’09 YZF-R6

SS KIT MANUAL

The Performance Edge
for excellent riders

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.
No. ˚ * * 1 2 3 4 * 5 PART No. 4C8-11181-70 5VY-11351-00 4C8-11603-00 5VY-1165A-01 93450-18157 PART NAME GASKET, CYLINDER HEAD 1 GASKET, CYLINDER 1 PISTON RING SET BOLT, CONNECTING ROD SPECIAL CIRCLIP Q’TY 3 3 12 24 24 REMARKS t=0.30mm

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.
WARNING

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 Engine Specifications................................................................................... 1 2 Kit Parts ......................................................................................................... 2
2-1 Engine Parts.................................................................................................... 2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Maintenance Set (2C0-MAINT-71) ....................................................................... 2 Spark plug set (5FL-R045Q-70, 13S-R373A-70).................................................. 3 Head Gasket ......................................................................................................... 4 Cam Shaft and Cam Sprocket .............................................................................. 5 Valve Spring Set (2C0-A2110-70) ........................................................................ 6 Oil Pump (2C0-13300-70)..................................................................................... 6 Air Funnel Set (MGC-A300908-00)....................................................................... 7 Throttle Body Clamp Assembly (2CO-1351A-70) ............................................... 10 AIS Plug Set (13S-A4890-70) ............................................................................. 11 Clutch Spring Set (2CO-A6330-70) .................................................................... 13 Friction Plate Set (2CO-A6321-70) ..................................................................... 14 Slipper Clutch Setting Set (4B1-A6377-70) ........................................................ 15 Transmission Gear.............................................................................................. 18 Mission Maintenance Set (2C0-A7000-70) ......................................................... 22 Drive Sprocket .................................................................................................... 25 Sprocket Nut Set (2C0-A7463-70) ...................................................................... 26 ACM Set (2C0-F1400-71) ................................................................................... 27 Wire Harness Set (13S-F2590-71) ..................................................................... 28 ECU Set (2C0-8591A-90) ................................................................................... 32 Cable Interface (13S-8533A-70) ......................................................................... 33

2-2 Vehicle Accessories..................................................................................... 36
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. Engine Protector Set (2C0-A5491-70) ................................................................ 36 Chassis Protector Set (2C0-C117G-70) ............................................................. 37 Oil Catch Tank Set (2C0-C1707-81)................................................................... 39 Rear Suspension ................................................................................................ 40 Rear Shock Spring.............................................................................................. 42 Front Fork ........................................................................................................... 43 Front Fork Spring ................................................................................................ 45 Steering Damper Stay Set (2C0-C3495-80) ....................................................... 50 Seat Cushion (13S-24713-70) ............................................................................ 51 Front Spare Wheel Assembly (2C0-25100-70)................................................... 52 Rear Spare Wheel Assembly (2C0-25300-70) ................................................... 53 Throttle Set (2C0-C6300-70) .............................................................................. 54 Throttle Set (13S-C6300-70)............................................................................... 55

3 Tightening Torque List ............................................................................... 56 4 YZF-R6 Wiring Diagram.............................................................................. 69

27) = 110° = 110° 0. EXT.25 targeted (0.0 × 42.62 12° BTDC 599cc 16000rpm 67. Squish height Clearance between the valve and the piston INT.10 12° ATDC = 1.22) = 0.5mm –1– . EXT.60mm = 1.1 Engine Specifications Spec Displacement Maximum engine speed (limiter controlled speed) Bore/Stroke Valve timing (event angle) INT.23 – 0. Clearance of valves (tappet) INT.20 targeted (0. EXT.18 – 0. = 0.

CONNECTING ROD NUT SEAL. OIL SCREW. ° * * * * * ° ° ° ° * * 1 2 3 4 5 6 7 8 9 10 11 12 13 PART No. TENSIONER GASKET. 2C0-11181-76 2C0-11603-00 93450-16159 2C0-1165A-00 90179-07001 4SV-12119-00 2C0-12213-00 2C0-13414-70 2C0-15451-70 2C0-15461-70 2C0-15456-70 93102-35017 90151-06024 PART NAME GASKET. 1 SEAL. CYLINDER HEAD PISTON RING SET CIRCLIP BOLT. CRANKCASE COVER 2 GSKT. CRANKCASE COVER 1 GASKET.45mm Parts List –2– .. CROSSRECESSED COUNTERSUNK Q'TY 3 12 24 24 24 48 3 3 3 3 3 3 9 ANTI STICK TYPE ANTI STICK TYPE ANTI STICK TYPE ANTI STICK TYPE FOR DRIVE AXLE FOR BEARING HOUSING REMARKS t=0. STRAINER GASKET. VALVE STEM OIL GASKET. Maintenance Set (2C0-MAINT-71) No.2 Kit Parts 2-1 Engine Parts 1.

13S-1119C-70 PART NAME PLUG. SPARK Q'TY 4 REMARKS NGK R0045Q-10 Parts List Angled ground strap Type (13S-R373A-70) No.2 kgf•m). When not checking the torque. 13S-R373A-70) Parts List Semi surface discharge Type (5FL-R045Q-70) No.2. The tightening torque is 10 – 12 N•m (1.0 – 1. 1. 1 TIP PART No. Spark plug set (5FL-R045Q-70. tighten by rotating through 15°. tighten by rotating through 30° after manual tightening in the case of new plugs. Reused (15°) New gasket (30°) –3– . 1 PART No. caution is needed during installation on the following points. 5FL-1119C-70 PART NAME PLUG. SPARK Q'TY 4 REMARKS NGK R0373A-10 Since these spark plugs have a copper gasket. When reusing plugs. 2.

These parts are used to adjust the squish height. Head Gasket No. CYLINDER HEAD GASKET. use the one with -76 (0. CYLINDER HEAD GASKET.50mm t=0. 2C0-11181-71 2C0-11181-76 2C0-11181-81 2C0-11181-86 PART NAME GASKET.45mm).3.55mm Parts List The thickness of the standard parts is 0. TIP Squish height means the gap between the flat portion of the piston and the head cylinder. 1 2 3 4 PART No.40mm t=0. CYLINDER HEAD Q'TY 1 1 1 1 REMARKS t=0. Stamping location –4– . make sure to check the squish height and use the gasket so that the squish height becomes 0. After processing the cylinder (upper case).45mm t=0.60mm. In normal cases. CYLINDER HEAD GASKET.60mm or above.

To regulate the valve timing. use the valve spring set 2C0-A2110-70. NOTICE • Make sure to align the valve timing when the camshaft is assembled. Sprocket assembly position –5– . there are 5 mounting holes at the angle of ±1° and ±2° against standard mounting. 2C0-12171-71 2C0-12181-71 2C0-12176-70 2C0-12177-70 PART NAME SHAFT. refer to the KIT TOOLS MANUAL. If otherwise. Tightening torque Assembly of Cam Sprocket For the cam sprocket for racing kit. Use of these holes enables regulation of valve timings. The following figure shows standard positions of the holes. CAM 1 SHAFT.4. the engine may be damaged. align the timing mark imprinted on the cam sprocket to adjust the angle shown by the timing mark figure against the standard angle. CAM 1 SPROCKET.4 m•kg) Parts List Q'TY 1 1 1 1 INT EXT INT EXT REMARKS STD FWD. Cam Shaft and Cam Sprocket No. TIP For valve timing adjustment. no intended performance can be expected and more over. 1 2 3 4 PART No. CAM 2 Tightening torque 24 N•m (2. CAM 2 SPROCKET. Align the timing mark of I (intake) and E (exhaust) to the alignment surface of the cylinder head upper surface. • When using this camshaft.

