intake pressure sensor malfunctions open circuit short circuit 14 Intake pressure sensor malfunctions piping system 15 Throttle opening sensor malfunctions open circuit short circuit ETV 20 Intake pressure sensor or atmospheric pressure sensor malfunctions 21 Water temperature sensor malfunctions open circuit short circuit 22 Intake temperature sensor malfunctions open circuit short circuit 23 Atmospheric pressure sensor malfunctions open circuit short circuit 33 Ignition coil 1 malfunctions open circuit 34 Ignition coil 2 malfunctions open circuit 35 Ignition coil 3 malfunctions open circuit 36 Ignition coil 4 malfunctions open circuit 39 Injector primary malfunctions open circuit 40 Injector secondary malfunctions open circuit 43 Battery voltage monitor malfunctions power source for fuel system 46 Power source for vehicle malfunctions 59 Accelerator opening sensor malfunctions open circuit short circuit 60 Throttle motor malfunctions drive system 38 2 2 Vehicle Accessories 24 Engine Protector Set 2C0 A5491 70 Parts List PART No 2C0 15491 70 PART NAME PROTECTOR REMARKS 91314 06025 BOLT HEX SOCKET HEAD 91314 06020 BOLT HEX SOCKET HEAD 39 25 Chassis Protector Set 2C0 C
42. ng passing over a gap etc Kit suspension specs By ensuring a damping force on the compression side the kit enables the rider to change the machine attitude gently and improves convergence when riding over a gap Damping force Depends on the stroke speed Others Kit suspension specs TiO coating inner tubes adopted Improves durability and lowers friction Spring support method changed Improves spring replacement operation Special tool included Bottoming rubber adopted Improves gap absorbability during braking Damping load N Commercially available machine Kit Stroke speed m s 30 Front Fork Spring Parts List PART No PART NAME REMARKS 13S 23151 70 SPRG Fr FORK 10 5 Identifying slits 3 13S 23151 75 SPRG Fr FORK 10 0 Identifying slits 2 13S 23151 80 SPRG Fr FORK 9 5 NMmm Identifying slits None 13S 23151 85 SPRG Fr FORK 9 0 NMmm Identifying slits 1 e There are slits at the ends of the spring for rate identification The number of slits indicates the rate as shown above e When using an optional spring for the STD fork replace the supplied preload tube with the set NOTICE When using an optional spring for the kit fork you do not need to replace the preload tube Use the original tube fitted to the fork TP A spanner SPECIAL TOOL and rod SPEC
43. o the standard secondary funnel Note the direction of the groove on the extension funnel and connect with wire so that it does not turn and come off Secondary funnel Extension funnel A Wire 6 Fitting the Secondary Funnel Fit the standard rubber seal to the secondary funnel before attaching the lever assembly Rubber seal Ycci System Control You can use the Ycci system as the kit funnel You can control the operation timing by using the YMS software packed together with the kit ECU You can also control the STD funnel by using the YMS software This set is made by MG Competition For details of the specification please check with MG Competition TEL 33 0 4 50 25 59 96 FAX 33 0 4 50 25 59 98 Web http www mgcompetition fr 11 11 Throttle Body Clamp Assembly 2CO 1351A 70 Parts List PARTNo PARTNAME QTY REMARKS 1 2C0 1351A 70 THROTTLE BODY CLAMP 1 ASSY This part is used to enhance maintenance performance of the throttle body Before using it cut off the protrusion for positioning bands at the cabjoint Cut it off The part has a collar to prevent over tightening In normal cases the part will not be tightened till it reaches to the collar Just manually tighten it Make sure to put a new band through a M4 x 0 7 tap before using it 12 12 AIS Plug Set 13S A4890 70 This plug set is used when the AIS Air Induction System an exhaust gas purification system
