Yamaha 2010 YZF-R6 Manual Instruction Download | Manualshive

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Transmission Assembly

Position the abutment joint of the circlip
right between the splines.

Circlip

Shaft

Edge

Portion R

Edge

Detail of installation of washer

Detail of installation of washer

Shaft

Washer

Washer

Matching mark

Matching mark

Portion R

Washer

Gear

The seal side should face outward (one side
seal bearing) and press in the bearing cup all
the way into the case until it touches bottom.

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
fit into the bearing cup of the bearing.
(Apply grease to the lip.)

Detail of installation of circlip

Detail of installation of circlip

Edge

Shaft

Washer

Washer

Matching mark

Matching mark

Portion R

Circlip
(Direction
not applicable)

Shaft

Washer

Gear

Position the abutment joint of the
circlip right between the splines.

Apply molybdenum oil to inside of 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.

TIP

•

Always use a new circlip.

•

Do not mistake the washer and circlip directions.
(See drawing below.)

Rotate washer so that its teeth meet axle-
spline teeth on the axle, and then lock with
washer s claw.
Assemble washer with putting together
their matching mark.

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Summary of Contents for 2010 YZF-R6

Page 1: ......

Page 2: ... change without notice for improvement Parts List Symbols 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 The circle mark means that when needed the individual part is sold separately to the kit set Symbol Marks Particularly important information is distinguished in this ma...

Page 3: ...Clutch Setting Set 4B1 A6377 70 17 16 Transmission Gear 20 17 Mission Maintenance Set 2C0 A7000 70 24 18 Drive Sprocket 27 19 Sprocket Nut Set 2C0 A7463 70 28 20 ACM Set 2C0 F1400 71 29 21 Wire Harness Set 13S F2590 71 30 22 ECU Set 2C0 8591A 91 35 23 Cable Interface 13S 8533A 70 36 2 2 Vehicle Accessories 39 24 Engine Protector Set 2C0 A5491 70 39 25 Chassis Protector Set 2C0 C117G 70 40 26 Oil C...

Page 4: ...3 Tightening Torque List 63 4 YZF R6 Wiring Diagram 76 ...

Page 5: ...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 INT 110 105 105 EXT 115 110 110 Squish height minimum 0 60 mm 0 60 mm 0 70 mm Clearance between valve and piston minimum INT 1 05 mm ATDC 12 1 05 mm ATDC 12 1 15 mm ATDC 12 EXT 1 62 mm BTDC 12 1 62 mm BTDC 12 1 80 mm BTDC 12 valve tappet clearance INT 0 15 0 19 m...

Page 6: ...OLT CONNECTING ROD 24 5 90179 07001 NUT 24 6 4SV 12119 00 SEAL VALVE STEM OIL 48 7 2C0 12213 00 GASKET TENSIONER 3 8 2C0 13414 70 GASKET STRAINER 3 ANTI STICK TYPE 9 2C0 15451 70 GASKET CRANKCASE COVER 1 3 ANTI STICK TYPE 10 2C0 15461 70 GASKET CRANKCASE COVER 2 3 ANTI STICK TYPE 11 2C0 15456 70 GSKT 1 3 ANTI STICK TYPE 12 93102 35017 SEAL OIL 3 FOR DRIVE AXLE 13 90151 06024 SCREW CROSSRECESSED CO...

Page 7: ...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 Parts List Semi surface discharge Type 5FL R045Q 70 No PART No PART NAME Q TY REMARKS 1 5FL 1119C 70 PLUG SPARK 4 NGK R0045Q 10 Parts List Angled ground strap Type 13S R373A 70 No PART No PART NAME Q TY REMARKS 1 13S 1119C 70 PLUG SPARK 4 NG...

Page 8: ...ish height and use the gasket so that the squish height becomes 0 60mm or above TIP Squish height means the gap between the flat portion of the piston and the head cylinder Parts List No PART No PART NAME Q TY REMARKS 1 2C0 11181 71 GASKET CYLINDER HEAD 1 t 0 40mm 2 2C0 11181 76 GASKET CYLINDER HEAD 1 t 0 45mm 3 2C0 11181 81 GASKET CYLINDER HEAD 1 t 0 50mm 4 2C0 11181 86 GASKET CYLINDER HEAD 1 t 0...

