’04 YZF-R6 SS KIT MANUAL The Performance Edge for excellent riders
003 YZF-R6 Kit Manual Please note: • Please understand that these parts are not covered by the warranty. • The manufacturer does not take any responsibility for problems caused by these parts. • These kit parts are intended exclusively for racing purposes. You are strictly requested not to use them for use on public roads. • The specifications and usage methods of these kit parts along with the contents of this manual are subject to change without notice for improvement.
CONTENTS 1 Standard Specifications (SS spec.) ............................................................. 1 2 Kit Parts ......................................................................................................... 2 2-1 Basic Kit Set Contents ................................................................................... 2 2-2 Engine Parts .................................................................................................... 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
3 Assembly Precautions.................................................................................46 3-1 Checking the Valve Seats.............................................................................46 3-2 Connecting Rod Installation Procedure ......................................................48 3-3 Cylinder Head Installation Precautions.......................................................49 3-4 Engine Mounting Procedure .....................................................................
1 Standard Specifications (SS spec.) Item Spec Engine type Liquid-cooled, 4-stroke, In-Line DOHC 4-valve Displacement 599.7 cc Bore × stroke 65.5 mm × 44.5 mm Compression ratio 12.4 – 13.0 : 1 Valve timing (event angle) Intake Exhaust = 105° = 110° Squish height 0.60 mm (minimum) Minimum valve x piston clearance Intake Exhaust = 0.75 mm (minimum), 10° after exhaust top dead center = 1.75 mm (minimum), 11° before exhaust top dead center Valve (tappet) clearance Intake Exhaust = 0.20 ±0.
2 Kit Parts 2-1 Basic Kit Set Contents Spark Plug Set (You can use STD SPARK PLUGS) Head Gasket (t = 0.45 mm) Camshafts and Cam Sprockets Air Funnel Set (Bell Mouth Set) Air Filter Element Assembly AIS Plug Set Clutch Spring Set ACM Set ECU and Wire Harness Set Kit Manual CAUTION: Although those parts indicated with an asterisk (*) in the parts list are included in the kit set, when individual parts are required, they are available through the general parts sales channel. 2-2 Engine Parts 1.
2. Spark Plugs Parts List No. PART No. 1 5FL-94700-70 PART NAME PLUG, SPARK Q'TY 1 REMARKS NGK R0045Q-10 Set No.: 5FL-R045Q-70 (R0045Q-10, 4 plugs) CAUTION: Since these spark plugs use a copper gasket, caution is required with respect to the following points during installation. 1. The tightening torque is 1.0 – 1.2 kg·m. 2. When not controlling torque, tighten by turning only 30° after tightening by hand in the case of new plugs. When reusing plugs, turn 15° to tighten.
4. Remove the cylinder head cover, then the four collars fitted in the head cover, and install the PIN (93608-16M16). 5. After removing the hose that was connected from the air-cut valve assembly to the air filter case, push in the plug (90338-08026) on the air filter side to clog up. 4. Head Gaskets Parts List No. PART No. PART NAME Q'TY REMARKS 1 5SL-11181-70 GASKET, HEAD CYL. 1 t=0.40 mm 2 5SL-11181-75 GASKET, HEAD CYL. 1 t=0.45 mm 3 5SL-11181-80 GASKET, HEAD CYL. 1 t=0.
Stamping location 5. Camshaft and Cam Sprockets Parts List No. PART No. PART NAME 1 5SL-12171-70 SHAFT, CAM 1 1 INT.296 2 5SL-12181-70 SHAFT, CAM 2 1 EXT.284 3 5SL-12176-70 SPROCKET, CAM 1 1 105° 4 5SL-12177-70 SPROCKET, CAM 2 1 110° Tightening torque Q'TY REMARKS 24 Nm (2.4 m·kg) STD FWD. Specifications Intake Exhaust Working angle 296° 284° Valve timing (sprocket) 105° 110° Valve clearance 0.17 – 0.23 mm 0.27 – 0.33 mm Cam lobe a: 33.45 – 33.55 mm b: 25.16 – 25.
Aligning of Valve Timing • When assembling the camshaft, always make sure to align the valve timing. If this is not done, not only will performance not be enhanced when the camshaft is assembled, it will also cause damage to the engine. • The valve timing (event angle) here refers to a crank angle formed from top dead center when the valve is lifted highest. • Use the cam sprocket included in the kit for aligning valve timing. The cam sprocket included in the kit allows selection of five valve timings.