6.. 1 PART No.1 Q'TY 8 REMARKS For 2C0-12171-71 (INT) Identifying color: Light blue For 2C0-12181-71 (EXT) Identifying color: Yellow Parts List 2 3 2C0-12114-70 2C0-12117-70 SPRING. and 2C0-12181-71. VALVE SPRING 8 16 • 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. 1 PART No. –6– .2 RET. NOTICE When using this valve spring. 2C0-12113-70 PART NAME SPRING. Oil Pump (2C0-13300-70) No.5. use the camshafts 2C0-12171-71. Valve Spring Set (2C0-A2110-70) No. 2C0-13300-70 PART NAME OIL PUMP ASSY Q'TY 1 REMARKS Parts List • This pump is capable of a larger discharge than the STD counterpart.

Fitting Method 1. don’t forget to put the small ring into the hole. Put only the 2 lower screw like on the schema. Use standard screw. PART NAME PRIMARY FUNNEL SUPPORT L SUPPORT R EXTENSION FUNNEL R EXTENSION FUNNEL L Q'TY 2 1 1 2 2 REMARKS L=15. 2. Installing the Primary Funnel Screw on the plates on the throttle body.9mm Parts List • This set is capable of higher intake efficiency than the STD counterpart. Lever* Bush* Bush* Support R Support L Lever assembly –7– . Assemble Support and Axle The axles are the standards ones. *Use the lever and bushing intended for a STD machine.7. 1 2 3 4 5 PART No. Air Funnel Set (MGC-A300908-00) No.

Begin by clipping white prismatic side to the motor axle.3. SHAFT ASSY. LEVER ASSY. Make sure that the axle can easily turn without friction. then clip other side to the tong of the inferior axle. Then put the screw on the superior part of the supports (shown by a red arrow on the photo Below). Secure using standard screws in the places illustrated. 4. Connecting Rod Use standard connecting rod. Mount the Assembly Secure the lever assembly to the primary funnel. A/C Motor side Lever side PRIMARY FUNNEL –8– .

fr/ –9– . TEL +33 (0) 4 50 25 59 96 FAX +33 (0) 4 50 25 59 98 Web http://www. You can also control the STD funnel by using the YMS software. 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. For details of the specification. please check with MG Competition. This set is made by MG Competition.5. Note the direction of the groove on the extension funnel and connect with wire so that it does not turn and come off.mgcompetition. Fitting the Extention Funnel Attach the extension funnel to the standard secondary funnel. You can control the operation timing by using the YMS software packed together with the kit ECU. Secondary funnel Extension funnel Rubber seal Wire 6.

8. cut off the protrusion for positioning bands at the cabjoint. Q'TY 1 REMARKS Parts List This part is used to enhance maintenance performance of the throttle body. 1 PART No. In normal cases. Make sure to put a new band through a M4 x 0.7 tap before using it. Before using it. 2C0-1351A-70 PART NAME THROTTLE BODY CLAMP ASSY. – 10 – . Just manually tighten it. the part will not be tightened till it reaches to the collar. Throttle Body Clamp Assembly (2CO-1351A-70) No. Cut it off The part has a collar to prevent over-tightening.

open the upper case of the air cleaner case and insert the PLUG (90336-10020) into the hole where the hose was connected. 2 PIN. 4. TAPER Q'TY 2 4 1 REMARKS Installation 1. 5SL-1482L-70 93608-16M16 90336-10020 PART NAME PLATE. an exhaust gas purification system. 3. 2. is removed. Remove the hose attached to the cylinder head cover and the air cut-off valve assembly accompanying the hose. Parts List No. AIS Plug Set (13S-A4890-70) This plug set is used when the AIS (Air Induction System). Remove the cylinder head cover and the four collars fitted to the cover. 5. 1 * 2 3 PART No. Remove the cap fitted to the hose and remove the reed valve and plate from the inside. Install the plate (5SL-1482L-70) in replacement of the cap. – 11 – . Apply liquid gasket to the plate. Install the PIN (93608-16M16). DOWEL PLUG. After removing the hose connected to the air cleaner case from the air-cut valve assembly.9.

STD A/C ASSY.  – 12 – . REMOVE KIT Insertion direction ! A/C ASSY.

Clutch Spring Set (2CO-A6330-70) Parts List No. 1 PART No. – 13 – . 2C0-16334-70 PART NAME SPRING. CLUTCH 2 Q'TY 6 REMARKS Identifying color: Green The clutch spring has a 20% higher mounting load on the STD.10.

the friction plate enhances durability and operation. 1 PART No. Friction Plate Set (2CO-A6321-70) Parts List No.11. FRICTION 1 Q'TY 9 REMARKS Compared to STD. Identification Paint (Violet) – 14 – . 5EB-16321-72 PART NAME PLATE.

* * 1 2 PART No.4 – 43.0 – 15 – . LOCK SHIM 2 1 Q’TY 1 3 REMARKS c b 42. Slipper Clutch Setting Set (4B1-A6377-70) Parts List No. 4B1-16377-70 4B1-16391-70 a PART NAME NUT.12.

(For details. please refer to the service manual published from YAMAHA MOTOR CO. the setting may be carried out according to the standard. – 16 – . a the number of springs. b the whole thickness of the clutch plate. When the 1 2 slipper clutch setting sets are to be installed. LTD. (Recommended setting method) To begin with. Spring load of the kit parts is designed to increase in 10% as compared with that of the standard parts. the dimensions of the clutch are re-set to the standard values. A clutch with a back torque limiter mechanism is installed in the YZF-R6 SP engines.(Setting of back torque limiter of clutch). c Spring may be selected from either one of the kit parts or the standard parts. The operation of the back torque limiter can be adjusted through adjusting: 2 the number of SHIMs (set up for the kit). and the strength of c spring (set up for the kit) of the slipper clutch setting set. and the number of the SHIMs are to be three in stack.

If its number being less than the above. 3 SHIMs As installed Stroke In operation – 17 – . 2 SHIMs 3 a springs. when decreasing the number of a spring (the number of standard setting is three) to two. When decreasing the number of SHIMs (standard setting is three) of slipper clutch setting set. 3 a springs.When installing the kit parts. the back torque limiter tends to be effective (Engine braking becomes less effective). 1 SHIM 3 a springs. NOTICE When decreasing the number of a spring to two. Standard 3 2 1 0 effective (Engine braking becomes less effective) Further. 3 SHIMs 3 a springs. the caution should be taken to surely use three pieces of SHIMs for the slipper clutch setting set. Decreasing the number of a spring to one is not allowed. the back torque limiter becomes effective (Engine braking becomes less effective). the back torque limiter tends not to be effective (Engine braking becomes more effective). 0 SHIM Load 2 a springs. the less load may be supported so as to exert serious influences on driving.

MAIN AXLE. AXLE. 6TH PINION GEAR. 5TH WHEEL GEAR. COLLAR GEAR.13. 6TH PINION GEAR. 3RD PINION GEAR. DRIVE BRG. 1ST WHEEL GEAR. MAIN HSG. 3RD WHEEL GEAR. MAIN AXLE. 5TH WHEEL GEAR. 2ND WHEEL GEAR. 5TH WHEEL GEAR. 2ND PINION DRIVE. 2C0-17411-80-A 2C0-17411-90-B 2C0-17411-00 2C0-15163-00 93306-20562 2C0-17151-71-A 2C0-17151-80-B 2C0-17151-90-C 2C0-17131-80-A 2C0-17131-71-B 2C0-17131-90-C 2C0-17161-70-A 2C0-17161-00 2C0-17161-90-C 2C0-17121-80-A 2C0-17121-90-B 2C0-17121-00 2C0-17402-70 2C0-17421-00 93305-20509 90387-25016 2C0-17221-81-A 2C0-17221-90-B 2C0-17221-00 2C0-17261-71-A 2C0-17261-80-B 2C0-17261-90-C 2C0-17241-80-A 2C0-17241-70-B 2C0-17241-90-C 2C0-17231-80-A 2C0-17231-70-B 2C0-17231-90-C 2C0-17251-71-A 2C0-17251-80-B 2C0-17251-90-C 2C0-17211-80-A 2C0-17211-90-B PART NAME AXLE. 2ND WHEEL GEAR. GEAR. 5TH PINION GEAR. 1 1 * * * 1 2 3 4 4 4 5 5 5 6 * 6 6 7 7 * * * * 7 8 9 10 11 12 12 * 12 13 13 13 14 14 14 15 15 15 16 16 16 17 17 PART No. 4TH WHEEL GEAR. 3RD WHEEL GEAR.. AXLE ASSY. 5TH PINION GEAR. 1ST WHEEL Q'TY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A B C A B C A B C A B C A B C A B A B C A B C A B C A B C A B C REMARKS – 18 – . Transmission Gear Parts List No. 4TH WHEEL GEAR. 6TH PINION GEAR. 4TH WHEEL GEAR. 6TH WHEEL GEAR. 5TH PINION GEAR. 2ND WHEEL GEAR. 6TH WHEEL GEAR. 2ND PINION GEAR. BEARING BRG. 3RD WHEEL GEAR. 6TH WHEEL GEAR. 3RD PINION GEAR. 3RD PINION GEAR. 2ND PINION GEAR.

