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YEC YZF-R6 SS KIT 2004, Manual

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Summary of Contents for YZF-R6 SS KIT 2004

Page 1: ...04 YZF R6 SS KIT MANUAL The Performance Edge for excellent riders WWW PlandeGraissage ORG...

Page 2: ...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 f...

Page 3: ...prockets 21 15 Clutch Spring Set 5EB A6330 70 22 16 Friction Plate and Clutch Boss 22 17 ACM Set 5SL F1400 70 23 18 Engine Control Unit ECU 24 19 Wire Harness Set 5SL F2590 70 32 20 Meter Stay Set 5SL...

Page 4: ...Engine Mounting Procedure 50 3 5 Rear Arm Installation Procedure 52 3 6 Front Wheel Installation Procedure 54 3 7 Please apply grease on the wall in AIR CLEANER CASE 56 4 R6 Front Fork Manual basic i...

Page 5: ...mum 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 03 m...

Page 6: ...eneral parts sales channel 2 2 Engine Parts 1 Maintenance Set 5SL MAINT 70 Parts List No PART No PART NAME Q TY REMARKS 1 5SL 11181 00 GASKET CYLINDER HEAD 3 2 5SL 11603 00 PISTON RING SET 12 3 93210...

Page 7: ...ed when AIS Air Induction System which is a device for purifying exhaust emissions is removed Installation 1 Remove the hose and accompanying air cut valve assembly from the cylinder head cover 2 Remo...

Page 8: ...ish height They are normally used at a squish height of 75 0 45 mm In the case of machining the cylinder upper case always make sure to measure the squish height and select the gaskets so that it is 0...

Page 9: ...2 1 EXT 284 3 5SL 12176 70 SPROCKET CAM 1 1 105 4 5SL 12177 70 SPROCKET CAM 2 1 110 Intake Exhaust Working angle 296 284 Valve timing sprocket 105 110 Valve clearance 0 17 0 23 mm 0 27 0 33 mm Cam lo...

Page 10: ...ve timings In the case of aligning for the purpose of attaining a minimum squish height of 0 60 mm use of the center mounting hole allows setting for intake valve timing of 105 and exhaust valve timin...

Page 11: ...7 WWW PlandeGraissage ORG...

Page 12: ...8 EVENT ANGLE INT EVENT ANGLE EXT WWW PlandeGraissage ORG...

Page 13: ...9 WWW PlandeGraissage ORG...

Page 14: ...outside of Joint hose 7 Trapped air in the water passage reduces the cooling efficiency When refilling water incline the motorcycle right and left to allow no water to remain in the water passage Afte...

Page 15: ...11 STD STD THERMOSTAT WATER PUMP SUB RADIATOR MAIN SUB Upper assembly diagram viewed in front WWW PlandeGraissage ORG...

Page 16: ...ine at engine speeds of 3000 rpm or below for long period of time 30 minutes or more Operation at low engine speeds for an extended period of time can cause engine problems In the case of installing i...

Page 17: ...to the funnel combination is as follows When the longer STD funnel is used for the 2 and 3 cylinders power tends to be weaker in the high rev range but easier to handle in the medium rev range When t...

Page 18: ...ded to prevent overtightening However under normal circumstances it would not become that tight Tightening by hand is sufficient When tightening the opening portion by hand the gap measures approx 9 m...

Page 19: ...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 4 1 5 5EB 14612 70 NUT RING 1 4 6 5EB 14622 70 NUT RING 2 4 7 92017 08016 BOLT 8 8 3YF 14613...

Page 20: ...utch 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 cowli...

Page 21: ...286 400 550 250 12 12 1 2 3 4 Connecting point 38 1 42 7 50 8 Pipe outside diameter Plate thickness t1 2 Exhaust port outlet Silencer Exhaust pipe Diffusser Inside diameter 60 Tapered portion EXT DIM...

Page 22: ...GEAR 2P 1 21T 12 5EB 15163 01 HOUSING 1 13 93306 30525 BEARING 1 14 90151 06008 SCREW 3 15 5SL 17421 00 AXLE DRIVE 1 16 93306 30546 BEARING 1 17 90387 2504A COLLAR 1 18 90387 2813C COLLAR 1 19 5SL 172...

Page 23: ...00 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...

Page 24: ...PART No PART NAME Q TY REMARKS 1 5SL 17411 70 AXLE MAIN 1 15T 2 5SL 17211 70 GEAR 1ST WHEEL 1 31T 3 5EB 15163 01 HOUSING 1 4 93306 30525 BRG 1 Parts List No PART No PART NAME Q TY REMARKS 1 5SL 17411...