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EVENT ANGLE INT. EVENT ANGLE EXT.
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6. Sub Radiator Set (5SL-A240A-70) Parts List * * * No. PART No. PART NAME Q'TY 1 5SL-1240A-80 SUB RADIATOR ASSY 1 2 5SL-12467-70 COVER, RADIATOR 1 3 90465-13275 CLAMP 4 4 5SL-1244E-70 BRKT., 1 1 5 91317-06012 BOLT 1 6 5SL-12578-70 HOSE, 3 1 7 5SL-12584-70 JOINT, HOSE 3 1 8 5SL-12579-70 HOSE, 4 1 9 5SL-12552-70 HOSE, 8 1 10 5SL-12589-70 HOSE, 6 1 11 5SL-12588-70 HOSE, 5 1 12 5SL-12582-70 JOINT, HOSE 2 1 13 90450-38040 HOSE CLAMP ASSY.
STD WATER PUMP THERMOSTAT SUB RADIATOR STD MAIN SUB Upper assembly diagram (viewed in front) – 11 –
7. Oil Pump Set (5MT-A3100-70) Parts List No. PART No. PART NAME Q'TY 1 5MT-13336-00 HOUSING, ROTOR 1 2 5EB-13316-70 COVER, PUMP 1 3 5EB-13330-70 PUMP SHAFT ASS'Y 1 * 4 1WG-13310-00 ROTOR ASS'Y 1 * 5 93603-17070 PIN, DOWEL 1 * 6 93603-09106 PIN, DOWEL 2 * 7 91317-06025 BOLT 3 * 8 90201-113K2 WASHER 1 9 5MT-13319-70 SPACER 1 REMARKS This kit reduces loss at high engine speeds by decreasing the rotor width.
8. Air Funnel Set (Bell-Mouth Set) (5SL-A4460-70) Parts List No. PART No. PART NAME 1 5SL-14463-70 JOINT. 2 2 2 5SL-14469-75 FUNNEL, 1 2 3 5SL-14454-70 JOINT 2 4 5SL-14479-70 FUNNEL 2 #2 #1 Q'TY #3 REMARKS L=24 mm L=9 mm #4 Installation Precautions: 1. Install the joint and funnel so that the air filter is located in-between. Before installation, remove the plate attached under the STD air filter case and then the STD funnel. 2.
10.Carburetor Clamp complete (5SL-1351A-70) Parts List No. PART No. PART NAME Q'TY * 1 90450-63001 BAND 4 * 2 95307-04600 NUT 4 3 5SL-13573-70 BOLT, 1 3 4 5SL-1358A-70 ROD COMP. 1 REMARKS This part is the one to improve the service of the carburetor. Cut off prominence for the positioning of the band is in “joint, carburetor 1” before using. Cut off The collar is provided to prevent overtightening. However, under normal circumstances, it would not become that tight.
11.Exhaust Pipe Set (5SL-A4600-70) Parts List No. PART No. PART NAME Q'TY 1 5SL-14611-70 PIPE, EXT. 1 1 2 5SL-14621-70 PIPE, EXT. 2 1 3 5SL-14631-70 PIPE, EXT. 3 1 4 5SL-14641-70 PIPE, EXT.
CAUTION: Reroute the clutch wire as shown below so as to prevent it from contacting the exhaust pipe. Piping for auto starter Pass the clutch wire on the outside of the radiator hose. Take care to avoid contact with the cowling.
EXT. DIMENSION Exhaust pipe Diffusser Silencer Pipe outside diameter (Plate thickness t1.2) ø 38.1 ø 42.7 ø 50.
12.Transmission Gear Set (5SL-A7400-70) Parts List No. PART No.
Gear Ratio Speed 5SL-A7400-70 No. of teeth (gear ratio) A (OPTION) No. of teeth (gear ratio) C (OPTION) No. of teeth (gear ratio) STD (Reference) No. of teeth (gear ratio) 1st 34/16 (2.125) 31/15 (2.066) 32/14 (2.285) 37/13 (2.846) 2nd 36/21 (1.714) 35/21 (1.666) — 37/19 (1.947) 3rd 27/19 (1.421) 29/21 (1.380) — 28/18 (1.555) 4th 31/25 (1.240) (←) — 32/24 (1.333) 5th 30/26 (1.153) (←) — 25/21 (1.190) 6th 24/22 (1.090) (←) — 26/24 (1.083) L/T 1.894 1.947 (2.095) 2.