• There is no compatibility with the ’06 model transmission set (2C0-A7400-70).583) 32/16 (2.304) 23/20 (1.857) 36/23 (1.444) 30/23 (1.667) 28/19 (1.565) 25/18 (1.000) 30/18 (1.150) C 31/12 (2.150) • No gear can be used for the kit transmission except for the specified STD gear.583) 32/16 (2.269) 25/22 (1.286) 23/20 (1.350) 26/22 (1. 2C0-17211-00 PART NAME GEAR.667) 26/18 (1.Parts List No.000) 30/18 (1.611) 26/18 (1.471) 39/20 (1.389) 33/26 (1. – 19 – .136) B 42/17 (2.950) 29/18 (1.313) 39/21 (1.444) 27/21 (1. * 17 PART No. 1ST WHEEL Q'TY 1 17 15 16 REMARKS C 14 13 12 9 2 3 1 8 10 11 4 5 6 7 • Gear Ratio std 1st 2nd 3rd 4th 5th 6th NOTICE A 37/16 (2.474) 27/20 (1.182) 31/12 (2.

– 20 – .444 2C0-17131-71-B 1.389 2C0-17131-80-A 1.667 2C0-17131-90-C 1.313 2C0-17411-80-A 2.565 2C0-17131-80-A 1.611 2C0-17131-71-B 1.350 2C0-17151-90-C 1.YZF-R6 Mission ratio Pinion gear GEAR PLAN Ratio Part number The Stamp number of teeth 16 17 12 21 20 16 23 18 18 18 18 19 26 23 20 22 20 22 C A B C A B C A B C A A B A B Wheel gear Part number The Stamp number of teeth 37 42 31 39 39 32 36 29 30 25 26 28 33 30 27 25 23 26 A B C A B C A B C A B C A B A B 1ST A B C 2.304 2C0-17151-80-B 1.150 2C0-17161-00 1.950 2C0-17121-90-B 2.182 2C0-17161-90-C 2C0-17211-80-A 2C0-17211-90-B 2C0-17211-00 2C0-17221-81-A 2C0-17221-90-B 2C0-17221-00 2C0-17231-80-A 2C0-17231-70-B 2C0-17231-90-C 2C0-17241-80-A 2C0-17241-70-B 2C0-17241-90-C 2C0-17251-71-A 2C0-17251-80-B 2C0-17251-90-C 2C0-17261-71-A 2C0-17261-80-B 2C0-17261-90-C 2ND A B C 3RD A B C 4TH A B C 5TH A B C 6TH A B C Make sure that the pinion and wheel gear are combined for use according to the chart plan.471 2C0-17411-90-B 2.000 2C0-17121-00 1.857 2C0-17121-80-A 1.583 2C0-17411-00 1.136 2C0-17161-70-A 1.474 2C0-17131-90-C 1.269 2C0-17151-71-A 1.

5 191.1 123.0 190.8 • Values in the speed table may vary slightly according to tire manufacturer and size.857 175.6 220.6 168.0 258.2 180.0 164.0 118.7 202.0 138.4 229.4 210.4 156.7 251.3 250.474 221.0 156.9 146.8 221.9 129.1 173.2 195.4 109.2 108.7 216.2 111.7 189.7 200.0 148.1 212.611 202.3 265.0 202.8 240.4 234.2 168.182 275.0 254.6 185.0 147.1 190.6 218.3 211.6 268.8 198.7 223.2 170.3 203.1 237.8 A 22 25 1.1 135.1 160.9 110.7 160.7 104.150 283.0 181.3 193.5 113.2 211.5 136.2 203.7 1st B 17 42 2.8 171.7 153.8 268.7 152.1 198.7 235.5 161.6 260.7 240.9 132.7 204.7 207.4 95.6 216.5 171.6 149.9 255.2 237.4 236.8 244.5 195.4 129.2 135.6 203.3 131.9 248.7 169.9 97.9 203.2 143.0 249.2 153.1 212.6 3rd B 18 29 1.3 150.5 253.5 274.0 242.8 154.0 140.2 126.350 241.5 231.8 106.3 206.5 172.4 167.6 217.5 215.9 187.8 263.5 225.6 222.3 188.9 118.2 Speed (km/h) C 18 30 1.3 183.4 150.7 149.9 181.4 190.4 158.6 207.7 167.5 178.0 147.0 182.0 151.9 160.4 225.4 219.1 230.7 157.4 232.1 213.5 171.0 196.9 157.5 224.5 124.1 226.0 138.8 161.0 175.4 172.304 249.1 192.4 99.1 169.9 142.0 145.2 144.9 248.8 199.1 257.3 163.7 198.9 189.6 114.4 A 23 36 1.3 167.2 247.6 118.5 134.3 189.6 134.0 240.3 202.6 185.9 167.4 239.6 C 22 26 1.0 232.3 113.5 151.0 163.8 210.5 C 12 31 2.7 174.0 211.9 164.2 194.3 123.0 195.2 C 20 27 1.2 210.2 194.5 159.1 194.2 142.0 152.8 133.9 128.5 164.7 121.0 126.471 131.0 174.9 157.4 186.3 263.1 231.5 239.7 221.2 205.7 224.3 121.5 132.4 120.3 103.6 189.1 170.3 186.2 229.6 146.5 137.4 236.1 108.5 243.8 209.0 106.2 199.2 216.8 196.3 118.5 184.1 154.2 223.2 234.6 143.1 183.4 116.4 A 26 33 1.444 225.6 185.8 216.2 220.3 203.7 183.6 115.1 186.7 118.6 231.0 247.8 224.1 216.2 107.7 132.4 179.3 206.1 211.9 121.4 189.0 103.YZF-R6 Speed List Engine speed (rpm) 16000 Tire radius (mm) 315 perimeter (m) 1.6 265.3 226.5 160.6 230.5 211.2 170.7 – 21 – 4th B 18 26 1.9 101.2 130.9 207.6 229.9 193.3 242.6 179.5 190.1 143.0 252.8 126.2 252.5 226.3 125.5 154.1 163.667 195.7 192.3 195.7 156.0 A 18 25 1.7 113.6 237.0 200.4 141.4 277.1 121. .4 229.5 242.2 244.5 182.7 213. • Select after referring to the value in the speed table.8 143.0 141.2 183.8 123.7 269.136 286.8 214.8 118.0 108.3 207.1 202.313 140.3 197.9 2nd B 20 39 1.2 178.1 224.4 177.3 110.6 108.1 177.7 199.4 146.0 206.6 194.8 123.3 139.0 175.4 114.5 258.3 238.2 221.4 165.9 208.8 194.3 176.0 106.950 167.6 141.4 217.2 198.6 208.269 256.4 217.1 226.1 116.000 162.4 182.6 129.1 129.6 112.565 208.0 140.8 177.2 235.1 218.0 212.3 221.6 220.1 150.4 5th B 23 30 1.4 115.4 195.2 193.2 271.5 102.2 259.2 190.2 137.8 151.8 C 19 28 1.6 157.2 175.8 280.979 Primary reduction ratio 41 85 2.9 111.8 168.2 208.8 99.9 143.0 126.7 185.0 250.2 179.3 165.9 245.7 123.9 137.5 153.2 191.7 221.1 170.1 132.3 156.389 234.4 146.2 232.3 123.9 227.5 109.7 174.8 206.1 113.8 115.3 187.3 101.0 198.2 215.0 181.3 A 21 39 1.9 115.3 179.9 159.3 120.5 C 16 32 2.9 202.2 182.2 111.5 207.3 197.8 181.7 174.0 186.2 234.0 219.0 215.3 115.8 235.9 183.3 110.0 220.3 177.0 258.6 215.9 134.3 241.2 245.9 245.5 177.5 199.2 148.1 6th B 20 23 1.583 126.5 191.073 16 48 45 49 46 50 47 51 48 45 52 49 46 50 47 51 48 52 49 50 51 52 15 16 15 16 15 16 15 14 16 15 14 15 14 15 14 15 14 14 14 14 GEAR PLAN The number of teeth 16 16 16 Ratio P W 45 46 47 Engine Secondary side reduction ratio Wheel (Sprocket) side A 16 37 2.2 206.2 246.4 253.0 228.2 153.7 264.4 105.0 202.1 162.

