The Performance Edge
Contents
1. TRES yg L Fong Pw L DESCH REES BLACK BLACK BLACK BLACK 28 Katz PE DEN KZ H v 0 COMPONENTS Tea sheet SASS EPIL g DES G WRIGy 1 WAY YWL rB r8B 3 2180 62 or or 2 1 BIRY x sl 2 NM n 1 BLACK 2 WIRE MINUS LEAD EE s LO 3 ACM2. Specifications Spec Displacement 599cc Maximum engine speed limiter controlled speed 16000rpm Bore Stroke 67 0 x 42 5mm Valve timing event angle INT EXT 110 110 Sduish height 0 60mm Clearance between the valve and the piston INT EXT 1 10 12 1 62 12 BTDC Clearance of valves tappet 0 20 targeted 0 18 0 22 0 25 targeted 0 23 0 27 2 Kit Parts 2 1 Engine Parts 1 Maintenance Set 2CO MAINT 71 Parts List PART 2C0 11181 76 PART NAME GASKET CYLINDER HEAD REMARKS 2C0 11603 00 PISTON RING SET 93450 16159 CIRCLIP 2C0 1165A 00 BOLT CONNECTING ROD 90179 07001 NUT 4SV 12119 00 SEAL VALVE STEM OIL 2C0 12213 00 GASKET TENSIONER 2C0 13414 70 GASKET STRAINER ANTI STICK TYPE 1 2 3 4 5 6 7 8 9 2C0 15451 70 GASKET CRANKCASE COVER 1 ANTISTICK TYPE 2 0 15461 70 GASKET CRANKCASE COVER 2 ANTI STICK TYPE 2C0 15456 70 GSKT 1 ANTI STICK TYPE 93102 35017 SEAL OIL FOR DRIVE AXLE 90151 06024 SCREW CROSSRECESSED COUNTERSUNK FOR BEARING HOUSING 2 Spark plug set 5 0450 70 Parts List PART No or REMARKS 5FL 94700 70 PLUG SPARK R0045Q 10 NOTE Since these spark plugs have a copper g
3. ai L Jar e 4 STARTER RELAY Zu Ir Se I 5 STARTER MOTOR mg 1 La id O cyn 6 3 xg BLACK 7 RECZREGU 1 8 d r I 1 eO ira a d e 9 RELAY ASSY 1 7 a 10 e lo 11 IG COIL AL so orcOors ors i E ls 1 E D T BLACK 12 IG COIL 2 ERR HE SCT 1 13 IG COIL 3 or ug t 2 14 IG COIL 4 M E JI al ips 15 MAIN FUSE DOS 88 un aL 4 R 16 5 LE se BLACK 17 E 1 18 FUSECIGNITION 19 u keem y B 5 20 i 21 IR E n I 1 8 8 22 ei 1 s 4 534 86189 0933 O 4 24 SW HANDLE EE Sg 25 FR STOP_SW RL B I 26 e RA L2 18 46189 09940 de eae tho 65 o 27 1 4 28 m 29 FUEL PUMP 182 30 METER I prior ora 31 INJECTOR 11 RR LA 32 INJECTOR 12 t is 33 INJECTOR 13 ADR sie l ponen 34 INJECTOR 14 i ples i BLACK BLACK 35 INJECTOR 21 Rae Sen 281 36 INJECTOR 2 Br L SIART I 12 37 INJECTOR 23 OFF BLUE BLUE dE 1 jOIO PUSH M f ueo GLAD
4. o I Besse GRAY Ison a 4 2 INJECTOR 24 CR O mag rer JT vives 25 lt I PN wig E WA AN m on Hc rad prn ary T n 42 ol el orc 43 44 AW TS Ps 7 r 4 iG 45 voi UT Bor pa n 47 SHIFT ged 48 E l 49 J IA El 50 51 at io GE PRS s 4 1 uu l 52 a i Em l Af vel 53 GH 1 eg EN 54011 LEVEL GAUGE DARK GREEN 55 2 _ ae a AMP 174374 4 a 56 4 Ga 57 ee ae 1 reve Pi bg 58 PO I O ARK BLU CL Suge ee See TURN i sm A 6189 0970 8 59 60 TPS PASS DIMER HORN 8 TT LZ 1 eg SE Sal swa ON OOO OFF OFF l l l L LA L M OFF on 10 ON JO 1 156 I I 1 62 DARK Suel 95 i tt i t t 63 4 amp xk6189 0970 wl mi 64 SENSOR LEAN ANGLE H 65 SHAFT SENSO I I 66 II CH ai 3 ILLUMINATION i CG al von 67 ATR_ TEMP SENSOR bbb 68WATER TEMP SENSOR 1 PES 69PRESSURE SENSOR Pb Er gack 808601 TOPRESSURE SEN
5. 53 APPLY LOCK ING AGENT LOCKTITE To be tightened Screw dia x pitch Tightening torque Nem kgfem Remarks REAR WHEEL 90185 10009 NUT SELF M10 x 1 25 90 109 SPROCKET amp LOCKING 9 2 11 1 CLUTCH HUB SPLIT BOLT for 91314 08040 BOLT M8 x 1 25 18 23 1 8 2 3 FRONT AXLE SOCKET HEAD 54 Tightening the Cylinder Head Tightening the Cylinder Head Turn of Nut Method 1 Tighten the bolts in the tightening sequence of 1 to 7 to a snug torque of 28Nem 2 8kgf m 2 Tighten the bolts in the tightening sequence of 8 and 9 to a snug torque of 36N m 3 6kgfem 3 Tighten the bolt in the tightening sequence of 10 to a snug torque of 28Nem 2 8kgfem 4 Retighten the bolts in the tightening sequence of 1 to 10 to a turn of nut angle of 55 NOTE 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 tightening sequence OVA ROR ARORA ROE Tee eie see ASA JO B GN E LA A 5 55 Installing the Crankcase Tightening the bolts 1 2 25258 Tighten the bolts in the tightening sequence of 1 to 10 to 20Nem 2 0kg m After loosening the bolts once in the tightening sequence of 1 to 10 retighten them one by to 12N m 1 2kg m Retighten t
6. bo 42 17 2 471 31 12 2 583 32 16 2 000 39 21 1 857 39 20 1 950 32 16 2 000 30 18 1 667 36 23 1 565 29 18 1 611 30 18 1 667 27 21 1 286 33 26 1 269 30 23 1 304 27 20 1 350 CAUTION 26 18 1 444 23 20 1 150 25 18 1 389 25 22 1 136 26 18 1 444 23 20 1 150 28 19 1 474 26 22 1 182 No gear used for the kit transmission except for the specified STD gear e There is no compatibility with the 06 model transmission set 2C0 A7400 70 46 YZF R6 Mission ratio Pinion gear Wheel gear The number of teeth Part number 2C0 17411 80 A The number of teeth Part number 2C0 17211 80 A 2C0 17411 90 B 2C0 17211 90 B 2C0 17411 00 2C0 17211 00 2C0 17121 80 A 2C0 17221 81 A 2C0 17121 90 B 2C0 17221 90 B 2C0 17121 00 2C0 17221 00 2C0 17131 80 A 2C0 17231 80 A 2C0 17131 71 B 2C0 17231 70 B 2C0 17131 90 C 2C0 17231 90 C 2C0 17131 80 A 2C0 17241 80 A 2C0 17131 71 B 2C0 17241 70 B 2C0 17131 90 C 2C0 17241 90 C 2C0 17151 71 A 2C0 17251 71 A 2C0 17151 80 B 2C0 17251 80 B 2C0 17151 90 C 2C0 17251 90 C 2C0 17161 70 A gt O DD Pp O D gt O U gt 2C0 17261 71 A DW p OO WD p O D gt O OU