44. or black 2 prong and the coupler for power white 2 prong Connecting them may cause a malfunction See diagram 6 Diagram 6 Coupler for resistor Coupler for power 32 e The bracket regulator provided with this set is for use when fitting a regulator in the position illustrated in Diagram 7 such as when not using a standard radiator Diagram 7 RECTIFIER REGULATOR e This harness has a coupler that connects to the 2D made data logger See diagram 8 For details of the specifications of the data logger please access the website Web http www 2d kit system com Diagram 8 32 e This harness comes with a coupler black 2 pole plug for use with a quick shifter Connection diagram 2 E G STP SW Diagram 9 You can use any quick shifter product Diagram 9 Connector for steering damper Connector for quick shifter 34 22 ECU Set 2C0 8591A 91 Parts List No PART No PART NAME Q TY REMARKS 2C0 8591A 91 ECU 1 2 135 2818 81 CD 1 YMS MANUAL e Use of this set and a wire harness included in the kit enables regulation or setting of fuel injection and ignition timing etc e For details as to how to regulate or set fuel injection and ignition timings etc refer to the manual in the CD ROM that comes with the set e There are two types of basic control data for the ECU included in this set SS Super Sports and ST Stock S
45. ports They can be switched over and vice versa To make it in the ST specification just remove two couplers located at the lower left of the kit harness fuel tank See the figure below Setting up Details SS specification Kit cam shaft and Recommended muffler ST specification Recommended muffler Recommended muffler Made by Akrapovic For details of the specification please access the website Web http www akrapovic exhaust com WIRE HARNESS ASSY THROTTLE BODY ASSY 2C0 8591A 70 2C0 82590 70 2C0 8591A 71 2C0 82590 80 2C0 8591A 80 2C0 8591A 90 135 13750 00 2 0 13750 00 135 82590 70 135 82590 71 2 0 8591 91 2008 2009 2010 models allow combination of ECU and wire harness Other models only allow the combinations shown in the table 35 23 Cable Interface 13S 8533A 70 Parts List PARS Jory 13S 8533A 70 CABLE INTERFACE 2 13S N81CD 70 8cm CD 1 USB driver e This cable connects the kit wire harness to the personal computer on which YEC FI Matching System YMS is installed e Please see the YMS manual for instructions on how to use YMS e When connecting the cable to the PC for the first time it is necessary to install the USB driver Refer to the USB Driver Installation Manual provided on the 8 cm CD for details on how to install the USB driver e The product vendor ID and product ID are provided by the Hamamatsu
46. s List PART No PART NAME REMARKS 2C0 12171 72 SHAFT CAM 1 2 0 12181 71 5 2 2 0 12176 80 SPROCKET CAM 1 2C0 12177 80 SPROCKET CAM 2 Tightening torque Assembly of Cam Sprocket By making the assembly holes of the cam sprocket of the racing kit long the valve timing can be adjusted within the range of 2 to 6 CA compared with standard timing TIP For valve timing adjustment refer to the KIT TOOLS MANUAL NOTICE e When fitting the camshaft use the cam sprockets of the kit and always set the valve timing to match If otherwise no intended performance can be expected and more over the engine may be damaged e When using this camshaft use the valve spring set 2C0 A2110 70 Sprocket assembly position at top dead center point of 1 cylinder compression 8 Valve Spring Set 2C0 A2110 70 Parts List PART No PART NAME REMARKS 2C0 12113 70 SPRING 1 For 2C0 12171 71 INT Identifying color Light blue 2C0 12114 70 SPRING 2 For 2C0 12181 71 EXT Identifying color Yellow 2C0 12117 70 RET VALVE SPRING e This set will be effective in improving the engine performance and durability if it is provided exclusively for the kit cam shaft and used in combination NOTICE When using this valve spring use the camshafts 2C0 12171 71 2C0 12171 72 and 2C0 12181 71 9 Oil Pump 2C0 13300 70 Parts List PARTNo PARTNAME
47. t between the splines D Detail of installation of circlip 26 18 Drive Sprocket Parts List PART No PART NAME REMARKS 2C0 17460 74 SPROCKET DRIVE 2 0 17460 75 SPROCKET DRIVE 2C0 17460 76 SPROCKET DRIVE These parts are for 520 chains STD 525 chain Use the nuts for the kit to mount the drive sprocket These sprockets are manufactured to be compatible with new and old models GROOVE MACHINING STAMP OF THE NUMBER OF TEETH ON BOTH SIDES 2CO 06 and after YZF R6 5SL 05 and previous YZF R6 Install with the grooved surface Install with the grooved surface facing outside of the chassis facing inside of the chassis NOTICE Take care not to install the sprocket in the wrong direction If it is installed in the wrong direction it will cause the misalignment of the drive and rear sprockets leading to the loss of power 27 19 Sprocket Nut Set 2C0 A7463 70 Parts List mr 7 PATNAIE ms 90179 20005 SPROCKET i 2 90215 21256 WASHER TONGUED 1 TIGHTEN NUT BEFORE BENDING J OL A 1 28 20 ACM Set 2C0 F1400 71 Parts List PART No PART NAME REMARKS 2 0 81410 70 STATOR ASSY 2 0 81450 70 ROTOR ASSY 2C0 15580 00 STARTER CLUTCH OUT ASSY 2C0 15536 00 CLIP STARTER 2C0 15411 71 COVER CRANKCASE 1 90149 06080 SCREW With screw lock 2C0 15451 70 GSKT CRANKCASE ANTI STICK TYPE COVER 1