13.Option Gear Set 1stGEAR SET A (5SL-A7411-70) Parts List No. PART No. 1 5SL-17411-70 PART NAME AXLE, MAIN 1ST Q'TY 1 15T 1 31T 2 5SL-17211-70 GEAR, 3 5EB-15163-01 HOUSING 1 4 93306-30525 BRG. 1 WHEEL REMARKS 1STGEAR SET C (5SL-A7411-90) Parts List No. PART No. PART NAME Q'TY REMARKS 1 5SL-17411-90 AXLE, MAIN 1 14T 2 5SL-17211-90 GEAR, 1ST WHEEL 1 32T 3 5EB-15163-01 HOUSING 1 4 93306-30525 BRG. 1 2ndGEAR SET A (5SL-A7421-70) Parts List No. PART No.
14.Sprockets Parts List No. PART No.
15.Clutch Spring Set (5EB-A6330-70) Parts List No. PART No. PART NAME Q'TY 1 3FV-2304E-70 SPRING 6 2 5EB-90159-70 SCREW 6 3 5EB-16559-70 WASHER 6 REMARKS Specifications Kit Standard Identification color Red White Free length 50.2 mm 50.0 mm Mounting load 24.1 kgf 19.8 kgf Mounting height 29.6 mm 29.6 mm Tightening torque 80 Nm (8.
17.ACM Set (5SL-F1400-70) Parts List No. PART No. PART NAME Q'TY 1 5SL-81410-70 STATOR ASS'Y 1 2 5SL-81450-70 ROTOR 1 3 5SL-15590-00 STARTER CLUTCH 1 4 90149-08003 BOLT 3 5 5SL-15411-70 COVER 1 6 91317-06025 BOLT 4 7 92907-06600 WASHER 4 8 5SL-15451-00 GASKET 1 REMARKS ASS’Y=5SL-81400-70 Installation Precautions 1. Before installing the rotor to the crank, degrease both of their tapers. 2.
18.Engine Control Unit (ECU) Parts List No. PART No. 1 5SL-8591A-70 PART NAME ENGINE CONTROL UNIT Q'TY REMARKS 1 • Using the wire harness supplied in the kit, you can switch to control data of SS (Super Sports) specification or to control data of ST (Stock Sports) specification. • SS specification is preset in the state in which the kit camshaft and the 2003 spec kit muffler and kit air filter are used. ST specification is preset in the state in which only the muffler is changed into kit parts.
A: Fuel injection Adjustment Fuel injection amount can be adjusted in the following four ranges: Code C1: Fuel amount injected at 25% or less of throttle opening and at 3000 rpm or less of engine speed Code C2: Fuel amount injected at 25% or less of throttle opening and at 3000 rpm or more of engine speed Code C3: Fuel amount injected at 25% to 90% of throttle opening Code C4: Fuel amount injected at 90% or more of throttle opening Engine speed (rpm) 0 3000 C1 C2 Throttle opening (%) 25% C3 90% C4 Be
Adjustment • Transfer to adjustment mode. While holding down both the “RESET” and “SELECT” buttons on the meter, turn on the main switch (the engine stop switch will not function). “Co” appears in the left of the area for displaying the time and distance. 1. Press both the “RESET” and “SELECT” buttons at the same time. The display changes from “Co” to “C1”. Each time the “SELECT” button is pressed in this state, the display changes to “C2”, “C3”, “C4”, and again “C1” and so forth.
B: Offset at ignition This function corrects the general differences in the ignition timing requirements caused by different fuels etc. Adjustment • Transfer to adjustment mode While holding down the “RESET” and “SELECT” buttons on the meter, turn on the main switch (the engine stop switch will not function). “Co” appears in the left of the display area for the time and distance. 1. Press the “SELECT” button. The display changes to “dIAG “. 2. Press both the “SELECT” and “RESET” buttons at the same time.