Page 9: ...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 3 Apply a thin coat of Vaseline to the valve face and set the IN and EX valves 4 Apply a thin c...

Page 10: ...bine them so that the small end weights are uniform by Yamaha s measuring method 6 Crankshaft 2C0 11411 70 Select a crankshaft with good balance Parts List No PART No PART NAME Q TY REMARKS 1 13S 11631 00 PISTON 4 2 2C0 11603 00 PISTON RING SET 4 3 2C0 11633 00 PIN PISTON 4 4 93450 16159 CIRCLIP 8 Parts List No PART No PART NAME Q TY REMARKS 1 13S 11650 00 CONN ROD ASSY 1 4 Parts List No PART No P...

Page 11: ...rockets 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 When using this camshaft use the valve spring set 2C0 A2110 70 Parts List No PART No PART NAME Q TY REMARKS 1 2C0 12171 72 SHAFT CAM 1 1 INT 2 2C0 12181 71 SHAFT CAM 2 1 EXT 3 2C0 12176 80 SPROCKET CAM 1 1 INT 4 2C0 12177 80 SPROCKET CAM 2 1 EXT S...

Page 12: ...ts 2C0 12171 71 2C0 12171 72 and 2C0 12181 71 9 Oil Pump 2C0 13300 70 This pump is capable of a larger discharge than the STD counterpart Parts List No PART No PART NAME Q TY REMARKS 1 2C0 12113 70 SPRING 1 8 For 2C0 12171 71 INT Identifying color Light blue 2 2C0 12114 70 SPRING 2 8 For 2C0 12181 71 EXT Identifying color Yellow 3 2C0 12117 70 RET VALVE SPRING 16 Parts List No PART No PART NAME Q ...

Page 13: ...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 Parts List No PART No PART NAME Q TY REMARKS 1 PRIMARY FUNNEL 2 L 15 9mm 2 SUPPORT L 1 3 SUPPORT R 1 4 EXTENSION FUNNEL R 2 5 EXTENSION FUNNEL L 2 Bush Bush Lever Support R Support L Le...

Page 14: ... 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 PRIMARY FUNNEL LEVER ASSY Motor side A C SHAFT ASSY Lever side ...

Page 15: ...unnel before attaching the lever assembly 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...

Page 16: ...sion for positioning bands at the cabjoint 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 Parts List No PART No PART NAME Q TY REMARKS 1 2C0 1351A 70 THROTTLE BODY CLAMP ASSY 1 Cut it off ...

Page 17: ...the inside 3 Install the plate 5SL 1482L 70 in replacement of the cap Apply liquid gasket to the plate 4 Remove the cylinder head cover and the four collars fitted to the cover Install the PIN 93608 16M16 5 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 hos...

Page 18: ... 14 A C ASSY STD KIT REMOVE A C ASSY Insertion direction ...

Page 19: ...5 13 Clutch Spring Set 2CO A6330 70 The clutch spring should have a bigger mounting load than standard Parts List No PART No PART NAME Q TY REMARKS 1 2C0 16334 70 SPRING CLUTCH 2 6 Identifying color Green ...

Page 20: ... Friction Plate Set 2CO A6321 70 Compared to STD the friction plate enhances durability and operation Parts List No PART No PART NAME Q TY REMARKS 1 5EB 16321 72 PLATE FRICTION 1 9 Identification Paint Violet ...

Page 21: ... 17 15 Slipper Clutch Setting Set 4B1 A6377 70 Parts List No PART No PART NAME Q TY REMARKS 1 4B1 16377 70 NUT LOCK 1 2 4B1 16391 70 SHIM 3 2 a 1 c b 42 4 43 0 ...

Page 22: ... setting is three of slipper clutch setting set the back torque limiter tends to be effective Engine braking becomes less effective Further when decreasing the number of spring the number of standard setting is three to two the back torque limiter becomes effective Engine braking becomes less effective The clutch spring can be either the kit item or the standard item If you mount the clutch spring...

