Yamaha YZF-R6 L 2000 Specifications

’04 YZF-R6SS KIT MANUALThe Performance Edgefor excellent riders

– 6 –Aligning of Valve Timing • When assembling the camshaft, always make sure to align the valve timing. If this isnot done, not only will performanc

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– 8 –EVENT ANGLE INT. EVENT ANGLE EXT.

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– 10 –6. Sub Radiator Set (5SL-A240A-70)Installation Precautions1. This kit assumes that the muffler kit set is used. It cannot be mounted on the STDm

– 11 –STDSTDTHERMOSTATWATER PUMPSUB RADIATORMAINSUBUpper assembly diagram (viewed in front)

– 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 –

– 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-

– 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

– 15 –11.Exhaust Pipe Set (5SL-A4600-70)Made entirely of titanium, this exhaust set has less weight and features a configurationthat allows a sub-radi

2003 YZF-R6 Kit Manual• Please understand that these parts are not covered by the warranty. • The manufacturer does not take any responsibility for pr

– 16 –CAUTION:Reroute the clutch wire as shown below so as to prevent it from contacting the exhaustpipe.Piping for auto starterPass the clutch wire o

– 17 –42043443742279(#1~#4)277286400 550250ø12ø12#1#2#3#4Connecting pointø 38.1 ø 42.7 ø 50.8Pipe outside diameter (Plate thickness t1.2)Exhaust port

– 18 –12.Transmission Gear Set (5SL-A7400-70)Parts ListNo. PART No. PART NAME Q'TY REMARKS1 5SL-17411-80 AXLE, MAIN 1 16T* 2 90387-253M6 COLLAR 1

– 19 –Gear RatioCAUTION:The gears of the kit transmission and those of the standard transmission are completelyincompatible. Only combine the gears pr

– 20 –13.Option Gear Set1stGEAR SET A (5SL-A7411-70)1STGEAR SET C (5SL-A7411-90)2ndGEAR SET A (5SL-A7421-70)3rdGEAR SET A (5SL-A7431-70)CAUTION:1. The

– 21 –14.SprocketsThese parts are for 520 chain size (the standard size is 532).Use the drive sprocket mounting nut from the kit.Parts ListNo. PART No

– 22 –15.Clutch Spring Set (5EB-A6330-70)Specifications This clutch spring set contains a spring featuring increased pressure load ofapproximately 20%

– 23 –17.ACM Set (5SL-F1400-70)Installation Precautions1. Before installing the rotor to the crank, degrease both of their tapers.2. Before installati

– 24 –18.Engine Control Unit (ECU)• Using the wire harness supplied in the kit, you can switch to control data of SS(Super Sports) specification or to

– 25 –A: Fuel injection AdjustmentFuel injection amount can be adjusted in the following four ranges:Code C1: Fuel amount injected at 25% or less of t

CONTENTS1 Standard Specifications (SS spec.)... 12 Kit Parts ...

– 26 –Adjustment• Transfer to adjustment mode.While holding down both the “RESET” and “SELECT” buttons on the meter, turn onthe main switch (the engin

– 27 –B: Offset at ignitionThis function corrects the general differences in the ignition timing requirements causedby different fuels etc.Adjustment•

– 28 –C: Location for water temperature display and unit conversionThe ECU in the kit has an additional function of displaying the water temperature i

– 29 –E: Diagnosis (function for checking the condition)The ECU in the kit makes it possible to check whether the sensors and switches areworking prop

– 30 –*NOTE: Even if the engine is capable of running during failure, it is a mere passingoperation and may not produce its intended function and perf

– 31 –Table 2 <Diagnosis function>CODE Item Operation of ECU01 Throttle sensor• Displays throttle sensor input value in angles.• Approx. [17] de

– 32 –19.Wire Harness Set (5SL-F2590-70)• Do not remove the AC generator but leave it to function. Using the battery alone willresult in the inability

– 33 –20.Meter Stay Set (5SL-C8350-70)The rearview mirror and headlight cannot be installed.Parts ListNo. PART No. PART NAME Q'TY REMARKS1 5SL-28

– 34 –2-3 Chassis Parts21.Oil Catcher Tank Set (5SL-C1707-70)This actual capacity of this oil tank is 1000 cc. Install behind the rear frame above the

– 35 –22.Engine Protector Set (5SL-A5491-70) This part reduces damage when the motorcycle tips over along with the chassisprotector. For the YZF-R6 in

3 Assembly Precautions...463-1 Checking the Valve Seats...

– 36 –23.Chassis Protector Set (5SL-C117G-70)Remove the arrowed bolts and install the chassis protector using the supplied bolts. Cutthe cowling to fi

– 37 –24.Rear Suspension SpringsThis spring is intended for use in the STD shock absorber. It is slightly shorter than theSTD so that the vehicle heig

– 38 –26.Front Fork SpringSpecificationCAUTION:1. The spring is longer than the STD in overall length because of its specification. Forsetting up, use

– 39 –27.Throttle Set (5SL-C6300-70)This part allows the throttle grip to be removed without removing the carburetor wire tofacilitate easier maintena