7. 11 12 Slipper Clutch Setting Set 481 6377 70 12 19 u Gat u 15 14 Mission Maintenance Set 2 0 7000 70 19 15 22 16 Sprocket Nut Set 2 0 7463 70 23 17 ACM Set 2C0 F1400 7 1 24 18 Wire Harness Set 13S F2590 70 EE 25 19 ECU Set 2C0 8591A 80 28 20 Cable Interface 13S 8533A 70 29 2 2 Vehicle ACC SSOrI6S eee 32 21 Engine Protector Set 200 A5491 70 32 22 Chassis Protector Set 2 0 1176 70 2 1 33 23 Oil Catch Tank Set 2C0 C1707 80 enne 35 24 Front Fork Spring Sel EE 36 25 Steering Damper Stay Set 260 3495 80 38 26 Seat Cushion 36 2413 001 39 27 Front Spare Wheel Assembly 260 25100 70 40 28 Rear Spare Wheel Assembly 2C0 25300 70 41 29 Throttle Set 2CO C6300 70 nennen 42 30 Throttle Set 135 CO300 D 43 3 Tightening Torque LIst 44 4 YZF R6 Wiring RRE E E 57 1
8. STUCK HOUSING BEARING 90151 06024 SCREW CROSS RECESSED COUNTER SUNK 12 0 2 1 2 0 2 CRIMP Install STOPPER SHAFT BAR 90110 06182 BOLT HEXAGON 10 0 2 1 0 0 2 STOPPER embedded in CRANKCASE 1D7 18127 00 STOPPER SCREW M8 x 1 25 22 0 2 2 2 0 2 Install ARM SHIFT 95822 06020 BOLT FLANGE 10 0 2 1 0 0 2 CHECK FOR SERRATION TIGHTENING UP Install ROTOR PICKUP 90105 08113 BOLT FLANGE M8 x 1 25 35 0 5 3 5 0 5 Install STARTER MOTOR 90105 06083 BOLT FLANGE SMALL HEAD 10 0 2 1 0 0 2 NEUTRAL SWITCH ASSY 3GB 82540 01 NEUTRAL S W ASSY M10 x 1 25 19 642 2 0 0 2 OVERTIGHTEN ING LEADS TO DAMAGE Install OIL LEVEL SENSOR 95022 06016 BOLT FLANGE SMALL HEAD 10 042 1 0 0 2 APPLY GREASE TO O RING SPEED SENSOR x C C 91312 06016 BOLT HEXAGON SOCKET HEAD 10 042 1 0 0 2 CAM SENSOR x COVER H C 90110 06175 BOLT HEXAGON SOCKET HEAD 7 5 1 5 0 75 0 15 WIRE HARNESS NEGATIVE LEAD WIRE 91380 06012 BOLT HEXAGON SOCKET HEAD _ 50 10 0 2 1 0 0 2 To be tightened Install O2 SENSOR 135 8592 00 O2 SEN SOR Screw dia X pitch M18 x 1 5 Tightening torque 45 0 5 4 5 0 5 Remarks Install THERMOSENSOR 8CC 85790 01 THERMO
9. 2C0 2349T 80 BRKT DAMPER 90201 07081 WASHER PLAIN gt 90149 06302 SCREW 5VY 26398 00 WASHER SPECIAL 91317 08025 BOLT HEX SOCKET HEAD 2 0 23439 71 STOPPER STRG 2 90387 06084 COLLAR 90201 07081 WASHER PLAIN 90149 06302 SCREW 2C0 23429 70 STOPPER 90151 04002 SCREW CROSSRECESSED COUNTERSUNK 38 M sch sch Il sch sch Po MI Sa sch sch 26 Seat 135 24713 70 Parts List mer PARTNAME REMARKS 13S 24713 70 CUSHION SEAT Anti slip seat Cut to any size for use 39 27 Front Spare Wheel Assembly 2 0 25100 70 Parts List PART 5SL 25168 00 PART NAME WHEEL CAST REMARKS MAT BLACK 4XV 25117 00 SPACER BEARING 93306 07208 BEARING 93106 28043 SEAL 93900 00030 VALVE 40 28 Spare Wheel Assembly 2 0 25300 70 Parts List PART PART NAME REMARKS 5SL 25338 00 WHEEL CAST MAT BLACK 93306 20531 BEARING 93106 40013 SEAL OIL 93317 43580 BEARING 93420 61M07 CIRCLIP 4XV 25317 00 SPACER BEARING 551 25383 00 COLLAR WHEEL SHAFT 93900 00030 VALVE RIM a Ww N gt S ed 41 29 Throttle Set 2C0 C6300 70 Parts List PART No
10. CRANKCASE 2 90110 06161 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 PIPE OIL x CRANKCASE 2 90110 06161 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 OIL COOLER x CARNKCASE 2 12822 00 BOLT UNION M20 x 1 5 63 043 6 3 0 3 APPLY OIL TO THREAD AND BEARING SUR FACE UPPER CASE x CAP CASE ASSY 92012 06020 BOLT BUTTON HEAD 5 0 0 5 0 5 0 05 UPPER CASE LOWER CASE 98902 05020 SCREW CROSS RECESS BINDING 2 0 0 5 0 2 0 05 ELEMENT UPPER 98902 05020 SCREW CROSS RECESS BINDING 2 0 0 5 0 2 0 05 JOINT CARBURETOR 1x THROTTLE 90450 56007 HOSE CLAMP ASSY 2 0 2 5 0 2 0 25 CONTACT FIT COLLAR OR TORQUE CON TROL THROTTLE x FUNNEL 90109 05011 BOLT 34 5 0 34 0 5 LOWERFILTER CASE x FUNNEL SUPPORT UNIT 90159 05035 SCREW WITH WASHER 2 5 0 5 0 25 0 05 Install THROTTLE WIRE 13S 26302 00 THROT TLE WIRE ASSY 3 5 5 5 0 35 0 55 NUT RING x HEAD 90179 08410 NUT M8 x 1 25 46 20 0 2 2 0 0 2 TIGHTEN EXHAUST PIPE amp HEAD be tightened STAY MUFFLER 1 2 x MUFFLER 91314 08035 BOLT HEXAGON SOCKET HEAD X pitch M8 x 1 25 Screw dia Tightening torque Nem kgfem 20 0 2 2 0 0 2 Remarks INSTALL EXHAUST PIPE STAY MUFFLER 2 x BRACKET MUFFLER 1 90
11. Tightening torque Nem kgfem Remarks APPLY SUMICO MORI ASSY OIL 150 2C0 1165A 00 BOLT CON ROD M7 x 0 75 APPLY SUMICO MORI ASSY OIL 150 90179 07001 NUT M7 x 0 75 14 7 1 47 1 5 0 15 180 5 APPLY SUMICO MORI ASSY OIL 150 ROTOR x CRANKSHAFT BOLT FLANGE M12 x 1 25 70 5 7 0 0 5 DEGREASE TAPERED SUR FACE APPLY OIL BOTH TO BOLT BEARING SURFACE AND THREAD AND TO BOTH SIDES OF WASHER USE MORI COATED WASHER TENSIONER ASSY x CYLINDER 90110 06106 12 042 1 2 0 2 INSTALL TEN SIONER ASSY Install COVER THERMOSTAT 91312 06020 12 042 1 2 0 2 Install JOINT 90105 06082 10 042 1 0 0 2 Install WATER PUMP 90110 06140 12 042 1 2 0 2 OIL PUMP ASSY x CRANKCASE 2 95812 06030 12 042 1 2 0 2 OIL PUMP ASSY x CRANKCASE 2 95812 06080 BOLT FLANGE 12 042 1 2 0 2 COVER STRAINER x CRANKCASE 2 90109 06015 12 042 1 2 0 2 DRAIN BOLT for COVER STRAINER 90340 14132 PLUG STRAIGHT SCREW M14 x 1 5 45 43 0 4 4 3 0 4 DRAIN BOLT be tightened Tighten UNION BOLT for FILTER 90401 20145 Screw dia X pitch M20 x 1 5 Tightening torque Nem 70 0 5 7 0 0 5 Remarks ELEMENT FILTER 5GH 13440 20 OIL CLEANER ASSY 20 1 5 17 042 1 7 0 2 APPLY GREASE TO O RING HOLDER