Page 23: ... 19 As installed In operation Stroke Load 3 a springs 3 SHIMs 3 a springs 2 SHIMs 3 a springs 1 SHIM 3 a springs 0 SHIM 2 a springs 3 SHIMs ...

Page 24: ...90 B GEAR 2ND PINION 1 B 7 2C0 17121 00 GEAR 2ND PINION 1 C 8 2C0 17402 70 DRIVE AXLE ASSY 1 9 2C0 17421 00 AXLE DRIVE 1 10 93305 20509 BRG 1 11 90387 25016 COLLAR 1 12 2C0 17221 81 A GEAR 2ND WHEEL 1 A 12 2C0 17221 90 B GEAR 2ND WHEEL 1 B 12 2C0 17221 00 GEAR 2ND WHEEL 1 C 13 2C0 17261 71 A GEAR 6TH WHEEL 1 A 13 2C0 17261 80 B GEAR 6TH WHEEL 1 B 13 2C0 17261 90 C GEAR 6TH WHEEL 1 C 14 2C0 17241 8...

Page 25: ...C std A B C 1st 31 12 2 583 37 16 2 313 42 17 2 471 31 12 2 583 2nd 32 16 2 000 39 21 1 857 39 20 1 950 32 16 2 000 3rd 30 18 1 667 36 23 1 565 29 18 1 611 30 18 1 667 4th 26 18 1 444 25 18 1 389 26 18 1 444 28 19 1 474 5th 27 21 1 286 33 26 1 269 30 23 1 304 27 20 1 350 6th 23 20 1 150 25 22 1 136 23 20 1 150 26 22 1 182 Parts List No PART No PART NAME Q TY REMARKS 16 13 14 15 17 7 6 5 4 12 3 2 1...

Page 26: ...B 2C0 17221 90 B 39 B C 2 000 2C0 17121 00 16 2C0 17221 00 32 3RD A 1 565 2C0 17131 80 A 23 A 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 C 2C0 17231 90 C 30 C 4TH A 1 389 2C0 17131 80 A 18 A 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 A 1 269 2C0 17151 71 A 26 A 2C0 17251 ...

Page 27: ...2 170 8 168 9 167 3 163 9 160 7 157 6 B 18 29 1 611 202 3 197 9 193 7 189 6 189 6 185 7 185 5 182 0 181 5 178 5 177 8 177 0 175 0 174 1 173 1 170 7 169 4 167 3 165 9 164 1 162 5 159 3 156 2 153 2 C 18 30 1 667 195 5 191 3 187 2 183 3 183 3 179 6 179 3 176 0 175 5 172 5 171 8 171 1 169 2 168 3 167 4 165 0 163 8 161 7 160 4 158 6 157 1 154 0 151 0 148 0 4th A 18 25 1 389 234 6 229 5 224 6 220 0 220 ...

Page 28: ...387 21003 COLLAR 3 25 90209 22352 WASHER 3 26 90209 21351 WASHER 3 27 90387 28011 COLLAR 3 28 90209 25011 WASHER 9 29 93440 28184 CIRCLIP 15 30 90387 25015 COLLAR 6 31 90214 25004 WASHER CLAW 3 32 90214 25003 WASHER CLAW 3 33 90387 21004 COLLAR 3 34 93102 35017 SEAL OIL 3 35 93440 52014 CIRCLIP 5 36 90201 20278 WASHER PLAIN 3 37 93306 20464 BRG 3 38 93306 20464 BRG 3 ...

Page 29: ... 25 28 29 30 28 29 30 32 31 26 25 24 22 23 33 36 38 28 29 23 37 22 21 34 27 35 ...

Page 30: ...up of the bearing Apply grease to the lip Detail of installation of circlip Detail of installation of circlip Edge Shaft Washer Washer Matching mark Matching mark Portion R Circlip Direction not applicable Shaft Washer Gear Position the abutment joint of the circlip right between the splines Apply molybdenum oil to inside of diameter After assembly it should rotate smoothly Apply molybdenum oil to...