C: Location for water temperature display and unit conversion The ECU in the kit has an additional function of displaying the water temperature in the speed display area. CAUTION: This function assumes that speed is displayed in the “km/h” unit on the meter. If the meter displays speed in miles, perform the following steps and change the speed display. 1. Turn on the main switch.
E: Diagnosis (function for checking the condition) The ECU in the kit makes it possible to check whether the sensors and switches are working properly through the following operation by using the STD meter. Operation 1. Turn on the main switch while holding down both the “SELECT” and “RESET” buttons at the same time. “Co” is displayed in the meter display area. 2. Press the “SELECT” button. The display changes to “dIAG”. 3. Press both the “SELECT” and “RESET” buttons at the same time.
Abnormal code Item 30 Turnover sensor (overturned checked) 33 Abnormal ignition #1 34 Abnormal ignition #2 35 Abnormal ignition #3 36 Abnormal ignition #4 Operation of ECU • Vehicle overturned • Engine can be restarted if code goes off when vehicle stands erect.
Table 2 CODE Item Operation of ECU 01 Throttle sensor • Displays throttle sensor input value in angles. • Approx. [17] deg at full closed throttle • Approx [95] deg at full open throttle 02 Ambient pressure sensor • Displays ambient pressure in mmHg. • Approx. [760] mm Hg at standard altitude 03 Intake pressure sensor • Displays intake negative pressure in kPa. • Approx.
19.Wire Harness Set (5SL-F2590-70) Parts List No. PART No. PART NAME Q'TY 1 5SL-82590-70 HARNESS ASS'Y 1 2 5FL-83976-70 SWITCH, MAIN 1 REMARKS • Do not remove the AC generator but leave it to function. Using the battery alone will result in the inability to run in a short time. • This harness enables the meter to light up when the main switch is turned on. • The circuit to the oil level gauge and the fuel sender need not be connected, though the oil warning light and fuel warning light come on.
20.Meter Stay Set (5SL-C8350-70) Parts List No. PART No. PART NAME 1 5SL-28356-70 STAY, 1 1 2 5SL-83519-70 BRKT., METER 1 * 3 90149-06298 SCREW 2 * 4 95704-06500 NUT, FLANGE 2 * 5 4XV-83513-00 DAMPER 3 6 5SL-28321-70 STAY, 1 1 LH 7 5SL-28322-70 STAY, 2 1 RH * 8 95807-06025 BOLT, FLANGE 2 * 9 95307-06600 NUTR, HEX.
2-3 Chassis Parts 21.Oil Catcher Tank Set (5SL-C1707-70) Parts List No. PART No. PART NAME Q'TY 1 5SL-21707-70 OIL TANK COMP 1 2 5EB-15373-70 PIPE, BREATHER 2 * 3 90464-15152 CLAMP 2 * 4 90450-25037 HOSE CLAMP ASS'Y 6 5 5SL-11166-70 PIPE, BREATHER 1 6 371-11166-01 PIPE, BREATHER 1 REMARKS L=370 mm This actual capacity of this oil tank is 1000 cc. Install behind the rear frame above the rear fender.
22.Engine Protector Set (5SL-A5491-70) Parts List No. PART No. PART NAME Q'TY 1 5SL-15491-70 PROTECTOR 1 * 2 91314-06030 BOLT 2 * 3 91314-06025 BOLT 1 * 4 90387-065X6 COLLAR 3 5 91314-06035 BOLT 2 REMARKS This part reduces damage when the motorcycle tips over along with the chassis protector. For the YZF-R6 in the 1999 to 2002 model years, use the collars 4 . Use 1 bolt 2 and 2 bolts 5 .
23.Chassis Protector Set (5SL-C117G-70) Parts List No. PART No. PART NAME Q'TY REMARKS 1 5EB-2117G-70 PROTECTOR 2 2 5SL-21472-70 COLLAR, PROTECTOR 1 LH 3 5SL-21477-70 COLLAR, PROTECTOR 2 1 RH 4 91317-10090 BOLT, HEX. SOCKET 1 LH 5 91317-10060 BOLT, HEX. SOCKET 1 RH 6 90201-10140 WASHER, PLATE 2 Tightening torque 40 Nm (4.0 m·kg) SUPT., ENGINE ENGINE Tightening torque 40 Nm (4.0 m·kg) FWD FRAME ENGINE RIGHT SUPT.