12. SPRING UPR 13S 23118 70 SPACER Parts List 13S C3151 80 PART No PART NAME REMARKS 1 13S 23141 80 SPRG 1 2 10 0 N mm 1 02 kgf mm Identification line 3 lines 2 13S 23142 00 SEAT SPRING UPR 2 3 13S 23118 70 SPACER 2 Parts List 13S C3151 85 PART No PART NAME REMARKS 13S 23141 85 SPRG 1 10 5 N mm 1 07 kgf mm Identification line 4 lines 13S 23142 00 SEAT SPRING UPR 13S 23118 70 SPACER 36 Standard Setting Standard front fork Kit spring Specifications Initial height of adjuster 9 5mm Oil level 103mm Suspension oil Yamaha Suspension Oil 01 Click position Stretching direction Make 20 notches backward from the fully stretched position Pushing direction Low speed side Make 15 notches backward from the fully stretched position High speed side Make two turns back from the fully stretched position NOTE Please build the spacer and the spring seat of the attachment detaching the STD spacer when the kit spring is set up e The spring rate is identified by the number of lines on its end Replace 25 Steering Damper Stay Set 2C0 C3495 80 Parts List PART 2C0 23495 80 PART NAME STAY DAMPER Q lt REMARKS 91317 06025 BOLT HEX SOCKET HEAD 2C0 23488 80 SPACER 91317 08110 BOLT HEX SOCKET HEAD 95607 08100 NUT U
13. When decreasing the number of SHIMs standard setting is three of slipper clutch setting set the back torque limiter tends to be effective Engine braking becomes less effective Standard 3 2 1 gt 0 lt gt 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 CAUTION When decreasing the number of spring to two the caution should be taken to surely use three pieces of SHIMs for the slipper clutch setting set If its number being less than the above the less load may be supported so as to exert serious influences on driving Decreasing the number of spring to is not allowed 3 springs 3 SHIMs 3 springs Y 2 SHIMs 3 springs 1 SHIM 3 springs 0 SHIM Load 2 springs 3 SHIMs installed In operation gt Stroke 44 13 Transmission Gear Parts List PART 2C0 17411 80 A PART NAME AXLE MAIN REMARKS 2C0 17411 90 B AXLE MAIN 2C0 17411 00 AXLE MAIN 2C0 15163 00 HSG BEARING 93306 20562 BRG 2C0 17151 71 A GEAR 5TH PINION 2C0 17151 80 B GEAR 5TH PINION 2C0 17151 90 C GEAR 5TH PINION 2C0 17131 80 A GEAR 3RD PINION 2C0 17
14. 08625 8 x 1 25 15 042 1 5 0 2 Tighten HEAD 90179 10006 M10 x 1 25 TURN OF NUT METHOD AXIAL FORCE 41kN 2kN SNUG TORQUE 28 2 8 ROTA TION ANGLE 55 APPLY OIL BOTH TO THREAD AND BEARING SUR FACE SEE page 55 FOR DETAILS Tighten HEAD 90176 10075 M10 x 1 25 TURN OF NUT METHOD AXIAL FORCE 41kN 2kN SNUG TORQUE 36 3 6 ROTA TION ANGLE 55 APPLY OIL BOTH TO THREAD AND BEARING SUR FACE SEE page 55 FOR DETAILS Tighten HEAD on side of CAM CHAIN compartment 90110 06094 BOLT HEXAGON SOCKET HEAD 12 0 2 1 2 0 2 WITH WASHER SPARK PLUG 5FL 94700 70 PLUG SPARK M10S x 1 0 10 12 10 12 SEE 3 FOR DETAILS HEAD COVER x HEAD 90109 066F0 BOLT M6 x 1 0 12 0 2 1 2 0 2 Plug for sand drain hole 90340 18002 PLUG STRAIGHT SCREW M18 x 1 5 42 4 4 3 0 4 APPLY LOCK ING AGENT LOCKTITE Check bolt for oil passage 95022 08012 BOLT FLANGE SMALL HEAD M8 x 1 25 15 0 2 1 5 0 2 Tighten Al CAP 90110 06175 BOLT HEX AGON SOCKET HEAD 10 0 2 1 0 0 2 CAMSHAFT x SPROCKET 90105 07004 BOLT FLANGE 24 0 2 2 4 0 2 JOINT CARBURETOR 1 HEAD 91312 06016 BOLT HEXAGON SOCKET HEAD 44 10 042 1 0 0 2 be tightened CON ROD X CAP CON ROD 2C0 11654 00 BOLT CON ROD Screw dia X pitch M7 x 0 75
15. 70 STATOR ASSY 1 2C0 81450 70 ROTOR ASSY 1 3 2C0 15580 00 STARTER CLUTCH OUT 1 ASSY 4 2C0 15536 00 CLIP STARTER 1 5 2C0 15411 71 COVER CRANKCASE 1 1 6 90149 06080 SCREW 3 7 2C0 15451 70 GSKT CRANKCASE 1 COVER 1 NOTE Regarding Assembly 1 Remove grease from the taper surfaces of both rotor and crank before assembling them 2 Apply engine oil on the thread and flange of mounting bolts before using them 3 Apply Loctite on the bolts before assembling stator coil to the cover m Y Tightening torque 70 Tightening torque 24 18 Wire Harness Set 13S F2590 70 Parts List PART PART NAME Q TY REMARKS 1 135 82590 70 WIRE HARNESS ASSY 1 2 5FL 83976 70 SWITCH ASSY 1 MAIN SWITCH 3 5GF 83976 00 SW HANDLE 1 1 PITROAD LIMITER 4 2C0 2128A 70 BRKT REGULATOR 1 1 5 2C0 82509 70 WIRE SUB LEAD 1 6 4C8 82188 70 RESISTOR ASSY 1 90480 13003 2 8 90560 06201 SPACER 2 9 90111 06051 BOLT HEX SOCKET 4 BUTTON 10 92907 06200 WASHER PLAIN 1 CAUTION Do not remove the AC generator but leave it to function Use on the battery alone will make the machine unable to run in a short time The wire harness will not function if it is not assembled with the ECU 2C0 8591A 80 of the kit The combination of this wire harness and ECU cannot be used with 07 mo