48. t suspension Differences compared with standard suspension on commercially available machines Spring characteristics Commercially Purpose available machine specs To increase comfort when riding in urban areas while preventing bottoming when suddenly riding over a gap while banking on a bend Performance characteristics At the lowest possible spring setting the air spring effect is increased depending on the oil level An oil lock mechanism is fitted for the purpose of preventing bottoming metal contact Problem with circuit Instability caused by excessive front dip movement during the initial braking period Stroke cannot be used up Stroke stops sharply in the second half of braking Kit suspension specs Linear spring characteristic can use up the entire range of the stroke while exerting the hold of the initial braking period Spring load Depends on the stroke Spring load N 1 SR Commercially available machine Stroke mm Damping force characteristics Commercially available machine specs Purpose To maintain comfort when riding in urban areas and improve road holding properties when banking into bends Performance characteristics Set the lowest possible damping force Problem with circuit Instability caused by excessive front dip movement during the initial braking period Reduces machine stability excessive movement when accelerati
49. tch spring from the kit the back torque limiter tends to be less effective the engine brake becomes stronger NOTICE When decreasing the number of spring to two the caution should be taken to surely use three pieces of SHIMs for the slipper clutch setting set If its number being less than the above the less load may be supported so as to exert serious influences on driving Decreasing the number of spring to one is not allowed 18 Load As installed In operation Stroke 19 3 springs 3 SHIMs 3 8 springs 2 SHIMs 3 8 springs 1 SHIM E 3 8 springs 0 SHIM 2 8 springs 3 SHIMs 16 Transmission Gear Parts List PART No 2C0 17411 80 A PART NAME AXLE MAIN REMARKS 2C0 17411 90 B AXLE MAIN 2C0 17411 00 AXLE MAIN 2C0 15163 00 HSG BEARING 93306 20562 BRG 2C0 17151 1 A GEAR 5TH PINION 2C0 17151 80 B GEAR 5TH PINION 2C0 17151 90 C GEAR 5TH PINION 2C0 17131 80 A GEAR 3RD PINION 2C0 17131 71 B GEAR 3RD PINION 2C0 17131 90 C GEAR 3RD PINION 2C0 17161 70 A GEAR 6TH PINION 2C0 17161 00 GEAR 6TH PINION 2C0 17161 90 C GEAR 6TH PINION 2C0 17121 80 A GEAR 2ND PINION 2C0 17121 90 B GEAR 2ND PINION 2C0 17121 00 GEAR 2ND PINION O gt O U gt O D O U gt COILNININI OL O
50. tor can damage it At High Speeds Turn clockwise to increase the damping force and anticlockwise to reduce the damping force The adjustment range is 4 steps back from the lightly tightened adjustor position Shipping position 3 turns back from the tightened adjustor position NOTICE When tightening the adjustor do it lightly Over tightening the adjustor can damage it 44 Performance and purpose of kit suspension Differences compared with standard suspension on commercially available machines Spring characteristics Commercially Purpose available machine To increase comfort when riding in urban areas while preventing bottoming even with two people on the bike specs Performance characteristics Combination of springs and bump rubbers Problem with circuit Easy to fully extend when braking high preload Road holding property of rear tire is easily lost during braking rear tire behavior hopping sliding etc easily occurs Kit suspension specs Addition of a rebound spring near full extension alleviates the above problem Damping force characteristics Commercially Purpose available machine To maintain comfort when riding in urban areas and improve road holding properties when banking into bends specs Performance characteristics Limits reaction force to the minimum required damping load Problem with circuit Reduces machine stability excessive movement wh
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