90387-250R3 90209-21332 93440-25186 90387-21003 90209-22352 90209-21351 90387-28011 90209-25011 93440-28184 90387-25015 90214-25004 90214-25003 90387-21004 93102-35017 93440-52014 90201-20278 93306-20464 93306-20464 PART NAME COLLAR WASHER CIRCLIP COLLAR WASHER WASHER COLLAR WASHER CIRCLIP COLLAR WASHER. BRG. CLAW WASHER. CLAW COLLAR SEAL.14. Q'TY 3 6 10 3 3 3 3 9 15 6 3 3 3 3 5 3 3 3 REMARKS – 22 – . OIL CIRCLIP WASHER. PLAIN BRG. Mission Maintenance Set (2C0-A7000-70) Parts List No. * * * * * * * * * * * * * * * * * * 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART No.

38 36 33 29 28 30 32 31 30

28

29 29

28

27

35 34 21 22 23 23 22 24 37 26

25

– 23 –

Transmission Assembly

The seal side should face outward (one side seal bearing) and press in the bearing cup all the way into the case until it touches bottom.

Apply molybdenum oil to inside of diameter. After assembly, it should rotate smoothly. Apply molybdenum oil to the inside diameter and 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 fit into the bearing cup of the bearing. (Apply grease to the lip.)

TIP
• Always use a new circlip. • Do not mistake the washer and circlip directions. (See drawing below.)
Matching mark Matching mark Washer Gear Washer Shaft Circlip Washer

Edge Shaft

Portion R Position the abutment joint of the circlip right between the splines.

Edge

Portion R

Detail of installation of washer

Rotate washer so that its teeth meet axlespline teeth on the axle, and then lock with washer s claw. Assemble washer with putting together their matching mark.

Detail of installation of circlip
Circlip (Direction not applicable) Shaft Washer

Matching mark Matching mark Washer Washer

Gear

Position the abutment joint of the circlip right between the splines.

Edge

Portion R

Shaft

Detail of installation of washer

Detail of installation of circlip

– 24 –

15. Drive Sprocket Parts List No. 1 2 3 PART No. 2C0-17460-74 2C0-17460-75 2C0-17460-76 PART NAME SPROCKET, DRIVE SPROCKET, DRIVE SPROCKET, DRIVE Q'TY 1 1 1 14T 15T 16T REMARKS

These parts are 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) Install with the grooved surface facing outside of the chassis.

5SL ('05 and previous YZF-R6) Install with the grooved surface facing inside of the chassis.

NOTICE

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.

– 25 –

90179-20005 90215-21256 PART NAME NUT. SPROCKET WASHER. Sprocket Nut Set (2C0-A7463-70) Parts List No. 1 * 2 PART No. TONGUED TIGHTEN NUT BEFORE BENDING Q'TY 1 1 REMARKS – 26 – .16.

ASSY..0 N•m Tightening torque – 27 – . STARTER CLUTCH OUT. 1 2 * * * 3 4 5 6 7 PART No. CRANKCASE COVER 1 Q'TY 1 1 1 1 1 3 1 With screw lock ANTI STICK TYPE REMARKS TIP Regarding Assembly 1. STARTER COVER. CRANKCASE 1 SCREW GSKT. ACM Set (2C0-F1400-71) Parts List No.17. ROTOR ASSY. 2C0-81410-70 2C0-81450-70 2C0-15580-00 2C0-15536-00 2C0-15411-71 90149-06080 2C0-15451-70 PART NAME STATOR ASSY. Apply engine oil on the thread and flange of mounting bolts before using them. 2. CLIP. STD Tightening torque 70 N•m Tightening torque 12. Remove grease from the taper surfaces of both rotor and crank before assembling them.

HEX. GROMMET SPACER BOLT.18.REGULATOR 1 WIRE SUB-LEAD RESISTOR ASSY. HANDLE 1 BRKT. check that proper riding is possible even when using either map. • You can use Map Select and Pit Road Limiter with the switches (2 types) included with this set. HANDLE 1 SW. 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-90) of the kit. • Map select switches Map 1 and Map 2 of the YMS “Comp. 13S-82590-71 5GF-83976-00 14B-83976-70 2C0-2128A-70 2C0-82509-70 4C8-82188-70 90480-13003 90560-06201 90111-06051 92907-06200 PART NAME WIRE HARNESS ASSY SW. FUEL. • The combination of this wire harness and ECU cannot be used with ’07 models.” NOTICE When switching to Map 1 or Map 2 using “Map Select” while riding.. 1 * 2 3 4 5 6 * * * * 7 8 9 10 PART No. SOCKET BUTTON WASHER. PLAIN Q'TY 1 1 1 1 1 1 2 2 4 1 Linked to wire harness PIT ROAD LIMITER MAP SELECT REMARKS NOTICE • Do not remove the AC generator but leave it to function. (See diagram 1) (Diagram 1) Main switch Map select 1 → Map 1 2 → Map 2 Engine stop switch Pit road limiter Starter switch – 28 – . Wire Harness Set (13S-F2590-71) Parts List No.

NOTICE Be careful not to pull the wire too strongly.) (Diagram 3) Main switch Pit road limiter ON OFF Not used Map select Lo → Map 1 Hi → Map 2 Pit road limiter ON ↔ ON PUSH=OFF Ignition cut switch Engine stop switch Starter switch – 29 – . (See diagram 3. (See diagram 2) Fitting it turns the power on and removing it turns the power off.• Use the 3-prong coupler in front with the red wire attached as the main switch. (Diagram 2) Main switch • The switch installed to the STD machine may be used as is.

(Diagram 4) 5 (Diagram 5) 6 NOTICE Do not connect the coupler for resistor (black. 2-prong) and the coupler for power (white.• The ignition cut switch function can be used by combining the harness and kit ECU. 1 To use the STD switch (left side) to function as the ignition cut switch. (See diagram 4. at the tail side. Turning the switch ON cuts the ignition. It will cease to function if it is bent. connect the wire sub-lead that was packaged with this set to the terminal that is normally connected to the left side horn. the ignition cut switch may malfunction in wet weather.) If you remove the resistor assy. (See diagram 5) NOTICE Do not bend the resistor assembly. 2-prong). Connecting them may cause a malfunction. 2 Install the switch to the 2-pin black coupler underneath the fuel tank. (See diagram 6) (Diagram 6) Coupler for resistor Coupler for power – 30 – .

such as when not using a standard radiator.• The bracket regulator provided with this set is for use when fitting a regulator in the position illustrated in Diagram 7. please access the website. (Diagram 7) 9 8 4 7 10 D FW FRAME RECTIFIER REGULATOR • This harness has a coupler that connects to the 2D made data logger. For details of the specifications of the data logger. Web http://www.com/ – 31 – .2d-kit-system.