16. Nem 10 0 2 1 0 0 2 Remarks APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 CRANKCASE 2 95812 06055 BOLT FLANGE 10 042 1 0 0 2 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 08065 BOLT FLANGE 8 x 1 25 2442 2 4 0 2 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 06065 BOLT FLANGE 10 042 1 0 0 2 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 06045 BOLT FLANGE 10 042 1 0 0 2 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 06030 BOLT FLANGE 10 042 1 0 0 2 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE Install COVER CRANKCASE 1 90109 06015 12 042 1 2 0 2 Install COVER CRANKCASE 2 90109 06031 12 042 1 2 0 2 Install COVER CRANKCASE 2 90110 06156 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 Install COVER 1 90110 06303 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 COVER 1 x HOLDER CLUTCH 90109 06015 BOLT 12 042 1 2 0 2 COVER 1 x BOLT 92014 08014 BOLT BUTTON HEAD 8 x 1 25 15 042 1 5 0 2 COVER 1 x PLUG STRAIGHT 90340 32004 PLUG STRAIGHT SCREW M32 x 1 5 48 CLOSE CON TACT WITH BEARING SUR FACE
17. SENSOR ASSY M12 x 1 5 54 17 642 1 8 0 2 Body To be tightened Part Part Name Screw dia Tightening Remarks X torque pitch kgf m HANDLE 91314 08030 BOLT M8x1 25 23 28 HEXAGON 2 3 2 8 CROWN SOCKET OUTER TUBE HEAD HANDLE 90170 28419 NUT HEX M28x 1 0 100 125 CROWN amp AGON 10 2 12 7 STEERING SHAFT HANDLE amp 91314 08030 BOLT 8 1 25 28 35 HEXAGON 2 8 3 6 OUTER TUBE SOCKET HEAD STEERING 90179 30691 NUT M30x1 0 12 15 SHAFT and Seck RING NUT OUTER TUBE amp 91314 08030 BOLT M8x1 25 20 25 HEXAGON 2 0 2 5 UNDER SOCKET BRACKET HEAD E G BRACKET 95024 10040 BOLT M10 1 25 35 45 FLANGE 9 6 4 6 FRONT SMALL HEAD E G BRACKET 90105 12228 BOLT M12 x 1 25 REAR UPPER 90179 12248 NUT 12 1 25 58 70 5 9 7 1 E G BRACKET 90105 12228 BOLT M12 x 1 25 REAR UNDER Cee 90179 12248 NUT 12 1 25 58 70 5 9 7 1 MAIN FRAME amp 90149 10002 SCREW M10 x 1 25 33 40 REAR FRAME 22527 PIVOT SHAFT amp 2 0 22141 SHAFT M32x1 5 12 19 FRAME 10 PIVOT 12 2 1 9 ARM RELAY 1 90109 10017 BOLT M10 x 1 25 SCREW IN FROM THE SMe LEFT SIDE 95602 10200 NUT U M10 1 25 31 49 FLANGE 3 2 5 ARM RELAY 1 90109 12010 BOLT M12 x 1 25 SCREW IN FROM THE SARMI LEFT SIDE 90185 12119 NUT SELF M12 x 125 31 49 LOCKING 3 2
18. angle of 1 and 2 against standard mounting Use of these holes enables regulation of valve timings The following figure shows standard positions of the holes Align the timing mark of intake and E exhaust to the alignment surface of the cylinder head upper surface To regulate the valve timing align the timing mark imprinted on the cam sprocket to adjust the angle shown by the timing mark figure against the standard angle CAUTION e Make sure to align the valve timing when the camshaft is assembled If otherwise no intended performance can be expected and more over the engine may be damaged e When using this camshaft use the valve spring set 2C0 A2110 70 Sprocket assembly position Cylinder head alignment surface 5 Valve Spring Set 2 0 2110 70 Parts List PART PART NAME REMARKS 2C0 12113 70 SPRING 1 For 2C0 12171 71 INT 2C0 12114 70 SPRING 2 For 2C0 12181 71 EXT 2C0 12117 70 RET VALVE SPRING e 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 CAUTION When using this valve spring use the camshafts 2C0 12171 71 and 2C0 12181 71 6 Oil Pump 2C0 13300 70 Parts List PART No PART NAME REMARKS 3 2999970 OLPUMPASSY a e This pump is capable of a larger discharge than the STD counterpart 7 Funnel Set 2CO A4460 80 Parts Li
19. be tightened PLATE BREATHER x C C1 90149 06082 Screw dia x pitch Tightening torque Nem kgfem 12 042 1 2 0 2 Remarks COVER CRANKCASE 1 x STATOR ASSY 90149 06080 10 042 1 0 0 2 PLUG WITH COMMUNICATION HOLE x CRANKCASE 1 90149 06082 12 042 1 2 0 2 Install COVER CHAIN CASE 90110 06060 10 042 1 0 0 2 Install M GALLERY PLUG 36Y 15189 00 M16 x 1 5 8 042 0 8 0 2 TAKE CARE NOT TO OVER TIGHTEN COVER CRANKCASE 1 x CLAMP 90149 06082 10 042 1 0 0 2 STATOR LEAD Install COVER 90109 06015 BOLT 12 042 1 2 0 2 Install OIL PIPE OUTSIDE 90110 06161 BOLT HEXAGON SOCKET HEAD 12 042 1 2 0 2 CRANKCASE 2 x PICKUP 90110 06168 BOLT HEXAGON SOCKET HEAD 10 042 1 0 0 2 Embedded in CRANKCASE x STUD EMBEDDED 90116 1002 BOLT STUD M10 x 1 25 HEIGHT 68 241 Install PRESSURE PLATE 90159 06024 8 0 2 0 8 0 2 BOSS CLUTCH x MAIN AXLE 4B1 16377 70 NUT LOCK M20 x 1 0 49 115 0 5 11 5 0 5 APPLY OIL BOTH TO THREAD AND BEARING SUR FACE be tightened BOSS PRESSURE PLATE x BOLT STUD 2C0 16374 00 Screw dia X pitch M8 x 1 25 Tightening torque Nem 25 042 2 5 0 2 Remarks Install SPROCKET DRIVE 90179 20005 M20 x 1 0 85 0 5 8 5 0 5 NO OIL SHALL
20. 08 YZF R6 SS MANUAL The Performance Edge S 1 i 1 a gt excellent Introduction e Please understand that these parts not covered by warranty e The manufacturer does not take any responsibility for problems caused by these parts e 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 e 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 e 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 Parts List Symbols e 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 e The circle mark means that when needed the individual part is sold separately to the kit set PART