Page 31: ...ng direction it will cause the misalignment of the drive and rear sprockets leading to the loss of power Parts List No PART No PART NAME Q TY REMARKS 1 2C0 17460 74 SPROCKET DRIVE 1 14T 2 2C0 17460 75 SPROCKET DRIVE 1 15T 3 2C0 17460 76 SPROCKET DRIVE 1 16T GROOVE MACHINING STAMP OF THE NUMBER OF TEETH ON BOTH SIDES 2CO 06 and after YZF R6 Install with the grooved surface facing outside of the cha...

Page 32: ... 28 19 Sprocket Nut Set 2C0 A7463 70 Parts List No PART No PART NAME Q TY REMARKS 1 90179 20005 NUT SPROCKET 1 2 90215 21256 WASHER TONGUED 1 TIGHTEN NUT BEFORE BENDING ...

Page 33: ...lts before using them Parts List No PART No PART NAME Q TY REMARKS 1 2C0 81410 70 STATOR ASSY 1 2 2C0 81450 70 ROTOR ASSY 1 3 2C0 15580 00 STARTER CLUTCH OUT ASSY 1 4 2C0 15536 00 CLIP STARTER 1 5 2C0 15411 71 COVER CRANKCASE 1 1 6 90149 06080 SCREW 3 With screw lock 7 2C0 15451 70 GSKT CRANKCASE COVER 1 1 ANTI STICK TYPE STD Tightening torque 70 N m Tightening torque 12 0 N m Tightening torque ...

Page 34: ...g check that proper riding is possible even when using either map You can use Map Select and Pit Road Limiter with the switches 2 types included with this set See diagram 1 Parts List No PART No PART NAME Q TY REMARKS 1 13S 82590 71 WIRE HARNESS ASSY 1 2 5GF 83976 00 SW HANDLE 1 1 PIT ROAD LIMITER 3 14B 83976 70 SW HANDLE 1 1 MAP SELECT 4 2C0 2128A 70 BRKT REGULATOR 1 1 5 2C0 82509 70 WIRE SUB LEA...

Page 35: ...g it turns the power off NOTICE Be careful not to pull the wire too strongly The switch installed to the STD machine may be used as is See diagram 3 Diagram 2 Main switch Engine stop switch Starter switch Pit road limiter ON ON PUSH OFF Not used Map select Lo Map 1 Hi Map 2 ON OFF Pit road limiter Main switch Diagram 3 Ignition cut switch ...

Page 36: ...tor 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 Install the switch to the 2 pin black coupler underneath the fuel tank Turning the switch ON cuts the ignition NOTICE Do not connect the coupler for resistor black 2 prong and the coupler for power white 2 prong Connecting t...

Page 37: ...n Diagram 7 such as when not using a standard radiator 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 7 9 8 7 4 10 FRAME FWD RECTIFIER REGULATOR Diagram 8 Coupler ...

Page 38: ... comes with a coupler black 2 pole plug for use with a quick shifter Connection diagram E G STP SW Diagram 9 You can use any quick shifter product 74 Diagram 9 Connector for steering damper Connector for quick shifter ...

Page 39: ...f 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 2008 2009 and 2010 models allow any combination of ECU and wire harness Other models only allow the combinat...

Page 40: ... 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 The product vendor ID and product ID are provided by the Hamamatsu TOA Electronics Inc Vendor ID 6837 Product ID 9001 Parts List No PART No PART NAME Q TY REMARKS 1 13S 8533A 70 CABLE INTERFACE 1 USB 2 13S...

Page 41: ...p C 06 Water temperature sensor Water Temp C 07 Vehicle speed sensor Speed Signal 08 Overturn sensor Lean Angle Signal V 09 Monitor voltage System Voltage V 13 Throttle sensor 2 TPS 2 deg 14 Accelerator sensor 1 APS 1 deg 15 Accelerator sensor 2 APS 2 deg 21 Neutral switch Neutral SW 30 Ignition coil 1 31 Ignition coil 2 32 Ignition coil 3 33 Ignition coil 4 36 Injector primary 1 37 Injector prima...

Page 42: ...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 ...

