Yamaha GYTR YZF-R6 2022 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.
•
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 although the part is included in the kit set it can also be
purchased individually.
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.
NOTICE
TIP

CONTENTS
................................................................................. 1
2 Kit Parts........................................................................................................ 2
2-1 Electric parts..................................................................................................2
1. Wire Harness Set (BN6-F2590-70) .................................................................... 2
2. ECU Set (BN6-8591A-71,BN6-8591A-A2, BN6-8591A-G0,BN6-8591A-B1)....11
3. Cable Interface (2CR-8533A-70)...................................................................... 14
4. CCU COMP.(2KS-85800-72) ........................................................................... 16
2-2 Engine Parts.................................................................................................21
5. Maintenance Set (2C0-MAINT-71) ................................................................... 21
6. Spark Plug Set (5FL-R045Q-70, 13S-R373A-70)............................................. 22
7. Head Gasket .................................................................................................... 23
8. Piston Set (13S-116A0-70)................................................................................ 24
9. Connecting Rod Set (13S-1165B-70)................................................................ 24
10. Crankshaft (2C0-11411-70) ............................................................................... 24
11. Cam Shaft and Cam Sprocket.......................................................................... 25
12. Valve Spring Set (2C0-A2110-70) .................................................................... 26
13. Oil Pump (2C0-13300-70) ................................................................................ 28
14. Throttle Body Clamp Assembly (2C0-1351A-70).............................................. 28
15. Air Funnel Set (BN6-1440B-70) for SS............................................................. 29
16. Air Funnel Set (BN6-1440B-80) for STK .......................................................... 31
17. AIS Plug Set (13S-A4890-70)........................................................................... 35
18. Clutch Spring Set (2C0-A6330-70) .................................................................. 37
19. Friction Plate Set (2C0-A6321-70).................................................................... 38
20. Slipper Clutch Setting Set (4B1-A6377-70)....................................................... 39
21. Transmission Gear ........................................................................................... 42
22. Mission Maintenance Set (2C0-A7000-70) ...................................................... 46
23. Drive Sprocket.................................................................................................. 49
24. Sprocket Nut Set (2C0-A7463-70).................................................................... 50
25. ACM Set (2C0-F1400-71) ..................................................................................51
2-3 Vehicle Accessories ....................................................................................52
26. Oil Catch Tank Set (2C0-C1707-81) ................................................................. 52
27. Rear Shock Spring ........................................................................................... 53
28. Front Fork Spring ............................................................................................. 54
29. Seat Cushion (13S-24713-70)........................................................................... 56
30. Front Spare Wheel Assembly (BN6-25100-70) ................................................ 57
31. Rear Spare Wheel Assembly (BN6-25300-70) ................................................ 58
31. Tube Guide (2CR-26243-70) ............................................................................ 59
3 Tightening Torque List .............................................................................. 60
4 YZF-R6 Wiring Diagram .............................................................................71
R6E20220202Rev

– 1 –
1
Spec SS STK STD
Displacement 599cm3599cm3599cm3
Bore/Storke 67.0 × 42.5 mm 67.0 × 42.5 mm 67.0 × 42.5 mm
Maximum engine speed
(limiter controlled speed) 16000 rpm 16000 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
Va l v e t i m i n g (e v e n t
angle)
INT. 110° 105° 105°
EXT. 115° 110° 110°
Squish height INT. 0.65-0.75mm 0.65-0.75mm 0.65-0.75mm
EXT. 0.95-1.00mm 0.95-1.00mm 0.95-1.00mm
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. 0.12 - 0.19 mm 0.12 - 0.19 mm 0.12 - 0.19 mm
EXT. 0.16 - 0.27 mm 0.16 - 0.23 mm 0.16 - 0.23 mm
R6E20220202Rev