) Web http://www. 2C0-8591A-90 13S-2818Y-80 PART NAME ECU CD Q'TY 1 1 YMS. please access the website.com/ MODEL 2006 2007 2008 2009 ECU 2C0-8591A-70 2C0-8591A-71 2C0-8591A-80 2C0-8591A-90 WIRE HARNESS ASSY.. • There are two types of basic control data for the ECU included in this set: SS (Super Sports) and ST (Stock Sports). THROTTLE BODY ASSY.) <Setting-up Details> SS specification: Kit cam shaft and *Recommended muffler ST specification: *Recommended muffler * Recommended muffler Made by Akrapovic (For details of the specification. To make it in the ST specification. 1 2 PART No. • For details as to how to regulate (or set) fuel injection and ignition timings. (See the figure below. just remove two couplers located at the lower left of the kit harness fuel tank. They can be switched over and vice versa. refer to the manual in the CD-ROM that comes with the set.19. etc. Other models only allow the combinations shown in the table. – 32 – . 2C0-82590-70 2C0-82590-80 13S-82590-70 13S-82590-71 2C0-13750-00 13S-13750-00 *2008 and 2009 models allow any combination of ECU and wire harness. MANUAL REMARKS • Use of this set and a wire harness included in the kit enables regulation (or setting) of fuel injection and ignition timing.akrapovic-exhaust. etc. ECU Set (2C0-8591A-90) Parts List No.

Cable Interface (13S-8533A-70) Parts List No. 1 2 PART No. it is necessary to install the USB driver. • When connecting the cable to the PC for the first time. INTERFACE 8cm CD Q'TY 1 1 USB USB driver REMARKS • This cable connects the kit wire harness to the personal computer on which YEC FI Matching System (YMS) is installed. 13S-8533A-70 13S-N81CD-70 PART NAME CABLE. • Please see the YMS manual for instructions on how to use YMS. Inc.20. Vendor ID: 6837 Product ID: 9001 – 33 – . • The product vendor ID and product ID are provided by the Hamamatsu TOA Electronics. Refer to the USB Driver Installation Manual provided on the 8 cm CD for details on how to install the USB driver.

(°C) Speed Signal (--) Lean Angle Signal (V) System Voltage (V) TPS 2 (deg) APS 1 (deg) APS 2 (deg) Neutral SW — — — — — — — — — — — — — — — – 34 – . <Diagnosis Functions> CODE 01 02 03 05 06 07 08 09 13 14 15 21 30 31 32 33 36 37 38 39 40 41 42 43 46 50 70 Contents Throttle sensor Atmospheric pressure sensor Intake pressure sensor 1 Intake temperature sensor Water temperature sensor Vehicle speed sensor Overturn sensor Monitor voltage Throttle sensor 2 Accelerator sensor 1 Accelerator sensor 2 Neutral switch Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 Injector (primary) #1 Injector (primary) #2 Injector (primary) #3 Injector (primary) #4 Injector (secondary) #1 Injector (secondary) #2 Injector (secondary) #3 Injector (secondary) #4 Intake funnel Main relay Program version *YMS-Monitor TPS 1(deg) Atmospheric (kPa) Intake Air (kPa) Air Temp. (°C) Water Temp. * YMS-Monitor: YEC FI Matching System also allows functioning of the code shown below.• Use of the ECU in the kit and the harness allows functioning of the following codes in the STD diagnosis.

Intake temperature sensor malfunctions (open circuit / short circuit). Ignition coil #4 malfunctions (open circuit). Intake pressure sensor or atmospheric pressure sensor malfunctions. Battery voltage monitor malfunctions (power source for fuel system). Water temperature sensor malfunctions (open circuit / short circuit). Description – 35 – .Self-Diagnosis Functions • The ECU and harness in the kit provide the functions for the following codes of standard self-diagnosis: CODE 00 11 12 13 14 15 20 21 22 23 33 34 35 36 39 40 43 46 59 60 All functions normally. Power source for vehicle malfunctions. Throttle motor malfunctions (drive system). Ignition coil #3 malfunctions (open circuit). Intake pressure sensor malfunctions (piping system). Throttle opening sensor malfunctions (open circuit / short circuit / ETV). Ignition coil #1 malfunctions (open circuit). Atmospheric pressure sensor malfunctions (open circuit / short circuit). Injector (secondary) malfunctions (open circuit). Injector (primary) malfunctions (open circuit). Ignition coil #2 malfunctions (open circuit). Accelerator opening sensor malfunctions (open circuit / short circuit). Crank angle sensor malfunctions. Cam angle sensor malfunctions. Intake pressure sensor malfunctions (open circuit / short circuit).

SOCKET HEAD BOLT. SOCKET HEAD Q'TY 1 2 1 REMARKS These parts protect the chassis as well as alleviating damage caused by overturning.2-2 Vehicle Accessories 21. 1 * * 2 3 PART No. HEX. 2C0-15491-70 91314-06025 91314-06020 PART NAME PROTECTOR BOLT. HEX. Engine Protector Set (2C0-A5491-70) Parts List No. – 36 – .

0 m•kg) Tightening torque 40 N•m (4. HEX. 1 2 3 * * 4 5 6 PART No. PROTECTOR BOLT.22.0 m•kg) ENGINE FWD Tightening torque – 37 – . PLAIN Q'TY 1 1 2 1 1 2 REMARKS Tightening torque 40 N•m (4. 2C0-2117G-70 2C0-2117G-90 2C0-21472-70 91317-10060 91314-10065 90201-10136 PART NAME PROTECTOR(LH LONG) PROTECTOR(RH SHORT) COLLAR. SOCKET HEAD BOLT. Chassis Protector Set (2C0-C117G-70) Parts List No. HEX. SOCKET HEAD WASHER.

– 38 – . See the figures below. cut the cowling so that the protector can fit against the chassis. cut by φ60 centered on the engine mount. As a rough guide.Before mounting the protector.

BREATHER Q'TY 1 4 1 1 1 2 2 2 1 For 2006 and 2007 models REMARKS This oil tank has the effective capacity of 540 cc. 6 OUT A/C 5 8 IN 7 3 9 4 2 OUT IN 1 545cc For 2008 and 2009 models For 2006 and 2007 models – 39 – . BOLT. HEX. 1 * 2 3 4 * * * * 5 6 7 8 9 PART No. PIPE. HOSE CLAMP ASSY. Oil Catch Tank Set (2C0-C1707-81) Parts List No. BREATHER 2 BRKT. W/WASHER PIPE. BREATHER PIPE.23. 2C0-21707-70 90450-25037 13S-15373-70 2C0-15393-70 2C0-2419F-00 91317-06020 90480-13018 90119-06044 2C0-15373-70 PART NAME OIL TANK COMP.SOCKET HEAD GROMMET BOLT. HEX.

24. Rr. Low-speed compression damping adjustor (bolt width 4mm. rebound damping and preload can be adjusted. hexagonal) Rebound damping adjustor Preload adjustor Preload Adjustment Method Turn the adjustor clockwise to increase the preload and anticlockwise to reduce the preload. Q'TY 1 REMARKS 98 N/mm Rear Suspension Performance Adjustment Method Low-speed compression damping. high-speed compression damping. 13S-22210-70 PART NAME SHOCK ABSORBER. 1 PART No. The adjustment range is 8mm (in steps of 1mm) Shipping position: Tightened 4 steps from the preload minimum position (fifth step) – 40 – . hexagonal hole) High-speed compression damping adjustor (bolt width 12mm. Rear Suspension Parts List No.

Shipping position: 3 turns back from the tightened adjustor position NOTICE When tightening the adjustor. At High Speeds Turn clockwise to increase the damping force and anticlockwise to reduce the damping force. do it lightly. Shipping position: 15 steps back from the tightened adjustor position NOTICE When tightening the adjustor. The adjustment range is between 3 to 20 steps back from the lightly tightened adjustor position. Compression Damping Adjustment Method At Low Speeds Turn clockwise to increase the damping force and anticlockwise to reduce the damping force. do it lightly. – 41 – . The adjustment range is 1 to 20 steps back from the lightly tightened adjustor position. do it lightly. Over-tightening the adjustor can damage it. Shipping position: 15 steps back from the tightened adjustor position NOTICE When tightening the adjustor.Rebound Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force. Over-tightening the adjustor can damage it. Over-tightening the adjustor can damage it. The adjustment range is 4 steps back from the lightly tightened adjustor position.