Page 43: ...r Set 2C0 A5491 70 These parts protect the chassis as well as alleviating damage caused by overturning Parts List No PART No PART NAME Q TY REMARKS 1 2C0 15491 70 PROTECTOR 1 2 91314 06025 BOLT HEX SOCKET HEAD 2 3 91314 06020 BOLT HEX SOCKET HEAD 1 ...

Page 44: ...17G 70 PROTECTOR LH LONG 1 2 2C0 2117G 90 PROTECTOR RH SHORT 1 3 2C0 21472 70 COLLAR PROTECTOR 2 4 91317 10060 BOLT HEX SOCKET HEAD 1 5 91314 10065 BOLT HEX SOCKET HEAD 1 6 90201 10136 WASHER PLAIN 2 Tightening torque 40 N m 4 0 m kg Tightening torque 40 N m 4 0 m kg Tightening torque FWD ENGINE ...

Page 45: ... 41 Before mounting the protector cut the cowling so that the protector can fit against the chassis As a rough guide cut by φ60 centered on the engine mount See the figures below ...

Page 46: ...P 1 2 90450 25037 HOSE CLAMP ASSY 4 3 13S 15373 70 PIPE BREATHER 1 4 2C0 15393 70 PIPE BREATHER 2 1 5 2C0 2419F 00 BRKT 1 6 91317 06020 BOLT HEX SOCKET HEAD 2 7 90480 13018 GROMMET 2 8 90119 06044 BOLT HEX W WASHER 2 9 2C0 15373 70 PIPE BREATHER 1 For 2006 and 2007 models 6 5 8 7 3 4 2 1 545cc OUT IN IN OUT A C 9 For 2008 and 2009 models For 2006 and 2007 models ...

Page 47: ...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 Parts List No PART No PART NAME Q TY REMARKS 1 13S 22210 71 SHOCK ABSORBER Rr 1 98 N mm Low speed compression damping adjustor bolt width 4mm hexagonal hole High speed compression damping adjustor bolt width 12mm hexagonal ...

Page 48: ...se 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 adjustor can damage it At High Speeds Turn clockwise to increase the damping force and anticlockwise to re...

Page 49: ... Commercially available machine specs Purpose To maintain comfort when riding in urban areas and improve road holding properties when banking into bends Performance characteristics Limits reaction force to the minimum required damping load Problem with circuit Reduces machine stability excessive movement when accelerating passing over a gap etc Reduces turning performance stroke volume is excessiv...

Page 50: ...he length diameter and rate For spring replacement see the 13S STD Service Manual The spring rate of the standard rear suspension is 103 N mm Parts List No PART No PART NAME Q TY REMARKS 1 13S 22222 70 SPRG Rr SHOCK 1 103 N mm Identifying stamp 165 55 103 2 13S 22222 75 SPRG Rr SHOCK 1 98 N mm Identifying stamp 165 55 98 3 13S 22222 80 SPRG Rr SHOCK 1 93 N mm Identifying stamp 165 55 93 ...

Page 51: ...bound 1 to 25 steps back from the adjustor s 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 ti...

Page 52: ... 48 Rebound damping adjustor Compression low speed damping adjustor Compression high speed damping adjustor ...

Page 53: ...istics 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 Line...

Page 54: ...iod Reduces machine stability excessive movement when accelerating 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 Others Kit suspension specs TiO coating inner tubes adopted Improves durability and lowers friction Spring support method cha...

Page 55: ... you do not need to replace the preload tube Use the original tube fitted to the fork TIP A spanner SPECIAL TOOL and rod SPECIAL TOOL are supplied with the front fork 13S 23102 70 Use Yamaha M1 suspension oil Parts List No PART No PART NAME Q TY REMARKS 1 13S 23151 70 SPRG Fr FORK 1 10 5 N mm Identifying slits 3 2 13S 23151 75 SPRG Fr FORK 1 10 0 N mm Identifying slits 2 3 13S 23151 80 SPRG Fr FOR...

Page 56: ...e until the dust seal touches the upper surface of the axle bracket 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 NOTICE Do not remove the spanner SPECIAL TOOL while doing this Axle bracket Rebound damping adjustor Preload adjustor Fork bolt Spanner SPECIAL TO...