– 2 –
1.
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 BN6-82590-70 WIRE HARNESS ASSY. 1
2 BN6-82386-70
WIRE, SUB-LEAD for TH INJECTOR
1 TH INJECTOR
3 BN6-83553-70 WIRE, LEAD for METER 1 METER
4 2CR-8231Y-70 WIRE, LEAD for FUEL PUMP 1 FUEL PUMP
* 5 5GF-83976-00 SW., HANDLE 1 1 Switch for TAIL LIGHT
6BN6-2128A-70 BRKT., REGULATOR 1 1
* 7 90480-13003 GROMMET 1
*8 90560-06201 SPACER 2
* 9 90111-06051
BOLT, HEX. SOCKET BUTTON
4
* 10 92907-06200 WASHER, PLAIN 1
• To ensure the power to run the vehicle, do not remove the AC generator. Use on the
battery alone will make the vehicle unable to run in a short time.
• The wire harness will not function if it is not assembled with the ECU (BN6-8591A-70,
71, A0, A1, A2, G0, B0, B1) of the kit.
• The combination of this wire harness and ECU can only be used with ’17 to '22
models.
•
in advance. Before starting assembly, remove the coupler of the main switch.
• Be sure to connect the Hydraulic unit assy. to the wire harness. The ABS does
not function when using the KIT ECU, but every electronic control does not work
without the connection. Also, change the installation position of the Hydraulic unit
assy. by following the instructions on following pages.
KIT PARTS
Installation
1. Remove the STD wire harness from the vehicle.
2. Remove the STD rectifier/regulator (on the left side of the radiator) from the
vehicle.
This wire harness is trim weighted from the STD part by reducing the lighting wiring
accessories.
NOTICE
R6EN20181106
R6E20220202Rev

– 3 –
4. Remove the Hydraulic unit assy. from the right side of the vehicle.
5. Remove the EXUP motor located under the seat.
6. To install the Hydraulic unit assy. to the position where the EXUP motor was removed, you
need to perform processing operation. Refer to the following images to perform processing
operation.
3. As illustrated, install the removed rectifier/regulator using the provided bracket
regulator, etc.
TIP
To install the Hydraulic unit assy., you need to perform processing operation to
create the installation space.

– 4 –
TIP
Fix the Hydraulic unit assy. with the rubber band located at the position indicated by
an arrow in the following image.
the size of the Hydraulic unit assy.

– 5 –
1 METER
AIR TEMP SENSOR
PRESSURE SENSOR
1
2
a
b
bSELECT SW.
Connect each wire lead to the following parts.
Check the position of the following parts.
WIREHARNESS ASSY.
MAIN SW
SW.HANDLE L 1/2
POWER SUPPLY 2
c
TIP
c Fix the harness that will be connected to SW.HANDLE L 1/2, etc. to 6
BLKT.,REGULATOR 1 using cable ties.
9. Assemble the wire harness to the chassis referring to the following materials.

– 6 –
1
2
3
1
METER
AIR TEMP SENSOR
PRESSURE SENSOR
WIREHARNESS ASSY.
MAIN SW
SW.HANDLE L 1/2
POWER SUPPLY 2
APS
THROTTLE MOTOR
TPS
PC/IF
FR WHEEL SENSOR
SW HANDLE R 2/3
4 WATER TEMP SENSOR
RR WHEEL SENSOR
GEAR PO.SENSOR
VI MOTOR
NEUTRAL SW.
LIGHT SW.
OIL SW.
SHIFT SW.
CRANK SHAFT SENSOR
WIRE SUBLEAD 1/4
WIRE,LEAD for FUEL PUMP
WIREHARNESS ASSY.
SELECT SW.
PRESSURER SENSOR
ABS ECU (Hydraulic unit assy.)
4
5
6
7
8
9
WIRE
TH INJECTOR
10
cd
e
c
d
e
Connect each wire lead to the following parts.
Check the position of the following parts.

– 7 –
WIREHARNESS ASSY.
11 MAIN FUSE
ST.RELAY 1
RELAY ASSY.
14 FUSE BOX 1
SERVICE TOOL
ECU
LEAN ANGLE SENSOR
POWER SUPPLY
TAIL LIGHT
11
12 13 14
15
16 17 18
19
Connect each wire lead to the following parts.