24.Rear Suspension Springs Parts List No. PART No. 1 5SL-22212-70 2 5SL-22212-80 PART NAME Q'TY REMARKS SPRING, 1 1 K=10.7 kgf/mm (Identification color: Black) SPRING, 1 1 K=11.2 kgf/mm (Identification color: Blue) This spring is intended for use in the STD shock absorber. It is slightly shorter than the STD so that the vehicle height is not changed when the spring rate is changed. Specification –70 –80 STD Free length 168 mm 167 mm 168.5 mm Spring rate 10.7 kgf/mm 11.2 kgf/mm 10.
26.Front Fork Spring Parts List No. PART No. PART NAME Q'TY REMARKS 1 5SL-23141-80 SPRING, 1 0.90 kgf/mm 1 5SL-23141-85 SPRING, 1 0.95 kgf/mm 1 5SL-23141-90 SPRING, 1 1.00 kgf/mm 1 5SL-23141-95 SPRING, 1 1.05 kgf/mm 2 5SL-23118-70 SPACER L=53 mm Specification –80 –85 –90 –95 STD Free length 290 mm 290 mm 290 mm 290 mm 250 mm Spring rate 0.90 kgf/mm 0.95 kgf/mm 1.00 kgf/mm 1.05 kgf/mm 0.85 kgf/mm No. of ID marks 3 4 5 6 Nil CAUTION: 1.
27.Throttle Set (5SL-C6300-70) Parts List No. PART No. 1 5EB-26281-81 CAP, GRIP UPPER 1 2 5EB-26282-81 CAP, GRIP UNDER 1 3 5FL-26391-80 CLIP, THROTTLE WIRE 1 4 5SL-26302-70 THROTTLE WIRE ASS’Y 1 * 5 91317-05020 BOLT 2 * 6 91317-05014 BOLT 1 * 7 5SL-26243-71 TUBE GUIDE 1 8 4YR-26242-00 GRIP2 1 9 90201-261L1 WASHER 1 10 4UN-83975-01 SW., HANDLE 2 1 11 5SL-8258A-70 EXTENTION, HARNESS 2 1 * PART NAME Q'TY REMARKS Install this part between SW.
28.Steering Damper Stay Set (5SL-C3495-70) Parts List No. PART No. 1 5EB-23495-70 STAY, DAMPER 1 * 2 91701-08038 PIN 1 * 3 90201-08455 WASHER 1 * 4 90468-16099 CLIP 1 * 5 91317-06025 BOLT, HEX. SOCKET 1 6 5EB-2349T-72 BRKT. 1 * 7 90101-08766 BOLT 2 * 8 92907-08200 WASHER 2 * 9 95707-08500 NUT, FLANGE 2 * 10 91317-08030 BOLT, HEX. SOCKET 1 11 5EB-21312-71 STOPPER, STRG.
29.Front Disk Brake Assembly (5SL-2581T-70) Parts List No. PART No. PART NAME Q'TY 1 5SL-2582T-70 DISK 1 2 5SL-25832-70 BRACKET 1 3 5EB-2581M-70 PIN 7 4 5EB-2581N-70 WASHER 7 5 5EB-93430-70 CIRCLIP 7 REMARKS The disk thickness and heat treatment of these parts has been changed for racing use, resulting in improved durability and operation. Yamaha genuine part 93430-09038 can also be used for the circlip. 30.Front Brake Pad Set (5SL-W0045-70) Parts List No. PART No.
31.Footrest Set (5SL-C7400-70) Parts List No. PART No. 1 5SL-27412-70 BRKT., 1 1 2 5SL-27452-70 BRKT.
Parts List * No. PART No. PART NAME Q'TY 39 5SL-21873-70 BRKT., TANK 1 40 90119-06044 BOLT, HEX.SOCKET 2 41 5SL-2741L-70 BRKT., 4 1 REMARKS This footrest kit is designed to allow its position to have a change of 10 mm upper and lower from the center. Its central position is located 15 mm higher than the STD. A change in the installation position of the arm 13 provides the pattern of 1-down 5-up shifts and 1-up 5-down shifts.