Page 57: ... SPECIAL TOOL to the piston rod 6 Grip the rod SPECIAL TOOL firmly and remove the spanner SPECIAL TOOL NOTICE Be very careful to apply downward pressure on the rod SPECIAL TOOL when you remove the spanner SPECIAL TOOL Push rod Rod SPECIAL TOOL ...

Page 58: ...preload tube before removing the rod SPECIAL TOOL 8 Remove the washer special nut and spring guide and replace the spring NOTICE When replacing the spring fit the new spring with the tapered closed end upwards Washer Special nut Spring guide ...

Page 59: ...il level Oil level in load state With the spring removed and the outer tube and 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 ...

Page 60: ...oke 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...

Page 61: ...C0 23488 80 SPACER 1 4 91317 08110 BOLT HEX SOCKET HEAD 1 5 95607 08100 NUT U 1 6 2C0 2349T 80 BRKT DAMPER 1 7 90201 07081 WASHER PLAIN 2 8 90149 06302 SCREW 2 9 5VY 26398 00 WASHER SPECIAL 1 10 91317 08025 BOLT HEX SOCKET HEAD 1 11 2C0 23439 71 STOPPER STRG 2 1 12 90387 06084 COLLAR 1 13 90201 07081 WASHER PLAIN 1 14 90149 06302 SCREW 1 15 2C0 23429 70 STOPPER 1 16 90151 04002 SCREW CROSSRECESSED...

Page 62: ... 58 32 Seat Cushion 13S 24713 70 Anti slip seat Cut to any size for use Parts List No PART No PART NAME Q TY REMARKS 1 13S 24713 70 CUSHION SEAT 1 ...

Page 63: ...mbly 2C0 25100 70 This kit does not include a tire This part is an assembly of bearings spacers and an air valve in a STD wheel Parts List No PART No PART NAME Q TY REMARKS 1 2C0 25160 00 CAST WHEEL ASSY 1 2 93900 00030 VALVE RIM 1 ...

Page 64: ...bly 2C0 25300 70 This kit does not include a tire This part is an assembly of bearings spacers and an air valve in a STD wheel Parts List No PART No PART NAME Q TY REMARKS 1 2C0 25370 00 CAST WHEEL ASSY 1 2 93900 00030 VALVE RIM 1 ...

Page 65: ...DE 1 4 2C0 26391 70 CLIP WIRE 1 1 5 2C0 26311 70 WIRE THROTTLE 1 2 Grip side Retracting sharing 6 2C0 26313 70 WIRE THROTTLE 3 2 Engine side Retracting sharing 7 2C0 26261 70 CYLINDER 2 8 5FL 26244 70 SLIDER 2 9 2C0 2639E 70 PROTECTOR 2 10 90201 261L1 WASHER PLAIN 1 11 91314 05020 BOLT HEX SOCKET HEAD 2 12 91314 05008 BOLT HEX SOCKET HEAD 1 2 1 Machining off the boss Scrape away CAP GRIP UPPER of ...

Page 66: ...PART NAME Q TY REMARKS 1 2C0 26281 70 CAP GRIP UPPER 1 2 5FL 26282 00 CAP GRIP UNDER 1 3 5SL 26243 71 TUBE GUIDE 1 4 2C0 26391 70 CLIP WIRE 1 1 5 13S 26302 70 THROTTLE WIRE ASSY 2 Common use for pulling back 6 90201 261L1 WASHER PLAIN 1 7 91314 05020 BOLT HEX SOCKET HEAD 2 8 91314 05008 BOLT HEX SOCKET HEAD 1 Machining off the boss Scrape away CAP GRIP UPPER of the kit as shown above ...

Page 67: ... ANGLE 55 2 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 M6 x 1 0 12 0 2 1 2 0 2 2 WITH WASHER SPARK PLUG 5FL 1119C 70 13S 1119C 70 PLUG SPARK M10S x 1 0 12 15 1 2 1 5 4 SEE page 3 FOR DETAILS HEAD COVER x HEAD 90109 066F0 BOLT M6 x 1 0 12 0 2 1 2 0 2 6 Plug for sand drain hole 90340 18002 P...