Page 25: ...OCKET REAR 1 46T 7 5SL 25447 70 SPROCKET REAR 1 47T 8 5SL 25448 70 SPROCKET REAR 1 48T 9 5SL 25449 70 SPROCKET REAR 1 49T 10 5SL 25450 70 SPROCKET REAR 1 50T 11 5SL 25451 70 SPROCKET REAR 1 51T 12 5SL...

Page 26: ...operation feel in comparison with the standard friction plate The clutch boss features improved durability as a result of surface treatment Parts List No PART No PART NAME Q TY REMARKS 1 3FV 2304E 70...

Page 27: ...oil to the cover apply LOCTITE to the bolts Parts List No PART No PART NAME Q TY REMARKS 1 5SL 81410 70 STATOR ASS Y 1 ASS Y 5SL 81400 70 2 5SL 81450 70 ROTOR 1 3 5SL 15590 00 STARTER CLUTCH 1 4 90149...

Page 28: ...omatically adjusted responding to a change in atmospheric temperature and pressure However a change in the engine specification as in the camshaft valve timing muffler compression ratio etc may result...

Page 29: ...and the feeling experienced during races Too rich an air fuel mixture may foul the spark plugs Code C2 At 25 or less of throttle opening and at 3000 rpm or more of engine speed This affects the feeli...

Page 30: ...e code display To change the adjustment value press either the RESET or the SELECT button Each time either button is pressed the display changes by 1 This value indicates the change in in relation to...

Page 31: ...he engine stop switch repeats the following sequential display starting from d60 00 d60 02 2 advance d60 04 4 advance d60 06 6 advance d60 86 6 retard d60 84 4 retard d60 82 2 retard d60 00 standard i...

Page 32: ...ESET and SELECT buttons held down Co appears in the left of the display area for the distance and time 2 Press the SELECT button The display changes to dIAG 3 Press both the RESET and SELECT buttons a...

Page 33: ...broken down Found during electric motor cranking Impossible 12 Crank sensor Crank sensor broken shorted Crank sensor broken down Found during electric motor cranking Impossible 13 Intake pressure sens...

Page 34: ...alue Impossible 33 Abnormal ignition 1 Ignition coil coming off broken Possible 34 Abnormal ignition 2 35 Abnormal ignition 3 36 Abnormal ignition 4 41 Turnover sensor Broken shorted Turnover sensor b...

Page 35: ...output voltage Erect 0 4 to 1 4 V Overturned 3 7 to 4 4 V Broken 5 0 V 09 Monitor voltage Displays battery voltage measured by ECU Approx 12 V when checking 20 Engine kill switch Displays switch cond...

Page 36: ...mergency stop switch take care to insert the coupler straight in so that the terminal is not bent Other functions Combination with the ECU in this harness kit enables the engine stop switch to be used...

Page 37: ...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 0660...

Page 38: ...Install behind the rear frame above the rear fender Parts List No PART No PART NAME Q TY REMARKS 1 5SL 21707 70 OIL TANK COMP 1 2 5EB 15373 70 PIPE BREATHER 2 3 90464 15152 CLAMP 2 L 370 mm 4 90450 25...

Page 39: ...with the chassis protector For the YZF R6 in the 1999 to 2002 model years use the collars Use 1 bolt and 2 bolts Parts List No PART No PART NAME Q TY REMARKS 1 5SL 15491 70 PROTECTOR 1 2 91314 06030...

Page 40: ...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 1...

Page 41: ...color Black 2 5SL 22212 80 SPRING 1 1 K 11 2 kgf mm Identification color Blue 70 80 STD Free length 168 mm 167 mm 168 5 mm Spring rate 10 7 kgf mm 11 2 kgf mm 10 0 kgf mm ID paint on number of end co...

Page 42: ...s the fork from full rebound 3 The spring rate is identified by the number of lines on its end Basic setting Parts List No PART No PART NAME Q TY REMARKS 1 5SL 23141 80 SPRING 1 0 90 kgf mm 1 5SL 2314...

Page 43: ...itioning Install the stop switch after removing this projection Parts List No PART No PART NAME Q TY REMARKS 1 5EB 26281 81 CAP GRIP UPPER 1 2 5EB 26282 81 CAP GRIP UNDER 1 3 5FL 26391 80 CLIP THROTTL...

Page 44: ...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...

Page 45: ...the standard pads if braking feels poorly when the brake is applied or if the pads appear to be slipping check the braking surface of the disk and replace the disk as necessary The supports are insta...

Page 46: ...12 BOLT BUTTON HEAD 2 16 5SL 18179 70 GUIDE 1 17 92017 06035 BOLT BUTTON HEAD 2 18 5PW 18115 00 ROD SHIFT 1 19 3TC 18116 00 JT ROD 1 1 20 95304 06700 NUT 1 21 3TC 18117 00 JT ROD 2 1 22 90170 06228 NU...