Install the return spring of the rear brake on the master cylinder by removing the rubber boot. Since the standard radiator recovery tank cannot be used, install the recovery tank provided in the kit.
2-4 Other 32.Valve Seat Cutter Set (5SL-M1112-70) Parts List No. PART No. PART NAME Q'TY REMARKS 1 5SL-92101-70-0 SPINDLE 1 2 5SL-92110-70-0 CUTTER, INT 1 1 60° 3 5SL-92110-80-0 CUTTER, INT 2 1 90° 4 5SL-92110-90-0 CUTTER, INT 3 1 120° 5 5SL-92120-70-0 CUTTER, EXT 1 1 60° 6 5SL-92120-80-0 CUTTER, EXT 2 1 90° 7 5SL-92120-90-0 CUTTER, EXT 3 1 120° This tool set is used for fine adjustment of the contact of the valve and valve seat.
3 Assembly Precautions NOTE: Please check next point for set up your motorcycle. 3-1 Checking the Valve Seats The following procedure applies to all of the valves and valve seats. 1. Eliminate: • carbon deposits (from the valve face and valve seat) 2. Check: • valve seat Pitting/wear → Replace the cylinder head. 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width 0.9 – 1.1 mm (0.0354 – 0.0433 in) : 1.6 mm (0.06 in) a.
4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound a to the valve face. CAUTION: Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d.
3-2 Connecting Rod Installation Procedure 1. Install the connecting rod 1 to the bearing 4 with the projections engaged. Apply oil generously to the bearing surface. 2. For installation, take care so that the letters “YY” are to the left. 3. Apply oil generously to the threaded portion of the bolt 2 , the contact surface of the connecting rod cap, and the contact surfaces of the nuts 3 . 4. Tighten the nuts 3 to 15Nm (1.5 m·kg) with a torque wrench. 5. Further tighten the nuts 3 to a rotation angle of 150°.
3-3 Cylinder Head Installation Precautions • For cylinder head installation, apply engine oil to the tightening bolts and washers and install in the tightening sequence. • Tighten the bolts and washers three times, each to the following torque value. 1st: 19 Nm (1.9 m·kg) 2nd: 35 Nm (3.5 m·kg) 3rd: 50 Nm (5.0 m·kg) • After tightening, half-fill oil in the bolt installation holes on the sprocket side.
3-4 Engine Mounting Procedure Strictly follow the steps below. If not, the frame stiffness and handling may be adversely affected. 1. Before mounting the engine to the frame, install the engine support 1 on the left of the engine using the bolts 2 . (Tightening torque: 45Nm, 4.5 m·kg) 2. Lightly tighten the 2 engine adjust bolts 3 beforehand on the inside of the rear right of the frame. 3. Mount the engine on the frame, insert the bolts 4 and 5 from the left at 2 rear places, and tighten them lightly. 4.
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3-5 Rear Arm Installation Procedure 1. Tighten to specification beforehand the bracket 11 using the bolt 13 and nut 14 on top of the shock absorber 10 . (Tightening torque: 44 Nm, 4.4 m·kg) 2. Tighten to specification the shock absorber 10 to the frame, using the nut 12 . (Tightening torque: 52 Nm, 5.2 m·kg) 3. Attach the adjust bolt 6 on the right inside of the frame and lightly tighten it. 4.
Parts List No. PART No. PART NAME 20 93315-31758 BRG. 2 21 90105-10018 BOLT,FLG.
3-6 Front Wheel Installation Procedure 1. Insert the wheel axle 2 from the left of the vehicle, and tighten the bolt 3 to specification on the right. (Tightening torque: 80 Nm, 8.0 m·kg) Apply grease to the contact surface of the bolt 3 . 2. Without temporary fitting, tighten to specification the bolts 8 in order of B and A and back to B again. (Tightening torque: 17 Nm, 1.7 m·kg) 3. Make sure that the end surface of the wheel axle 2 is flush with the end surface on the front fork side (the portions A).
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3-7 Please apply grease on the wall in AIR CLEANER CASE. This grease will catch some dusts.
4 R6 Front Fork Manual (basic information) ADJUSTMENT The adjustment of your front fork can be changed by following factors: • • • • • • Spring rate Preload on the spring Oil level Viscosity and quality of the oil Compression damping Rebound damping The combined working of these factors will influence the working of the front fork and the balance of the bike. The standard adjustments are based on several years of experience and are in most of the cases the best adjustment.