Page 68: ...ASHER TENSIONER ASSY x CYLINDER 90110 06106 BOLT HEXAGON SOCKET HEAD M6 x 1 0 12 0 2 1 2 0 2 2 INSTALL TEN SIONER ASSY Install COVER THERMOSTAT 91312 06020 BOLT HEXAGON SOCKET HEAD M6 x 1 0 12 0 2 1 2 0 2 2 Install JOINT 90105 06082 BOLT FLANGE SMALL HEAD M6 x 1 0 10 0 2 1 0 0 2 2 Install WATER PUMP 90110 06140 BOLT HEXAGON SOCKET HEAD M6 x 1 0 12 0 2 1 2 0 2 2 OIL PUMP ASSY x CRANKCASE 2 95812 06...

Page 69: ...AD AND BEARING SUR FACE UPPER CASE x CAP CASE ASSY 92012 06020 BOLT BUTTON HEAD M6 x 1 0 5 0 0 5 0 5 0 05 4 UPPER CASE x LOWER CASE 98902 05020 SCREW CROSS RECESS BINDING M5 x 0 8 2 0 0 5 0 2 0 05 10 ELEMENT x UPPER CASE 98902 05020 SCREW CROSS RECESS BINDING M5 x 0 8 2 0 0 5 0 2 0 05 1 JOINT CARBURETOR 1 x THROTTLE 90450 56007 HOSE CLAMP ASSY M5 x 0 8 2 0 2 5 0 2 0 25 4 CONTACT FIT COLLAR OR TORQ...

Page 70: ... 7 0 5 0 7 1 1 PULLEY x GEARED MOTOR 90110 05028 BOLT HEXAGON SOCKET HEAD M5 x 0 8 6 5 1 5 0 65 0 15 1 BRACKET 7 x FRAME 95827 06014 BOLT FLANGE SMALL HEAD M6 x 1 0 6 10 0 6 1 0 2 BRACKET 7 x SERVOMOTOR 95027 06025 BOLT FLANGE SMALL HEAD M6 x 1 0 5 8 0 5 0 8 2 Install MUFFLER PROTECTOR 90111 06071 BOLT HEXAGON SOCKET BUTTON M6 x 1 0 8 0 1 5 0 8 0 15 1 Install MUFFLER PROTECTOR 90111 06099 BOLT HEX...

Page 71: ...READ AND TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 06045 BOLT FLANGE M6 x 1 0 10 0 2 1 0 0 2 3 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 06030 BOLT FLANGE M6 x 1 0 10 0 2 1 0 0 2 1 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE Install COVER CRANKCASE 1 90109 06015 BOLT M6 x 1 0 12 0 2 1 2 0 2 9 Install COVER CRANKCASE 2 90109 06031 BOLT M6 x 1 0 12 ...

Page 72: ... TO OVER TIGHTEN COVER CRANKCASE 1 x CLAMP 90149 06082 SCREW M6 x 1 0 10 0 2 1 0 0 2 1 STATOR LEAD Install COVER 90109 06015 BOLT M6 x 1 0 12 0 2 1 2 0 2 5 Install OIL PIPE OUTSIDE 90110 06161 BOLT HEXAGON SOCKET HEAD M6 x 1 0 12 0 2 1 2 0 2 2 CRANKCASE 2 x PICKUP 90110 06168 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 0 2 1 0 0 2 2 Embedded in CRANKCASE x STUD EMBEDDED 90116 1002 BOLT STUD M10 x 1 25 HE...

Page 73: ...stall ROTOR PICKUP 90105 08113 BOLT FLANGE M8 x 1 25 35 0 5 3 5 0 5 1 Install STARTER MOTOR 90105 06083 BOLT FLANGE SMALL HEAD M6 x 1 0 10 0 2 1 0 0 2 2 NEUTRAL SWITCH ASSY 3GB 82540 01 NEUTRAL S W ASSY M10 x 1 25 19 6 2 2 0 0 2 1 OVERTIGHTEN ING LEADS TO DAMAGE Install OIL LEVEL SENSOR 95022 06016 BOLT FLANGE SMALL HEAD M6 x 1 0 10 0 2 1 0 0 2 2 APPLY GREASE TO O RING SPEED SENSOR x C C 91312 060...