Page 47: ...ral position is located 15 mm higher than the STD A change in the installation position of the arm provides the pattern of 1 down 5 up shifts and 1 up 5 down shifts 39 5SL 21873 70 BRKT TANK 1 40 9011...

Page 48: ...he 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 WWW PlandeG...

Page 49: ...d do the rubbing again Check the contact area and width of the valve and seat If there is 1 mm wide rubbed area in the center of the 90 deg surface of the valve no correction is needed If it is off to...

Page 50: ...head 3 Measure valve seat width Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem onto the valve face b Install the valve into the cylinder head c Press the valve th...

Page 51: ...n off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve f...

Page 52: ...hten the nuts to 15Nm 1 5 m kg with a torque wrench 5 Further tighten the nuts to a rotation angle of 150 CAUTION Perform steps 4 and 5 on both nuts Be sure to check the direction in which to install...

Page 53: ...htening 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 A...

Page 54: ...ighten to specification the engine adjust bolts toward the engine from the lower one Tightening torque 7Nm 0 7 m kg Make sure that the engine and the seating surfaces of the adjust bolts are in contac...

Page 55: ...51 WWW PlandeGraissage ORG...

Page 56: ...install the rear arm and the shock absorber to the frame Insert the bolt from the left of the vehicle Install the nut to the specified torque Tightening torque 44 Nm 4 4 m kg Install the relay arms wi...

Page 57: ...53 20 93315 31758 BRG 2 21 90105 10018 BOLT FLG 1 22 90387 1013U COLLAR 1 Parts List No PART No PART NAME Q TY REMARKS WWW PlandeGraissage ORG...

Page 58: ...e that the end surface of the wheel axle is flush with the end surface on the front fork side the portions A If not make them flush by hand or with a rubber mallet 4 Without temporal fitting tighten t...

Page 59: ...55 WWW PlandeGraissage ORG...

Page 60: ...56 3 7 Please apply grease on the wall in AIR CLEANER CASE This grease will catch some dusts apply grease WWW PlandeGraissage ORG...

Page 61: ...The spring preload can be adjusted according to the weight and riding style of the rider Oil level The oil level is important for the lubrication and the general function of the front fork and has th...

Page 62: ...ive Preload on the spring Spring rate Oil level Viscosity of the oil Compression and rebound damping It is not always easy to ascribe a problem or a certain behavior of the front fork to one of these...

Page 63: ...03 model KIT Suspension Settings R6 WP R6 Ohlins R6 Front fork STD STD Damping unit Cartrige WP Ohlins Spring rate 0 90 0 85 Preload 6 mm 12 mm Oil level 110 mm 110 mm Oil SAE 5 SAE 5 Protrusion from...

Page 64: ...e dives A increase spring rate B raise oil level C increase preload D increase compression 2 Head shakes when braking A increase spring rate B raise oil level C increase compression 3 Harsh when braki...

Page 65: ...te B raise outer tubes in clamps C decrease preload Downhill Feels low A decrease rebound B lower outer tubes in clamps C increase compression D increase preload Other 1 Too soft A increase spring rat...

Page 66: ...moved of the bike mount the shock in a vice and turn the preload nut in the way you want to adjust softer or harder Adjustment of compression damping The compression refers to the hydraulic damping wh...

Page 67: ...le GUIDE LINES FOR THE ADJUSTMENT The working of a shock is dependent of different factors like type of spring linear of progressive spring rate preload on the spring nitrogen pressure in the tank vis...

Page 68: ...iff over a series of small bumps and is not absorbing not following these the bike has little traction the bike feels low Standard specification 2003 model KIT Rear shock Brand WP Ohlins Spring rate 9...

Page 69: ...decrease rebound 2 Squats A increase spring preload B increase spring rate C increase compression G Loads 1 Bottoms A increase spring rate B increase compression 2 Kicks out A increase spring rate B d...

Page 70: ...A decrease spring rate B decrease compression 2 Feels springy A decrease compression 3 Feels like it s not using enough stroke A decrease spring rate B decrease compression Place Terrain Problem Adjus...

Page 71: ...67 2003 YZF R6 Wiring Diagram WWW PlandeGraissage ORG...

Page 72: ...8 203 4 205 9 207 8 210 1 212 4 214 5 216 3 217 2 219 0 220 6 222 3 223 8 225 1 227 6 228 7 229 8 230 7 233 9 234 7 235 3 239 4 239 8 240 1 245 1 245 1 245 1 250 3 250 7 255 7 256 5 261 4 262 6 267 4...

Page 73: ...YEC CO LTD 3622 8 Nishikaizuka Iwata Shizuoka 438 0026 Japan Tel 0538 37 4488 Fax 0538 37 6186 WWW PlandeGraissage ORG...

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