Adjustment of rebound damping The rebound refers to the hydraulic damping when the front fork moves out. The rebound can be changed by the rebound adjuster which is located on the top of the fork. The rebound damping fixes the speed of the front fork moving out. Before you want to change the rebound, it is essential to know the standard set up. The best set up for different circuits/roads can be obtained by adjusting the compression and rebound damping to your personal feeling.
Compression damping • Standard adjustment • Not enough damping: - the front fork is bottoming easy • Too much damping: - the front fork feels had and harsh - the full stroke has not been used - the front is not absorbing the small bumps Rebound Damping • Standard adjustment • Not enough damping: - the front fork feels springy (feels like not enough hydraulic damping) - the front is coming out to quickly - the bike feels riding high in front • Too much damping: - the front fork feels harsh over small bumps a
SOLVING PROBLEMS Place Terrain Problem 1. Springy 2. Feels hard, stiff Straight line Small bumps Adjustment Increase rebound Decrease preload A: decrease compression B: decrease rebound C: decrease preload A: decrease rebound 3. Not reacting to bumps B: decrease compression C: decrease preload A: increase spring rate 1. Nose dives B: raise oil level C: increase preload D: increase compression Heading into a turn Corners 2.
Place Terrain Under acceleration Problem Head shakes Adjustment Increase rebound A: decrease spring rate B: decrease preload Feels harsh Uphill C: decrease rebound D: decrease compression Consecutive small bumps A: decrease spring rate Feels high B: raise outer tubes in clamps C: decrease preload A: decrease rebound Downhill Feels low B: lower outer tubes in clamps C: increase compression D: increase preload A: increase spring rate 1.
5 R6 Shock Absorber Manual (basic information) ADJUSTMENT Following factors can change the adjustment of a shock: • spring rate • preload on the string • compression damping • rebound damping The combined working of these factors will influence the working of the shock and the balance of the bike. The standard adjustments are based on several years of experience and are the best adjustments for general use. Adjustment is possible for extreme wishes of circuit of rider (weight).
Adjustment of rebound damping The rebound refers to the hydraulic damping when the shock moves out. The rebound can be changed by the rebound adjuster which is located on the bottom of the shock. The rebound damping fixes the speed of the shock moving out. Before you want to change the rebound, it is essential to know the standard set up.
Compression damping • standard adjustment • not enough compression: • too much compression: Rebound damping • standard adjustment • not enough rebound: • too much rebound the shock is bottoming easy the bike sits low the bike turns difficult the bike is feeling hard and stiff the bike feels high the shock is not using complete stroke the shock just hits the bumps and is not absorbing these - the shock feels springy (feels like no hydraulic damping) the shock moves out too quickly, kicks up the bike feel
SOLVING PROBLEMS Place In straight line Terrain Small bumps Problem Adjustment 1. Springy Increase rebound 2. Feels heavy Decrease rebound 3. Lack of traction Decrease rebound A: decrease spring rate Heading into a turn 1. Springs back B: decrease spring preload C: increase rebound D: decrease compression Corners 1. Lack of traction Accelerating out of a turn 2. Squats A: decrease spring rate B: decrease rebound A: increase spring preload B: increase spring rate C: increase compression 1.
Place Terrain Problem Adjustment A: decrease spring rate 1. Too stiff overall Other 2. Feels springy 3.
2003 YZF-R6 Wiring Diagram – 67 –
Speed × Ratio table for YZF-R6 (2003) Name gearbox Std Wheel circumflex (m) Max RPM 1.98 15000 Primary ratio 44 Gear 13 13 13 13 14 13 14 13 14 13 14 15 13 14 15 13 14 15 13 14 15 16 14 15 16 14 15 16 14 15 16 16 15 16 15 16 15 16 16 16 51 50 49 48 51 47 50 46 49 45 48 51 44 47 50 43 46 49 42 45 48 51 44 47 50 43 46 49 42 45 48 47 44 46 43 45 42 44 43 42 Prim Sec 86 1st 13 37 81.7 83.3 85.0 86.8 87.9 88.6 89.
YEC CO.,LTD. 3622-8 Nishikaizuka. Iwata. Shizuoka.