SHOCK SPRG. The spring rate of the standard rear suspension is 103 N/mm. see the 13S STD. Rear Shock Spring Parts List No. There is a stamp on the side of the springs for rate identification. Rr. 13S-22222-70 PART NAME SPRG. SHOCK Q'TY 1 REMARKS 103 N/mm Identifying stamp: 165-55103 98 N/mm Identifying stamp: 165-55-98 93 N/mm Identifying stamp: 165-55-93 2 3 • • • • • 13S-22222-75 13S-22222-80 SPRG. Service Manual. The stamp number indicates the length. Rr. SHOCK 1 1 These springs can be used with the standard or kit shock absorbers.. diameter and rate. For spring replacement.. Rr.. – 42 – . 1 PART No.25.

Shipping position: Rebound : 20 steps back from the tightened adjustor position.26. compression high-speed damping. Front Fork Parts List No. Compression high speeds: 2 turns back from the tightened adjustor position. Compression low speeds : 10 steps back from the tightened adjustor position. 1 2 PART No. – 43 – . 13S-23102-70 13S-23103-70 PART NAME Fr. FORK ASSY. rebound damping and preload can be adjusted.5 N/mm Front Fork Performance Adjustment Method Compression low-speed damping. Compression high speeds: 4 turns back from the adjustor’s clockwise lightly tightened position. The adjustment range is 15mm (1mm/turn) Shipping position: Tightened 6 turns from preload minimum position the Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force. FORK ASSY. Compression low speeds : 1 to 20 steps back from the adjustor’s clockwise lightly tightened position. Preload Adjustment Method Turn clockwise to increase the preload and anticlockwise to reduce the preload. do it lightly.5 N/mm 9. RH Q'TY 1 1 REMARKS 9. The adjustment range is: Rebound : 1 to 25 steps back from the adjustor’s clockwise lightly tightened position. NOTICE When tightening the adjustor. Over-tightening the adjustor can damage it. LH Fr.

Rebound damping adjustor Compression low-speed damping adjustor Compression high-speed damping adjustor – 44 – .

FORK SPRG.. Fr. Fr.0 N/mm Identifying slits 1 • There are slits at the ends of the spring for rate identification.0 N/mm Identifying slits 2 9. replace the supplied preload tube with the set. Fr. FORK Q'TY 1 1 1 1 REMARKS 10. FORK SPRG. 13S-23151-70 13S-23151-75 13S-23151-80 13S-23151-85 PART NAME SPRG. • Use Yamaha M1 suspension oil. Front Fork Spring Parts List No.. 1 2 3 4 PART No. • When using an optional spring for the STD fork. Use the original tube fitted to the fork.. TIP • A spanner (SPECIAL TOOL) and rod (SPECIAL TOOL) are supplied with the front fork (13S23102-70). FORK SPRG. you do not need to replace the preload tube. • The number of slits indicates the rate as shown above.27. NOTICE When using an optional spring for the kit fork.5 N/mm Identifying slits 3 10.5 N/mm Identifying slits None 9.. – 45 – . Fr.

Insert the spanner (SPECIAL TOOL) into the notch of the spring seat upper and clamp the 14mm special nut.Front Fork Spring Replacement Method 1. turn the fork bolt anticlockwise to lower the outer tube until the dust seal touches the upper surface of the axle bracket. 4. Turn the damping adjustor and preload adjustor anticlockwise to set to the weakest position. Use a 14mm box spanner on the preload adjustor to remove the cap bolt assembly. After fixing the axle bracket in a vice. Spanner (SPECIAL TOOL) Spring seat upper Preload tube – 46 – . 2. Rebound damping adjustor Preload adjustor Fork bolt Axle bracket 3. NOTICE Do not remove the spanner (SPECIAL TOOL) while doing this.

Remove the push rod and fit the rod (SPECIAL TOOL) to the piston rod. NOTICE Be very careful to apply downward pressure on the rod (SPECIAL TOOL) when you remove the spanner (SPECIAL TOOL).5. – 47 – . Grip the rod (SPECIAL TOOL) firmly and remove the spanner (SPECIAL TOOL). Push rod Rod (SPECIAL TOOL) 6.

7. Remove the spring seat upper and preload tube before removing the rod (SPECIAL TOOL). NOTICE When replacing the spring. special nut and spring guide and replace the spring. fit the new spring with the tapered closed end upwards. 8. Remove the washer. Washer Special nut Spring guide – 48 – .

• Oil level in load state: With the spring removed and the outer tube and rod lowered.9. 10. Tightening torque: 20N/m – 49 – . 140mm from the top of the outer tube. Reassemble the parts after oil level adjustment by following the disassembly procedure in reverse. Press the rod downwards before adjusting the oil level.

PLAIN SCREW WASHER. SOCKET HEAD SPACER BOLT. STRG. SOCKET HEAD NUT. – 50 – . HEX.. Steering Damper Stay Set (2C0-C3495-80) Parts List No. PLAIN SCREW STOPPER SCREW. 2C0-23495-80 91317-06025 2C0-23488-80 91317-08110 95607-08100 2C0-2349T-80 90201-07081 90149-06302 5VY-26398-00 91317-08025 2C0-23439-71 90387-06084 90201-07081 90149-06302 2C0-23429-70 90151-04002 PART NAME STAY. HEX. HEX. SOCKET HEAD STOPPER. use [OHLINS SD121 STROKE 68mm]. DAMPER BOLT. SPECIAL BOLT. 1 * * 2 3 4 5 6 * * * 7 8 9 10 11 12 * * * 13 14 15 16 PART No. U BRKT.28. DAMPER WASHER. CROSSRECESSED COUNTERSUNK Q'TY 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 REMARKS For the steering damper. 2 COLLAR WASHER.

1 PART No. 13S-24713-70 PART NAME CUSHION SEAT Q’TY 1 REMARKS Anti slip seat. Cut to any size for use. – 51 – . Seat Cushion (13S-24713-70) Parts List No.29.

VALVE. This part is an assembly of bearings. – 52 – . 2C0-25160-00 93900-00030 PART NAME CAST WHEEL ASSY. spacers and an air valve in a STD wheel. Front Spare Wheel Assembly (2C0-25100-70) Parts List No.30. RIM Q'TY 1 1 REMARKS *This kit does not include a tire. 1 * 2 PART No.

This part is an assembly of bearings. spacers and an air valve in a STD wheel. Rear Spare Wheel Assembly (2C0-25300-70) Parts List No. VALVE. 2C0-25370-00 93900-00030 PART NAME CAST WHEEL ASSY. – 53 – . 1 * 2 PART No.31. RIM Q'TY 1 1 REMARKS *This kit does not include a tire.

THROTTLE 3 CYLINDER SLIDER PROTECTOR WASHER. SOCKET HEAD Q'TY 1 1 1 1 2 2 2 2 2 1 2 1 Grip side: Retracting sharing Engine side: Retracting sharing REMARKS 12 4 10 5 7 8 9 6 3 1 2 11 Machining off the boss. Scrape away CAP. ° * ° ° ° ° ° ° * * * 1 2 3 4 5 6 7 8 9 10 11 12 PART No. HEX.32. GRIP UNDER TUBE. GRIP UPPER of the kit as shown above. WIRE 1 WIRE. 2C0-26281-70 5FL-26282-00 5SL-26243-71 2C0-26391-70 2C0-26311-70 2C0-26313-70 2C0-26261-70 5FL-26244-70 2C0-2639E-70 90201-261L1 91314-05020 91314-05008 PART NAME CAP. PLAIN BOLT. THROTTLE 1 WIRE. GRIP UPPER CAP. GUIDE CLIP. SOCKET HEAD BOLT. HEX. – 54 – . Throttle Set (2C0-C6300-70) Parts List No.