21. 105 08054 BOLT FLANGE SMALL HEAD 8 x 1 25 34 034 3 4 0 4 INSTALL DAMPER Tighten BAND MUFFLER 91314 06030 BOLT HEXAGON SOCKET HEAD 10 042 1 0 0 2 SILENCER x FOOT REST 90105 08063 BOLT FLANGE 8 x 1 25 20 0 2 2 0 0 2 Install WIRE PULLEY 13S 1133E 00 13S 1133F 00 WIRE PULLEY 1 WIRE PULLEY 2 5 7 0 5 0 7 PULLEY x GEARED MOTOR 90110 05028 BOLT HEXAGON SOCKET HEAD 6 5 1 5 0 65 0 15 BRACKET 7 x FRAME 95827 06014 BOLT FLANGE SMALL HEAD 6 10 0 6 1 0 BRACKET 7 x SERVOMOTOR 95027 06025 BOLT FLANGE SMALL HEAD 5 8 0 5 0 8 Install MUFFLER PROTECTOR 90111 06071 BOLT HEXAGON SOCKET BUTTON 8 0 1 5 0 8 0 15 Install MUFFLER PROTECTOR 90111 06099 BOLT HEXAGON SOCKET BUTTON 6 5 1 5 0 65 0 15 EXHAUST VALVE SUBASSY 90179 06063 NUT 6 5 1 5 0 65 0 15 CRANKCASE 1 x CRANKCASE 2 90119 08083 BOLT HEXAGON WITH WASHER M8 x 1 25 See page 56 for details APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE CRANKCASE 1 CRANKCASE 2 90119 08084 BOLT HEXAGON WITH WASHER 8 x 1 25 47 See 56 for details APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE be tightened CRANKCASE 1 x CRANKCASE 2 90109 06100 Screw dia x pitch Tightening torque
22. 131 71 B GEAR 3RD PINION 2C0 17131 90 C GEAR 3RD PINION 2C0 17161 70 A GEAR 6TH PINION 2C0 17161 00 GEAR 6TH PINION 2C0 17161 90 C GEAR 6TH PINION 2C0 17121 80 A GEAR 2ND PINION 2C0 17121 90 B GEAR 2ND PINION 2C0 17121 00 GEAR 2ND PINION O gt O U gt O D O D gt COILNININI OI O O 2C0 17402 70 DRIVE AXLE ASSY 2C0 17421 00 AXLE DRIVE 93305 20509 BRG 90387 25016 COLLAR 2C0 17221 81 A GEAR 2ND WHEEL 2C0 17221 90 B GEAR 2ND WHEEL 2C0 17221 00 GEAR 2ND WHEEL 2C0 17261 71 A GEAR 6TH WHEEL 2C0 17261 80 B GEAR 6TH WHEEL 2C0 17261 90 C GEAR 6TH WHEEL 2C0 17241 80 A GEAR 4TH WHEEL 2C0 17241 70 B GEAR 4TH WHEEL 2C0 17241 90 C GEAR 4TH WHEEL 2C0 17231 80 A GEAR 3RD WHEEL 2C0 17231 70 B GEAR 3RD WHEEL 2C0 17231 90 C GEAR 3RD WHEEL 2C0 17251 71 A GEAR 5TH WHEEL 2C0 17251 80 B GEAR 5TH WHEEL 2C0 17251 90 C GEAR 5TH WHEEL 2C0 17211 80 A GEAR 1ST WHEEL 2C0 17211 90 B GEAR 1ST WHEEL 15 o aaa gt p O WD Pp O BD O DU FS O DD Pp O gt Parts List mr PARTNE REMARKS 2 0 17211 00 GEAR 1ST WHEEL CS ES Gear Ratio 31 12 2 583 VM 37 16 2 313
23. 14 CIRCLIP 90201 20278 WASHER PLAIN 93306 20464 BRG 93306 20464 BRG 19 a O O 20 Transmission Assembly The seal side should face outward one side 3 seal press the bearing all the into the case until it touches bottom EN d Apply molybdenum to inside of diameter After assembly it should rotate smoothly Apply molybdenum oil to the inside diameter end After assembly it should rotate smoothly Apply molybdenum oil to teeth of spline After assembly it should slide smoothly 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 2 3 2 2 3 2 fit into the bearing cup of the bearing Apply grease to the lip G D NOTE e Always use a new circlip e Do not mistake the washer and circlip directions See drawing below Matching mark Matching mark Portion R Circlip Washer Portion R Position the abutment joint of the circlip right between the splines A Detail of installation of washer washer s claw their matching mark Rotate washer so that its teeth meet axle spline teeth on the axle and then lock with Detail of installation of cir
24. 14 Intake pressure sensor malfunctions piping system 15 Throttle opening sensor malfunctions open circuit short circuit ETV 20 Intake pressure sensor or atmospheric pressure sensor malfunctions 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 primary malfunctions open circuit 40 Injector secondary malfunctions open circuit 43 Battery voltage monitor malfunctions power source for fuel system 46 Power source for vehicle malfunctions 59 Accelerator opening sensor malfunctions open circuit short circuit 60 Throttle motor malfunctions drive system 34 2 2 Vehicle Accessories 21 Engine Protector Set 2C0 A5491 70 Parts List PART No 2C0 15491 70 PART NAME PROTECTOR REMARKS 91314 06025 BOLT HEX SOCKET HEAD 91314 06020 BOLT HEX SOCKET HEAD 32 22 Chassis Protector Set 2C0 C117G 70 Parts List PART No PART NAME REMARKS 2C0 2117G 70 PROTECTOR LH LONG 2C0 2117G 90 PROTECTOR RH SHORT 2C0 21472 70 COLLAR PROTECTOR 91317 10060 BOL
25. 5 52 be tightened ARM REAR ARM 90109 12010 X pitch M12 x 1 25 Screw dia Tightening torque Nem kgfem Remarks SCREW IN FROM THE LEFT SIDE 90185 12119 NUT SELF LOCKING M12 x 1 25 REAR CUSHION amp ARM RELAY 1 90109 12011 BOLT M12 x 1 25 SCREW IN FROM THE LEFT SIDE 90185 12119 NUT SELF LOCKING M12 x 1 25 CHAIN PULLER ADJUST NUT 95604 08200 NUT U FLANGE M8 x 1 25 SHAFT PIVOT amp LOCK NUT 2C0 22252 00 NUT 2 M32 x 1 5 SHAFT PIVOT amp U NUT 90185 22002 NUT SELF LOCKING M22 x 1 5 FUEL PUMP amp FUEL TANK 90110 05028 BOLT HEXAGON SOCKET HEAD FRONT STAY for FUEL TANK amp FRAME 90110 06233 BOLT HEXAGON SOCKET HEAD Mid portion of FUEL TANK amp STAY 91312 06016 BOLT HEXAGON SOCKET HEAD BRACKET TANK rear amp FUEL TANK 91312 06090 BOLT HEXAGON SOCKET HEAD BRACKET TANK rear amp REAR FRAME 90111 06071 BOLT HEXAGON SOCKET BUTTON FRONT WHEEL SHAFT amp FR FORK 90105 14002 BOLT FLANGE M14 x 1 5 REAR WHEEL SHAFT amp NUT 90185 24007 NUT SELF LOCKING M24 x 1 5 FR CALIPER amp FR FORK 90401 10012 BOLT UNION M10 x 1 25 DISC BRAKE amp FR WHEEL 90149 06043 SCREW APPLY LOCK ING AGENT LOCKTITE DISC BRAKE amp RR WHEEL 90149 08009 8 x 1 25