Page 74: ...13S 8592A 00 O2 SEN SOR M18 x 1 5 45 0 5 4 5 0 5 1 Install THERMOSENSOR 8CC 85790 01 THERMO SENSOR ASSY M12 x 1 5 17 6 2 1 8 0 2 1 To be tightened Part No Part Name Screw dia x pitch Tightening torque N m kgf m Q ty Remarks ...

Page 75: ... 20 25 2 0 2 5 4 E G BRACKET FRONT 95024 10040 BOLT FLANGE SMALL HEAD M10 x 1 25 35 45 3 6 4 6 2 E G BRACKET REAR UPPER 90105 12228 BOLT FLANGE M12 x 1 25 1 90179 12248 NUT M12 x 1 25 58 70 5 9 7 1 1 E G BRACKET REAR UNDER 90105 12228 BOLT FLANGE M12 x 1 25 1 90179 12248 NUT M12 x 1 25 58 70 5 9 7 1 1 MAIN FRAME REAR FRAME 90149 10002 SCREW M10 x 1 25 33 40 3 3 4 1 4 PIVOT SHAFT FRAME 2C0 22141 10...

Page 76: ... BOLT HEXAGON SOCKET HEAD M6 x 1 0 5 8 0 5 0 8 1 Mid portion of FUEL TANK STAY 91312 06016 BOLT HEXAGON SOCKET HEAD M6 x 1 0 7 10 0 7 1 0 2 BRACKET TANK rear FUEL TANK 91312 06090 BOLT HEXAGON SOCKET HEAD M6 x 1 0 5 8 0 5 0 8 1 BRACKET TANK rear REAR FRAME 90111 06071 BOLT HEXAGON SOCKET BUTTON M6 x 1 0 5 8 0 5 0 8 4 FRONT WHEEL SHAFT FR FORK 90105 14002 BOLT FLANGE M14 x 1 5 1 REAR WHEEL SHAFT NU...

Page 77: ...0185 10009 NUT SELF LOCKING M10 x 1 25 90 109 9 2 11 1 6 SPLIT BOLT for FRONT AXLE 91314 08040 BOLT HEXAGON SOCKET HEAD M8 x 1 25 18 23 1 8 2 3 4 To be tightened Part No Part Name Screw dia x pitch Tightening torque N m kgf m Q ty Remarks ...

Page 78: ...uence of 8 and 9 to a snug torque of 36N m 3 6kgf m 3 Tighten the bolt in the tightening sequence of 10 to a snug torque of 28N m 2 8kgf m 4 Retighten the bolts in the tightening sequence of 1 to 10 to a turn of nut angle of 55 TIP 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 tigh...

Page 79: ...50 5 4 Retighten the bolts in the tightening sequence of 8 and 9 to a turn of nut angle of 75 5 5 Retighten the bolt in the sequence of 10 to a turn of nut angle of 50 5 6 Tighten the bolts in the tightening sequence of 11 and 12 to 24 2N m 2 4 0 2kgf m 7 Tighten the bolts in the tightening sequence of 13 to 29 to 10 2N m 1 0 0 2kgf m TIP The numbers 1 to 29 show the sequence in which the bolts ar...

Page 80: ... INJECTOR 22 INJECTOR 23 INJECTOR 24 OIL LEVEL GAUGE APS TPS THROTTLE MOTOR SENSOR LEAN ANGLE CRANK SHAFT SENSOR AIR TEMP SENSOR WATER TEMP SENSOR PRESSURE SENSOR Pb CAM SHAFT SENSOR SPEED SENSOR E G EARTH E G STOP SW SELECT SW MEASUREMENT TOOL POWER SUPPLY P C I F MAIN SW SW HANDLE SUB LD PIT ROAD LIMIT SW VI MOTOR ECU RESISTOR ASSY No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2...

Page 81: ...Published by YAMAHA MOTOR ENGINEERING co LTD ...

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