2C0-26281-70 5FL-26282-00 5SL-26243-71 2C0-26391-70 13S-26302-70 90201-261L1 91314-05020 91314-05008 PART NAME CAP. Throttle Set (13S-C6300-70) Parts List No. GRIP UNDER TUBE. Scrape away CAP. WASHER. HEX. GRIP UPPER CAP. HEX. SOCKET HEAD Q'TY 1 1 1 1 2 1 2 1 Common use for pulling back. GRIP UPPER of the kit as shown above.33. WIRE 1 THROTTLE WIRE ASSY. PLAIN BOLT. SOCKET HEAD BOLT. – 55 – . ° * ° ° ° * * * 1 2 3 4 5 6 7 8 PART No. REMARKS & " $ # !  % Machining off the boss. GUIDE CLIP.

0±2 (1.2) 6 90340-18002 PLUG.0 – 1. HEXAGON SOCKET HEAD PLUG.25 2 Tighten HEAD on side of CAM CHAIN compartment.0±0. HEAD COVER x HEAD Plug for sand drain hole Check bolt for oil passage Tighten AI CAP.25 TURN-OF-NUT METHOD AXIAL FORCE 41kN±2kN SNUG TORQUE 28(2.0±0. FLANGE.0±2 (1. FLANGE BOLT. STRAIGHT SCREW BOLT.2) 10 APPLY OIL BOTH TO THREAD AND BEARING SURFACE. FLANGE M6 x 1.2) 1 90110-06175 M6 x 1.5±0. CAP M10 x 1.0±2 (1. x pitch BOLT.5 42±4 (4. SPARK M6 x 1.0 12. APPLY OIL BOTH TO THREAD AND BEARING SURFACE. STUD NUT M8 x 1. Part Name Screw dia.2) 8 – 56 – .8) +ROTATION ANGLE 55° TURN-OF-NUT METHOD AXIAL FORCE 41kN±2kN SNUG TORQUE 36(3.0±2 (1.0±2 (1. 95612-08625 BOLT.25 15.2) 8 90179-10006 M10 x 1.5±0.2±0.0 2 5FL-1119C70 13S-1119C70 90109-066F0 M10S x 1. SMALL HEAD BOLT HEXAGON SOCKET HEAD BOLT.2) 4 91312-06016 M6 x 1.4) 3 APPLY LOCKING AGENT (LOCKTITE®). CARBURETOR 1 x HEAD 90105-07004 M7 x 1. 90176-10075 NUT.0±0. SEE page 67 FOR DETAILS.2) Q’ty Remarks CAP.4±0.0 24.0 Tightening torque N•m (kgf•m) 10. HEXAGON SOCKET HEAD M18 x 1.0±2 (2.0±2 (1.0 10 – 12 (1. WITH WASHER Tighten HEAD.2±0.25 15.2) 4 CAMSHAFT x SPROCKET JOINT.0 10.3 Tightening Torque List Engine To be tightened Part No. CAMSHAFT x HEAD Embedded in HEAD Tighten HEAD. BOLT M6 x 1. SEE page 67 FOR DETAILS.3±0.0±2 (1. 95022-08012 M8 x 1.2) 4 SEE page 3 FOR DETAILS.0 10. SPARK PLUG 90110-06094 BOLT.6) +ROTATION ANGLE 55° 12. 90105-06027 20 CAM SHAFT SHALL TURN LIGHTLY.

STRAINER x CRANKCASE 2 DRAIN BOLT for COVER.3±0. CON ROD NUT M7 x 0. CON ROD BOLT. DEGREASE TAPERED SURFACE. CON ROD 2C0-1165400 2C0-1165A00 90179-07001 8 APPLY SUMICO MORI ASSY OIL 150.0±2 (1.To be tightened Part No. x pitch BOLT.5 43. HEXAGON SOCKET HEAD BOLT.2) 1 90109-06015 BOLT M6 x 1. FLANGE M6 x 1. THERMOSTAT. FLANGE M6 x 1.7±1.0±2 (1.0±0. 90110-06106 BOLT.0 12.2±0.15) +180°±5° 70±5 (7. Part Name Screw dia. OIL PUMP ASSY x CRANKCASE 2 OIL PUMP ASSY x CRANKCASE 2 COVER. STRAIGHT SCREW M14 x 1. STRAINER 90110-06140 M6 x 1. HEXAGON SOCKET HEAD BOLT.2) 2 95812-06030 M6 x 1. USE MORICOATED WASHER.75 Tightening torque N•m (kgf•m) Q’ty Remarks CON ROD X CAP. FLANGE M12 x 1.5±0.4) 1 DRAIN BOLT – 57 – .2±0.0 10.2) 2 91312-06020 M6 x 1.0 12.0±2 (1.2) 2 90105-06082 M6 x 1.2) 2 95812-06080 BOLT. Install JOINT.5) 8 ACM ROTOR x CRANKSHAFT 90105126A8 BOLT. APPLY SUMICO MORI ASSY OIL 150.0±2 (1. APPLY OIL BOTH TO BOLT BEARING SURFACE AND THREAD AND TO BOTH SIDES OF WASHER.0 12.2) 2 Install WATER PUMP.2±0.0 12. HEXAGON SOCKET HEAD BOLT.47 (1.2±0.0 12.0 12. APPLY SUMICO MORI ASSY OIL 150.75 14.0±0.2±0. FLANGE. SMALL HEAD BOLT.0±2 (1. M7 x 0.0±4 (4.2±0.0±2 (1.2) 13 90340-14132 PLUG.75 8 M7 x 0.25 1 TENSIONER ASSY x CYLINDER Install COVER. INSTALL TENSIONER ASSY.0±2 (1.

Part Name Screw dia.0±0.5) 2.0±0. CARBURETOR 1 x THROTTLE THROTTLE x FUNNEL LOWER FILTER CASE x FUNNEL (SUPPORT UNIT) Install THROTTLE WIRE NUT.0±0.25) 4 CONTACT-FIT COLLAR OR TORQUE CONTROL 90109-05011 M5 x 0. OIL x CRANKCASE 2 OIL COOLER x CARNKCASE 2 UPPER CASE x CAP CASE ASSY UPPER CASE x LOWER CASE ELEMENT x UPPER CASE JOINT.0 5.5±0.8 2.2±0.5 (0.2 – 0.To be tightened Part No.5 – 5.0±2 (2.0 3.05) 4 98902-05020 M5 x 0.0±2 (1.0±2 (1. HEXAGON SOCKET HEAD BOLT. BUTTON HEAD SCREW.0±0.2) 2 90110-06161 M6 x 1.2) 1 APPLY GREASE TO O-RING.2±0.3±0.34 – 0. – 58 – .0 12. WITH WASHER M5 x 0.2) 8 TIGHTEN EXHAUST PIPE & HEAD.0±3 (6.5 63.0±0.05) 6 90159-05035 SCREW.05) 10 98902-05020 M5 x 0.8 2. 92012-06020 BOLT.3) 1 APPLY OIL TO THREAD AND BEARING SURFACE.0±2 (1. NUT M6 x 1.5 (0.8 3.25±0.7±0.35 – 0. UNION M20 x 1.5 17. ELEMENT.05) 1 90450-56007 M5 x 0.2) 2 5EB-1282200 M20 x 1.5 (0. M6 x 1. CROSS RECESS BINDING SCREW.5 (0. x pitch BOLT. CROSS RECESS BINDING HOSE CLAMP ASSY BOLT M6 x 1.25 20.2±0.5) Q’ty Remarks Tighten UNION BOLT for FILTER.0 – 2. HEXAGON SOCKET HEAD BOLT.2±0.55) 2 90179-08410 M8 x 1.5 (0. UNION M20 x 1.5 (0.5 Tightening torque N•m (kgf•m) 70.4 – 5 (0. RING x HEAD 90401-20145 1 5GH-1344020 90110-06161 OIL CLEANER ASSY BOLT.8 2.0 12.8 2 13S-2630200 THROTTLE WIRE ASSY.5±0.0±5 (7. OIL FILTER HOLDER x CRANKCASE 2 PIPE.