– 40 –28.Steering Damper Stay Set (5SL-C3495-70) Use the steering damper OHLINS SD1210 with a 68 mm stroke.Parts ListNo. PART No. PART NAME Q'TY

– 41 –29.Front Disk Brake Assembly (5SL-2581T-70)The disk thickness and heat treatment of these parts has been changed for racing use,resulting in imp

– 42 –31.Footrest Set (5SL-C7400-70)Parts ListNo. PART No. PART NAME Q'TY REMARKS1 5SL-27412-70 BRKT., 1 12 5SL-27452-70 BRKT., FOOTREST 1 1* 3 9

– 43 –This footrest kit is designed to allow its position to have a change of 10 mm upper andlower from the center. Its central position is located 15

– 44 –Install the return spring of the rear brake on the master cylinder by removing the rubberboot. Since the standard radiator recovery tank cannot

– 45 –2-4 Other32.Valve Seat Cutter Set (5SL-M1112-70)This tool set is used for fine adjustment of the contact of the valve and valve seat.• This set

– 1 –1Standard Specifications (SS spec.) Item SpecEngine type Liquid-cooled, 4-stroke, In-Line DOHC 4-valveDisplacement 599.7 ccBore × stroke 65.5 mm

– 46 –3Assembly PrecautionsNOTE:Please check next point for set up yourmotorcycle.3-1 Checking the Valve SeatsThe following procedure applies to all o

– 47 –4. Lap:• valve face • valve seat NOTE:After replacing the cylinder head orreplacing the valve and valve guide, thevalve seat and valve face shou

– 48 –3-2 Connecting Rod Installation Procedure1. Install the connecting rod to the bearing with the projections engaged. Apply oilgenerously to t

– 49 –3-3 Cylinder Head Installation Precautions• For cylinder head installation, apply engine oil to the tightening bolts and washersand install in t

– 50 –3-4 Engine Mounting ProcedureStrictly follow the steps below. If not, the frame stiffness and handling may be adverselyaffected.1. Before mounti

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– 52 –3-5 Rear Arm Installation Procedure1. Tighten to specification beforehand the bracket using the bolt and nut on topof the shock absorber

– 53 –20 93315-31758 BRG. 221 90105-10018 BOLT,FLG. 122 90387-1013U COLLAR 1Parts ListNo. PART No. PART NAME Q'TY REMARKS

– 54 –3-6 Front Wheel Installation Procedure1. Insert the wheel axle from the left of the vehicle, and tighten the bolt tospecification on the rig

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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 Funn

– 56 –3-7 Please apply grease on the wall in AIR CLEANER CASE.This grease will catch some dusts. apply grease

– 57 –4R6 Front Fork Manual (basic information)ADJUSTMENTThe adjustment of your front fork can be changed by following factors: • Spring rate• Preload

– 58 –Adjustment of rebound dampingThe rebound refers to the hydraulic damping when the front fork moves out. Therebound can be changed by the rebound

– 59 –Compression damping • Standard adjustment • Not enough damping: - the front fork is bottoming easy • Too much damping: - the front fork feels ha

– 60 –SOLVING PROBLEMSPlace Terrain Problem AdjustmentStraight line Small bumps1. SpringyIncrease reboundDecrease preload2. Feels hard, stiffA: decrea

– 61 –UphillUnder acceleration Head shakes Increase reboundConsecutive small bumpsFeels harshA: decrease spring rateB: decrease preloadC: decrease reb

– 62 –5R6 Shock Absorber Manual (basic information) ADJUSTMENTFollowing factors can change the adjustment of a shock: • spring rate • preload on the s

– 63 –Adjustment of rebound dampingThe rebound refers to the hydraulic damping when the shock moves out. The reboundcan be changed by the rebound adju

– 64 –Compression damping• standard adjustment• not enough compression:- the shock is bottoming easy - the bike sits low- the bike turns difficult• t

– 65 –SOLVING PROBLEMSPlace Terrain Problem AdjustmentIn straight lineSmall bumps1. Springy Increase rebound2. Feels heavy Decrease rebound3. Lack of

– 3 –2. Spark PlugsSet No.: 5FL-R045Q-70 (R0045Q-10, 4 plugs) CAUTION:Since these spark plugs use a copper gasket, caution is required with respect to

– 66 –Other1. Too stiff overallA: decrease spring rateB: decrease compression2. Feels springyA: decrease compression3. Feels like it’s not using enoug

– 67 –2003 YZF-R6 Wiring Diagram

– 68 –Speed × Ratio table for YZF-R6 (2003)Name gearbox StdWheel circumflex (m) 1.98Max RPM 15000Primary ratio 44 86Gear Prim 13 13 13 13 14 13 14 13

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– 4 –4. Remove the cylinder head cover, then the four collars fitted in the head cover, andinstall the PIN (93608-16M16).5. After removing the hose th

– 5 –5. Camshaft and Cam Sprockets Specifications Parts ListNo. PART No. PART NAME Q'TY REMARKS1 5SL-12171-70 SHAFT, CAM 1 1 INT.2962 5SL-12181-7