Yamaha 2010 YZF-R6 User manual

Introduction
•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.
•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
•Please understand that these parts are not covered by warranty.
•The Manufacturer does not take any responsibility for problems caused by these parts.
Request
•These kit parts are intended exclusively for racing purposes. You are strictly requested not to
use them 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.
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 manual by the following notations.
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.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
No. PART No. PART NAME Q’TY REMARKS
˚ 1 4C8-11181-70 GASKET, CYLINDER
HEAD 1
3 t=0.30mm
* 2 5VY-11351-00 GASKET, CYLINDER 1 3
* 3 4C8-11603-00 PISTON RING SET 12
4 5VY-1165A-01 BOLT, CONNECTING ROD
SPECIAL
24
* 5 93450-18157 CIRCLIP 24
WARNING
NOTICE
TIP

CONTENTS
1 Engine Specifications................................................................................... 1
2 Kit Parts ......................................................................................................... 2
2-1 Engine Parts.................................................................................................... 2
1. Maintenance Set (2C0-MAINT-71) ....................................................................... 2
2. Spark Plug Set (5FL-R045Q-70, 13S-R373A-70)................................................. 3
3. Head Gasket ......................................................................................................... 4
4. Piston Set (13S-116A0-70) ................................................................................... 6
5. Connecting Rod Set (13S-1165B-70) ................................................................... 6
6. Crankshaft (2C0-11411-70) .................................................................................. 6
7. Cam Shaft and Cam Sprocket .............................................................................. 7
8. Valve Spring Set (2C0-A2110-70) ........................................................................ 8
9. Oil Pump (2C0-13300-70)..................................................................................... 8
10. Air Funnel Set (MGC-A300908-10)....................................................................... 9
11. Throttle Body Clamp Assembly (2CO-1351A-70) ............................................... 12
12. AIS Plug Set (13S-A4890-70)............................................................................. 13
13. Clutch Spring Set (2CO-A6330-70) .................................................................... 15
14. Friction Plate Set (2CO-A6321-70) ..................................................................... 16
15. Slipper 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 Catch Tank Set (2C0-C1707-81)................................................................... 42
27. Rear Suspension ................................................................................................ 43
28. Rear Shock Spring.............................................................................................. 46
29. Front Fork ........................................................................................................... 47
30. Front Fork Spring ................................................................................................ 51
31. Steering Damper Stay Set (2C0-C3495-80) ....................................................... 57
32. Seat Cushion (13S-24713-70) ............................................................................ 58
33. Front Spare Wheel Assembly (2C0-25100-70)................................................... 59
34. Rear Spare Wheel Assembly (2C0-25300-70) ................................................... 60
35. Throttle Set (2C0-C6300-70) .............................................................................. 61
36. Throttle Set (13S-C6300-70)............................................................................... 62

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

– 1 –
1Engine Specifications
Spec SSP STK STD
Displacement 599 cm³ 599 cm³ 599 cm³
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) 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 mm 0.18 – 0.22 mm 0.18 – 0.22 mm
EXT. 0.23 – 0.27 mm 0.23 – 0.27 mm 0.23 – 0.27 mm

– 2 –
2Kit Parts
2-1 Engine Parts
1. Maintenance Set (2C0-MAINT-71)
Parts List
No. PART No. PART NAME Q'TY REMARKS
° 1 2C0-11181-76 GASKET, CYLINDER HEAD 3 t=0.45mm
* 2 2C0-11603-00 PISTON RING SET 12
* 3 93450-16159 CIRCLIP 24
4 2C0-1165A-00 BOLT, 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
COUNTERSUNK
9 FOR BEARING
HOUSING

– 3 –
2. Spark Plug Set (5FL-R045Q-70, 13S-R373A-70)
TIP
Since these spark plugs have a copper gasket, caution is needed during installation on
the following points.
1. The tightening torque is 12 – 15 N•m (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°.
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 NGK R0373A-10



 

– 4 –
3. Head Gasket
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
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=0.55mm
Stamping location

– 5 –
Measuring the volume of the cylinder head combustion chamber
TIP
To obtain the highest performance for race 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
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 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.

– 6 –
4. Piston Set (13S-116A0-70)
Select four pistons so that the difference in their weights does not exceed 0.5g.
5. Connecting Rod Set (13S-1165B-70)
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 (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. PART NAME Q'TY REMARKS
* 1 2C0-11411-00 CRANKSHAFT 1

– 7 –
7. Cam Shaft and Cam Sprocket
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 -2º to +6 º (CA) compared with standard timing.
TIP
For valve timing adjustment, refer to the KIT TOOLS MANUAL.
NOTICE
•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.
•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
STD
FWD.
Tightening torque
24 N•m (2.4 m•kg)
Tightening torque
Sprocket assembly position at top dead center point of #1 cylinder compression

– 8 –
8. Valve Spring Set (2C0-A2110-70)
•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)
•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'TY REMARKS
1 2C0-13300-70 OIL PUMP ASSY 1

– 9 –
10. Air Funnel Set (MGC-A300908-10)
•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.
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
Lever assembly

– 10 –
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.
PRIMARY FUNNEL
LEVER ASSY.
Motor side
A/C
SHAFT ASSY.
Lever side

– 11 –
5. Fitting the Extention Funnel
Attach the extension funnel to 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.
6. Fitting the Secondary Funnel
Fit the standard rubber seal to the secondary funnel 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 [phone]
FAX [phone]
Web http://www.mgcompetition.fr/
Extension funnel
Secondary funnel
Rubber seal Wire

– 12 –
11. Throttle Body Clamp Assembly (2CO-1351A-70)
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.
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

– 13 –
12. AIS Plug Set (13S-A4890-70)
This plug set is used when the AIS (Air Induction System), an exhaust gas purification system,
is removed.
Installation
1. Remove the hose attached to the cylinder head cover and the air cut-off valve assembly
accompanying the hose.
2. Remove the cap fitted to the hose and remove the reed valve and plate from 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 hose was connected.
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 5SL-1482L-70 PLATE, 2 2
* 2 93608-16M16 PIN, DOWEL 4
3 90336-10020 PLUG, TAPER 1

– 14 –
A/C ASSY.
STD
KIT
REMOVE
A/C ASSY.
Insertion
direction

– 15 –
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

– 16 –
14. 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)