26. 632172 PLATE FRICTION Compared to STD the friction plate enhances durability and operation Identification Paint Violet 41 12 Slipper Clutch Setting Set 4B1 A6377 70 Parts List No PART REMARKS 1 4B1 16377 70 NUT LOCK 1 2 4B1 16391 70 SHIM 3 12 Setting of back torque limiter of clutch A clutch with a back torque limiter mechanism is installed in the YZF R6 SP engines The operation of the back torque limiter can be adjusted through adjusting 2 the number of SHIMs set up for the kit the number of springs the whole thickness of the clutch plate and the strength of spring set up for the kit of the slipper clutch setting set Recommended setting method To begin with the dimensions of the clutch are re set to the standard values For details please refer to the service manual published from YAMAHA MOTOR CO LTD When the 2 slipper clutch setting sets are to be installed and the number of the SHIMs to be three in stack the setting may be carried out according to the standard Spring may be selected from either of the kit parts or the standard parts Spring load of the kit parts is designed to increase in 10 as compared with that of the standard parts 13 When installing the kit parts the back torque limiter tends not to be effective Engine braking becomes more effective
27. DD Pp O D gt 2C0 17161 00 2C0 17261 80 B O 2C0 17161 90 C O 2C0 17261 90 C O DD gt O gt O D D O D gt Make sure that the pinion and wheel gear are combined for use according to the chart plan 17 odp peeds y ul y ol Jaye Daag ezis pue 1 ol 6ulpJoooe peeds y ui senjeA e lt m lt m O lt m O lt m O lt m O lt m O 8 11991 Jo AiepuooeSs eu 8L0Z Sg oes 6267 GLE snipe 00091 p ds 1511 peeds 93 JZA 18 14 Mission Maintenance Set 2 0 7000 70 Parts List PART 90387 250R3 PART NAME COLLAR Q x REMARKS 90209 21332 WASHER O w 93440 25186 CIRCLIP 90387 21003 COLLAR 90209 22352 WASHER 90209 21351 WASHER 90387 28011 COLLAR 90209 25011 WASHER 93440 28184 CIRCLIP 0387 25015 COLLAR 90214 25004 WASHER CLAW 90214 25003 WASHER CLAW 90387 21004 COLLAR 93102 35017 SEAL OIL 93440 520
28. No PART NAME REMARKS 1 2C0 11181 76 GASKET CYLINDER HEAD 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 2 0 12213 00 GASKET TENSIONER 3 8 2C0 13414 70 GASKET STRAINER 3 ANTI STICK TYPE KEE x 3 ANTI STICK TYPE Symbol Marks The information necessary for correct handling and inspections and maintenance is shown with the following symbol marks CAUTION This indicates the possibility of injury or material damage occurring if mishandled NOTE This shows the method for correct operation and the points for inspection and maintenance CONTENTS 1 Engine Specifications et 1 2 prr te 2 241 Engine Parts as s sss suya 2 1 Maintenance Set 2CO MAINT 71 2 2 Spark plug set SFL R045Q 70 e 3 87 WIR EE 4 4 Cam Shaft and Cam Sprocket pp 5 5 Valve Spring Set 2CO A21 10 70 a 6 65 Ol Pump42G0 13300 70 EE 6 7 Air Funnel Set 2CO A4460 80 8 6 8 Throttle Body Clamp Assembly 2 1351 70 8 9 AIS Plug Set 195 4890 T0 nudo u 9 10 Clutch Spring Set 2CO A6330 70 EE EE 11 11 Friction Plate Set 2CO A6321 70
29. PART NAME REMARKS 2 0 26281 70 CAP GRIP UPPER 5FL 26282 00 CAP GRIP UNDER 5SL 26243 71 TUBE GUIDE 2 0 26391 70 CLIP WIRE 1 2 0 26311 70 WIRE THROTTLE 1 Grip side Retracting sharing 2C0 26313 70 WIRE THROTTLE 3 Engine side Retracting sharing 2C0 26261 70 CYLINDER 5FL 26244 70 SLIDER 2C0 2639E 70 PROTECTOR 90201 261L1 WASHER PLAIN 91314 05020 BOLT HEX SOCKET HEAD 91314 05008 BOLT HEX SOCKET HEAD N Hm EA ICH me Machining off the boss Scrape away CAP GRIP UPPER of the kit as shown above 42 30 Throttle Set 13S C6300 70 Parts List PART No 2C0 26281 70 PART NAME CAP GRIP UPPER REMARKS 5FL 26282 00 CAP GRIP UNDER 5SL 26243 71 TUBE GUIDE 2 0 26391 70 CLIP WIRE 1 135 26302 70 THROTTLE WIRE ASSY Common use for pulling back 90201 261L1 WASHER PLAIN 91314 05020 BOLT HEX SOCKET HEAD 91314 05008 BOLT HEX SOCKET HEAD Machining off the boss Scrape away CAP GRIP UPPER of the kit as shown above 43 Tightening Torque List Engine To be tightened CAP CAMSHAFT x HEAD Part No 90105 06027 Part Name BOLT FLANGE Screw dia x pitch Tightening torque kgfem 10 042 1 0 0 2 Remarks CAM SHAFT SHALL TURN LIGHTLY Embedded in HEAD 95612
30. SOR 4 SS 71 CAM SHAFT SENSOR ie e L 1 Tan BLACK 72 SENSOR Besseres ae 1 73 EARTH SCH SRI D 74 E G STOP SW Am 337 LT 75 SELECT SW E 1 76 MEASUREMENT TOOL il ei Gl 28 27 power suPPLY HL i 78 PLC_I E Cho obo 4 4 79 SW vi Ny 80 SW HANDLE E 81 SUB LD 82PIT ROAD LIMIT SW 83 VI MOTOR k 84 ECU 85 RESISTOR ASSY 57 Published by YAMAHA MOTOR ENGINEERING co LTD
31. T HEX SOCKET HEAD 91314 10065 BOLT HEX SOCKET HEAD 90201 10136 WASHER PLAIN Tightening torque 40 Nem 4 0 m kg NE ENGINE Tightening torque A 40 4 0 m kg e Tightening torque R SIDE L SIDE FRAME FRAME 65 1 ENGINE lem 3 A 33 Before mounting the protector cut the cowling so that the protector fit against the chassis As a rough guide cut 60 centered on the engine mount See the figures below 34 23 Oil Catch Tank Set 2C0 C1707 80 Parts List PART No 2C0 21707 70 PART NAME OIL TANK COMP REMARKS 90450 25037 HOSE CLAMP ASSY 13S 15373 70 PIPE BREATHER 2C0 15393 70 PIPE BREATHER 2 2C0 2419F 00 BRKT 91317 06020 BOLT HEX SOCKET HEAD 90480 13018 GROMMET 90119 06044 BOLT W WASHER YIN N a DA 24 Front Fork Spring Set Parts List 13S C3151 70 PART PART NAME REMARKS 135 23141 70 SPRG 1 8 5 N mm 0 87 kgf mm Identification line 1 line 13S 23142 00 SEAT SPRING UPR 13S 23118 70 SPACER Parts List 13S C3151 75 No PART No PART NAME Q TY REMARKS 1 13S 23141 75 SPRG 1 2 9 5 N mm 0 97 kgf mm Identification line 2 lines 13S 23142 00 SEAT
