YEC YZF-R6 SS KIT 2004 User manual

’04 YZF-R6
SS KIT MANUAL
The Performance Edge
for excellent riders
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2003 YZF-R6 Kit Manual
•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.
•This manual has been written for persons having knowledge and experience in the
field of motorcycles. Please refer to the service manual for information on part
assembly and maintenance.
Please note:
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CONTENTS
1 Standard Specifications (SS spec.)............................................................. 1
2 Kit Parts ......................................................................................................... 2
2-1 Basic Kit Set Contents ................................................................................... 2
2-2 Engine Parts.................................................................................................... 2
1. Maintenance Set (5SL-MAINT-70).....................................................................2
2. Spark Plugs..........................................................................................................3
3. AIS Plug Set (5SL-A4890-70)..............................................................................3
4. Head Gaskets.......................................................................................................4
5. Camshaft and Cam Sprockets............................................................................5
6. Sub Radiator Set (5SL-A240A-70)....................................................................10
7. Oil Pump Set (5MT-A3100-70)..........................................................................12
8. Air Funnel Set (Bell-Mouth Set) (5SL-A4460-70)............................................13
9. Air Filter Element Assembly.............................................................................13
10. Carburetor Clamp complete (5SL-1351A-70)..................................................14
11. Exhaust Pipe Set (5SL-A4600-70).....................................................................15
12. Transmission Gear Set (5SL-A7400-70) ..........................................................18
13. Option Gear Set.................................................................................................20
14. Sprockets...........................................................................................................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-C8350-70)........................................................................33
2-3 Chassis Parts................................................................................................. 34
21. Oil Catcher Tank Set (5SL-C1707-70)...............................................................34
22. Engine Protector Set (5SL-A5491-70)..............................................................35
23. Chassis Protector Set (5SL-C117G-70) ............................................................36
24. Rear Suspension Springs.................................................................................37
25. Front Fork Damper - Complete Set (5SL-C3170-70).......................................37
26. Front Fork Spring..............................................................................................38
27. Throttle Set (5SL-C6300-70) .............................................................................39
28. Steering Damper Stay Set (5SL-C3495-70).....................................................40
29. Front Disk Brake Assembly (5SL-2581T-70)....................................................41
30. Front Brake Pad Set (5SL-W0045-70)...............................................................41
31. Footrest Set (5SL-C7400-70).............................................................................42
2-4 Other.............................................................................................................. 45
32. Valve Seat Cutter Set (5SL-M1112-70) ............................................................45
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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 ........................................................................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 information)................................................57
5 R6 Shock Absorber Manual (basic information).......................................62
2003 YZF-R6 Wiring Diagram .........................................................................67
Speed ×
××
×Ratio table for YZF-R6 (2003)...........................................................68
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– 1 –
1Standard 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 ±0.03 mm = 0.30 ±0.03 mm
Throttle body 38EIS MIKUNI
minimum bore = 37.5 mm,
throttle bore = 38.0 mm
Exhaust system 4-2-1 system, #1-2, #3-4 exhaust pipe coupling
Transmission Constant mesh type, 6 speeds
Clutch Wet, multi-disk type
Ignition system DC-CDI
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– 2 –
2Kit 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. 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 93210-17129 CIRCLIP 24
* 4 5SL-1165A-00 BOLT, CON-ROD 24
* 5 90179-07652 NUT 24
* 6 4TV-12119-00 SEAL, VALVE STEM 48
* 7 4FM-12213-00 GASKET, TENTIONER 3
* 8 5SL-13414-00 GASKET, STRAINER 3
* 9 5SL-15451-00 GASKET, COVER 1 3
* 10 5SL-15461-00 GASKET, COVER 2 3
* 11 5SL-15456-00 GASKET 1 3
* 12 5SL-15463-00 GASKET 2 3
* 13 93102-35423 SEAL, OIL 3 FOR DRIVE AXLE
* 14 90215-20231 WASHER 3 FOR CLUTCH BOSS
* 15 90151-06008 SCREW 9 FOR BEARING HOUSING
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– 3 –
2. Spark Plugs
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.
3. AIS Plug Set (5SL-A4890-70)
This plug set is used 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. Remove the cap from the hose and take out the reed valve and plate from inside.
3. Install the plate (5SL-1482L-70) in place of the cap. Be sure to apply liquid gasket to
the plate.
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 5FL-94700-70 PLUG, SPARK 1 NGK R0045Q-10
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 5SL-1482L-70 PLATE 2
2 93608-16M16 PIN 4
3 90338-08026 PLUG 1
(15˚)
(30˚)
Reused
New gasket
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– 4 –
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
•The standard gaskets have a thickness of 0.60 mm.
•These gaskets are used to adjust squish 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 0.60 mm
or more.
NOTE:
Squish height refers to the clearance between the flat surface of the piston and the
surface along the head cylinder.