32. asket caution is needed during installation on the following points 1 The tightening torque is 10 12 Nem 1 0 1 2 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 4 Reused 15 New gasket 307 3 Head Gasket Parts List PART No 2C0 11181 71 PART NAME GASKET CYLINDER HEAD REMARKS t 0 40mm 2C0 11181 76 GASKET CYLINDER HEAD t 0 45mm 2C0 11181 81 GASKET CYLINDER HEAD t 0 50mm 2C0 11181 86 GASKET CYLINDER HEAD The thickness of the standard parts is 0 60 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 NOTE t 0 55mm Squish height means the gap between the flat portion of the piston and the head cylinder Stamping location 4 Shaft and Sprocket Parts List PART PART NAME REMARKS 2 0 12171 71 SHAFT 1 2 0 12181 71 2 2C0 12176 70 SPROCKET 1 2 0 12177 70 SPROCKET CAM 2 Tightening torque 24 Nem 2 4 mekg Tightening torque Assembly of Cam Sprocket For the cam sprocket for racing kit there are 5 mounting holes at the
33. clip Assemble washer with putting together Circlip Washer Matching mark Matching mark Washer C Detail of installation of washer Direction not applicable Gear Shaft Position the abutment joint of the circlip right between the splines D Detail of installation of circlip 21 15 Drive Sprocket Parts List PART PART NAME REMARKS 2 0 17460 74 SPROCKET DRIVE 2 0 17460 75 SPROCKET DRIVE 2 0 17460 76 SPROCKET DRIVE These parts for 520 chains STD 525 chain Use the nuts for the kit to mount the drive sprocket These sprockets are manufactured to be compatible with new and old models GROOVE MACHINING STAMP OF THE NUMBER OF TEETH ON BOTH SIDES 2CO 06 and after YZF R6 5SL 05 and previous YZF R6 Install with the grooved surface Install with the grooved surface facing outside of the chassis facing inside of the chassis CAUTION Take care not to install the sprocket in the wrong direction If it is installed in the wrong direction it will cause the misalignment of the drive and rear sprockets leading to the loss of power 22 16 Sprocket Nut Set 2C0 A7463 70 Parts List TE em eme Rear 90179 20005 SPROCKET E 90215 21256 WASHER TONGUED 1 22 17 ACM Set 2 0 1400 71 Parts List PART No PART NAME REMARKS 2 0 81410
34. dels The switches 2 types supplied in this set enable the main switch and pit road limiter to be used See diagram 1 Diagram 1 Main switch Pit road a i 9 Engine limiter Switch FON VS _ Starter switch 25 e switch installed to the STD machine be used as See diagram 2 e Map select switches Map 1 and Map 2 of the YMS Comp FUEL CAUTION When switching to Map 1 or Map 2 using Map Select while riding check that proper riding is possible even when using either map Use 5FL 83976 70 SWITCH ASSY supplied in this package as a main switch gt CK Engine stop yw switch gt J Diagram 2 JJ Pit road limiter ON OFF Not used Map oe H Lo Map 1 Hi Map 2 Pit rai BENI 7 Starter limiter switch ONON PUSH OFF ignition cut switch function be used by combining the harness kit ECU D To use the STD switch left side to function as the ignition cut switch connect the wire sub lead that was packaged with this set to the terminal that is normally connected to the left side horn See diagram 3 However if the resistor assembly that was packaged with the set is not installed there is the possibility that the ignition cut switch will operate incorrectly in rainy weather The resistor assembly is installed to the 2 pin black coup
35. he bolts in the tightening sequence of 1 to 7 to a turn of nut angle of 50 5 Retighten the bolts in the tightening sequence of 8 and 9 to a turn of nut angle of 75 5 Retighten the bolt in the sequence of 10 to a turn of nut angle of 50 5 Tighten the bolts in the tightening sequence of 11 and 12 to 24x2N m 2 4x0 2kgf m Tighten the bolts in the tightening sequence of 13 to 29 to 10 23 1 0x0 2kgf m NOTE The numbers 1 to 29 show the sequence in which the bolts are tightened Apply engine oil to the bolt threads and both sides of the washers These numbers indicate the tightening sequence 56 4 YZF R6 Wiring Diagram
36. iagnosis YMS Monitor YEC Matching System also allows functioning of the code shown below lt Diagnosis Functions gt Contents Throttle sensor YMS Monitor TPS 1 deg Atmospheric pressure sensor Atmospheric kPa Intake pressure sensor 1 Intake Air kPa Intake temperature sensor Air Temp C Water temperature sensor Water Temp CC Vehicle speed sensor Speed Signal Overturn sensor Lean Angle Signal V Monitor voltage System Voltage V Throttle sensor 2 TPS 2 deg Accelerator sensor 1 APS 1 deg Accelerator sensor 2 APS 2 deg Neutral switch Neutral SW Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Injector primary 1 Injector primary 2 Injector primary 43 Injector primary 4 Injector secondary 1 Injector secondary 2 Injector secondary 3 Injector secondary 4 Intake funnel Main relay Program version 30 Self Diagnosis Functions e The ECU and harness in the kit provide the functions for the following codes of standard self diagnosis 00 All functions normally 11 Cam angle sensor malfunctions 12 Crank angle sensor malfunctions 13 Intake pressure sensor malfunctions open circuit short circuit
37. ler at the tail See diagram 4 CAUTION Do not bend the resistor assembly It will cease to function if it is bent 2 Install the switch to the 2 pin black coupler underneath the fuel tank Turning the switch ON cuts the ignition Diagram 3 Diagram 4 26 f the kit s large radiator is installed for the bracket regulator packaged with this set use it when the regulator is installed to the position shown in drawing 5 Diagram 5 i FRAME RECTIFIER REGULATOR O e This harness has a coupler that connects to the 2D made data logger For details of the specifications of the data logger please access the website Web http www 2d kit system com 27 19 Set 2C0 8591A 80 Parts List PART PART Q TY REMARKS 2C0 8591A 80 ECU 1 2 13S 2818Y 70 CD 1 YMS MANUAL e Use of this set and wire harness included the kit enables regulation or setting of fuel injection and ignition timing etc e For details as to how to regulate or set fuel injection and ignition timings etc refer to the manual in the CD ROM that comes with the set e There are two types of basic control data for the ECU included in this set SS Super Sports and ST Stock Sports They can be switched over and vice versa To make it in the ST specification just remove two couplers located at the lower left of the kit harness fuel tank See the figure below lt Setti
38. ng up Details gt 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 CAUTION e The ECU of this set will not function if it is not assembled with the wire harness 13S 82590 70 of the kit Do not use the ECU of this set for any other assembly than the one below ECU WIRE HARNESS ASSY THROTTLE BODY ASSY 2006 Models 2C0 8591A 70 2 0 82590 70 2 0 13750 00 2007 Models 2C0 8591A 71 2C0 82590 80 2C0 13750 00 2008 Models 2C0 8591A 80 13S 82590 70 135 13750 00 28 20 Cable Interface 13S 8533A 70 Parts List 13S 8533A 70 CABLE INTERFACE 2 13S N81CD 70 8cm CD 1 USB driver e This cable connects the kit wire harness to the personal computer on which YEC FI Matching System YMS is installed e Please see the YMS manual for instructions on how to use YMS e When connecting 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 e The product vendor ID and product ID are provided by the Hamamatsu TOA Electronics Inc Vendor ID 6837 Product ID 9001 _ 29 e Use of the ECU in the kit and the harness allows functioning of the following codes in the STD d
39. st PARTNo PARTNAME or REMARKS FUN gt e This set is capable of higher intake efficiency than the STD counterpart NOTE e The air cleaner case is fastened by the STD funnel Remove the STD funnel and mount the plate e Apply a thin amount of grease to the screws of the funnel and plate before attaching 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 50 25 59 98 Web http www mgcompetition fr K T Reference Ge Standard L 25 9 Selecting the Funnel In addition to the funnel set in the the ycci system mounted the STD vehicle also be This is capable of being controlled in operation timing etc by the use of YMS software accompanying KIT ECU ycci control is possible by using 2 kinds of basic control data SS spec ST spec included KIT ECU 8 Throttle Body Clamp Assembly 2 1351 70 Parts List PART No PART NAME REMARKS 90450 56005 HOSE CLAMP ASSY 95307 04600 NUT HEX 551 13573 70 BOLT 1 5SL 1358A 70 ROD COMP 2C0 13573 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 Cut it off The part has a collar to prevent over tightening In normal cases the part will not be tigh
40. tened 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 9 AIS Plug Set 13S A4890 70 This plug set is used when the AIS Air Induction System an exhaust gas purification system is removed Parts List PART No PART NAME REMARKS 551 14821 70 PLATE 2 93608 16M16 PIN DOWEL 90336 10020 PLUG TAPER Installation 1 Remove the hose attached to the cylinder head cover and the air cut off valve assembly accompanying the hose Remove the cap fitted to the hose and remove the reed valve and plate from the inside Install the plate 551 14821 70 in replacement of the cap Apply liquid gasket to the plate Remove the cylinder head cover and the four collars fitted to the cover Install the PIN 93608 16M16 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 STD ASSY K m Insertion H L direction NS ASSY 10 10 Clutch Spring Set 2CO A6330 70 Parts List No PARTNo mr mme 2C0 16334 70 SPRING CLUTCH 2 6 The clutch spring has a 20 higher mounting load on the STD 11 Friction Plate Set 2 6321 70 Parts List Ne PARTNAME REMARKS 7 11 5EB 1
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