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=0.50 mm
4 5SL-11181-85 GASKET, HEAD CYL. 1 t=0.55 mm
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5. Camshaft and Cam Sprockets
Specifications
Parts List
No. PART No. PART NAME Q'TY REMARKS
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°
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 – 25.26 mm a: 32.55 – 32.65 mm b: 25.09 – 25.19 mm
Stamping location
STD
Tightening torque 24 Nm (2.4 m·kg)
FWD.
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–6 –
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. 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 timing
of 110°.
•Valve timing adjustment range can be changed to either ±1°or ±2°relative to the
center mounting hole.
CAUTION:
1. In the case of using a new cam chain, make sure to wear in by assembling on the
cam sprockets as shown in the diagram below. Since the cam chain stretches by
approximately 1° after completion of wear-in, adjust by changing the cam sprocket
mounting positions after re-measuring the cam timing.
Cam sprocket mounting positions
(When cam chain is new)
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–7 –
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–8 –
EVENT ANGLE INT. EVENT ANGLE EXT.
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–9 –
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–10 –
6. Sub Radiator Set (5SL-A240A-70)
Installation Precautions
1. This kit assumes that the muffler kit set is used. It cannot be mounted on the STD
muffler by itself, or may not be mounted either when a competitor’s muffler is
installed.
2. Use the STD main radiator. Also use the STD hose that goes into the radiator from
the oil cooler.
3. Remove the cleaning fan attached to the STD radiator.
4. Do not fasten the hose clamp too tight. The hose may become deformed and leak
water.
5. After installation, check that the radiator and hose are not in contact with the exhaust
pipe.
6. Pass the clutch wire alongside on the 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.
After refilling, idle run the engine for a while with the radiator cap removed. Then add
water to fill up the vacancy produced by escaping water and tighten the cap securely
on the radiator.
Parts List
No. PART No. PART NAME Q'TY REMARKS
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. 12
12
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–11 –
STD
STD
THERMOSTAT
WATER PUMP
SUB
RADIATOR
MAIN
SUB
Upper assembly diagram (viewed in front)
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–12 –
7. Oil Pump Set (5MT-A3100-70)
This kit reduces loss at high engine speeds by decreasing the rotor width. This can be
expected to result in a 1 –2% improvement in output.
CAUTION:
During maintenance, place engine oil inside the pump after assembling and rotate the
shaft to confirm that it rotates smoothly.
Since the amount of oil discharged is less than the STD oil pump, do not run the engine
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 in a 1999 or 2000 engine, use the housing of the STD oil pump
for housing .
Parts List
No. PART No. PART NAME Q'TY REMARKS
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
1
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–13 –
8. Air Funnel Set (Bell-Mouth Set) (5SL-A4460-70)
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. Install the funnel and joint after applying a thin coat of grease to their threads. They
may have a little gap between them and the case but do not become loose with the
STD rubber joint and plate fastened.
3. For the standard settings, use the 9 mm funnel for the #1 and #4 cylinders and the 24
mm funnel for the #2 and #3 cylinders. This combination may change according to
the exhaust pipe specifications or to the rider’s preference.
4. Tendency subject 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 the shorter STD funnel is used, the engine tends to be more responsive in the
high-rev range but produce less torque in the medium-rev range.
9. Air Filter Element Assembly
This air element is an improvement on the STD with an increased 20% of intake
efficiency. The raising in the air passage sheds water, so the element is also effective in a
run in rainy weather. Regular maintenance is simple; simply blow air on the back of the
element.
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 5SL-14463-70 JOINT. 2 2
2 5SL-14469-75 FUNNEL, 1 2 L=24 mm
3 5SL-14454-70 JOINT 2
4 5SL-14479-70 FUNNEL 2 L=9 mm
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 5SL-14450-70 ELEMENT ASS'Y 1
#1 #2 #3 #4
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–14 –
10.Carburetor Clamp complete (5SL-1351A-70)
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.
The collar is provided 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 mm.
After threading M4 ×0.7, a new band must be used.
Parts List
No. PART No. PART NAME Q'TY REMARKS
* 1 90450-63001 BAND 4
* 2 95307-04600 NUT 4
3 5SL-13573-70 BOLT, 1 3
4 5SL-1358A-70 ROD COMP. 1
Cut off
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–15 –
11.Exhaust Pipe Set (5SL-A4600-70)
Made entirely of titanium, this exhaust set has less weight and features a configuration
that allows a sub-radiator to be installed.
Parts List
No. PART No. PART NAME Q'TY REMARKS
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-14613-01 GASKET 4
9 5SL-14785-70 DIFFUSER 1
10 5SL-14750-70 SILENCER ASS'Y 1
11 5SL-1471K-70 BRACKET 1
12 5SL-21445-70 STAY 1
* 13 92014-08020 BOLT 3
* 14 95607-08200 NUT 3
* 15 90507-20030 SPRING 10
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–16 –
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.
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