2 – 59 – . MUFFLER. HEXAGON SOCKET HEAD BOLT.0 6. 2 BOLT. 8 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE.25 20.5±1.5 (0.15) 1 90111-06099 M6 x 1.15) 2 90179-06063 M6 x 1. EXHAUST VALVE SUBASSY CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 91314-08035 2 INSTALL EXHAUST PIPE.0±4 (3.5 – 0. FLANGE (SMALL HEAD) BOLT. 90119-08084 M8 x 1.0±0. PULLEY. x pitch BOLT.0±2 (1.7) 1 1 M5 x 0.0 6.25 See page 68 for details.65±0. HEXAGON WITH WASHER BOLT. APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE.0±1.65±0.6 – 1.8) 2 90111-06071 M6 x 1. MUFFLER 1.0 5 – 8 (0. HEXAGON WITH WASHER M8 x 1. 90105-08054 M8 x 1.0±0. FLANGE (SMALL HEAD) BOLT.15) 1 90119-08083 BOLT. HEXAGON SOCKET HEAD BOLT.25 34. PULLEY. MUFFLER 2 x BRACKET.0±2 (2.5 – 0.2) Q’ty Remarks STAY.8±0.5 (0. SILENCER x FOOT REST Install WIRE PULLEY. Install MUFFLER PROTECTOR.0 10.0) 2 95027-06025 M6 x 1.0 6 – 10 (0. 91314-06030 M6 x 1. 1 WIRE.25 Tightening torque N•m (kgf•m) 20.5±1.0 5 – 7 (0. HEXAGON SOCKET HEAD BOLT. 2 x MUFFLER STAY.5±1.2) 1 90105-08063 M8 x 1. HEXAGON SOCKET BUTTON BOLT.0 8. MUFFLER 1 Tighten BAND.2) 1 13S-1133E00 13S-1133F00 90110-05028 M6 x 1. Part Name Screw dia.4) 1 INSTALL DAMPER. HEXAGON SOCKET BUTTON NUT M8 x 1.5 (0.To be tightened Part No.0±2 (2.8 6.4±0.25 See page 68 for details. FLANGE (SMALL HEAD) BOLT.5 (0.0±0.65±0. PULLEY x GEARED MOTOR BRACKET 7 x FRAME BRACKET 7 x SERVOMOTOR Install MUFFLER PROTECTOR.15) 1 95827-06014 M6 x 1. FLANGE WIRE.

2±0.0±2 (1.5 CLOSE CONTACT WITH BEARING SURFACE 1 – 60 – .0±2 (1.0 10.0±2 (1. Part Name Screw dia.0 12. CRANKCASE 2. Install COVER.25 15.To be tightened Part No.0±0.2) 3 95812-06045 BOLT.0±0.0 Tightening torque N•m (kgf•m) 10.0 10.2) 7 90110-06156 BOLT. FLANGE M6 x 1.4±0. 95812-06055 BOLT.0±2 (1. CRANKCASE 2.2) 1 90109-06015 BOLT M6 x 1.0±2 (1.0±2 (1. COVER 1 x HOLDER.2±0.0 12. x pitch BOLT M6 x 1. FLANGE M6 x 1.2) 2 90110-06303 M6 x 1.0±2 (1. STRAIGHT 90109-06100 2 APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE.0±0.2) 3 95812-06030 BOLT.2) 2 92014-08014 BOLT.2) Q’ty Remarks CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 Install COVER. Install COVER.0±2 (1. STRAIGHT SCREW M8 x 1. APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE.0±2 (1. APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE.2) 9 90109-06031 BOLT M6 x 1.5±0.2±0. FLANGE M6 x 1. CRANKCASE 1.0±0. CLUTCH COVER 1 x BOLT COVER 1 x PLUG.0±2 (1.0 12.2) 2 95812-06065 BOLT. FLANGE M8 x 1.0 10.2) 5 90109-06015 M6 x 1.2±0.2) 1 90340-32004 M32 x 1. APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE. BUTTON HEAD PLUG. Install COVER 1. APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE. HEXAGON SOCKET HEAD BOLT.2±0.25 24±2 (2.0 10.0 12.0±2 (1. FLANGE M6 x 1.2) 7 95812-08065 BOLT. APPLY OIL BOTH TO THREAD AND TO BEARING SURFACE.0 12. HEXAGON SOCKET HEAD BOLT M6 x 1.0±0.

2±0.0±2 (1.0±0.8±0.0±2 (0. CRANKCASE 1 x STATOR ASSY PLUG WITH COMMUNICATION HOLE x CRANKCASE 1 Install COVER.2) 12.0 10.0±0. HEXAGON SOCKET HEAD BOLT.0±0. BOSS. CRANKCASE 1 x CLAMP Install COVER.0 10.0±2 (1.2) 1 90109-06015 90110-06161 BOLT BOLT.0±2 (1.2) 5 2 90110-06168 M6 x 1.2) 3 90149-06082 SCREW M6 x 1.0±2 (1.2±0.0±2 (1.8±0. CLUTCH x MAIN AXLE 90149-06082 3 90149-06080 SCREW M6 x 1.25 (HEIGHT 68. COVER.0±2 (0. HEXAGON SOCKET HEAD BOLT.0 Tightening torque N•m (kgf•m) 12. – 61 – . LOCK M20 x 1.2) 2 TAKE CARE NOT TO OVERTIGHTEN STATOR LEAD 90149-06082 SCREW M6 x 1.2) 6 4B1-1637770 NUT.0±2 (1. Install M GALLERY PLUG. Part Name Screw dia.5) 1 CRIMP AND APPLY OIL BOTH TO THREAD AND BEARING SURFACE. EMBEDDED Install PRESSURE PLATE.0 115.0 M6 x 1.0±2 (1.2) 3 36Y-1518900 M16 x 1.0 12.To be tightened Part No. W/W M6 x 1.2) Q’ty Remarks PLATE.2±0.5±0. Install OIL PIPE (OUTSIDE) CRANKCASE 2 x PICKUP Embedded in CRANKCASE x STUD.0 10. HEXAGON SOCKET HEAD PLUG M6 x 1.2±1) 10 90159-06024 SCREW.0±2 (1.5 8.0 8.0±0. BREATHER x C/ C1 COVER.2) 2 90116-1002* M10 x 1.0 12.2) 1 90110-06060 BOLT. STUD M6 x 1. x pitch SCREW M6 x 1.0±5 (11.0 10.2±0. CHAIN CASE.

HEXAGON M6 x 1.0±2 (1. HEXAGON SOCKET HEAD BOLT.2) 1 95822-06020 BOLT.25 Tightening torque N•m (kgf•m) 25.0 10.0 12.0±2 (1. STUD Install SPROCKET. FLANGE BOLT. FLANGE (SMALL HEAD) BOLT. HEXAGON SOCKET HEAD BOLT.2±0.0 10.25 22. NEUTRAL SWITCH ASSY Install OIL LEVEL SENSOR.To be tightened Part No.2) 2 91312-06016 M6 x 1.5±0.5 (0.0±2 (1.0±2 (1.0±0. SHAFT BAR.2) 3 CRIMP. STOPPER embedded in CRANKCASE Install ARM.25 19. DRIVE. M6 x 1.2) Q’ty Remarks BOSS.2) 1 CHECK FOR SERRATION TIGHTENING UP.0±0.5) 1 90105-06083 M6 x 1.5±1.0±0. APPLY GREASE TO O-RING. Part Name Screw dia.0±2 (1. PRESSURE PLATE x BOLT. HOUSING.2±0.0 10.5±0.0 10. STUD M8 x 1.0±0.0 85.0 7.0±2 (2.0±0.2) 2 3GB-8254001 95022-06016 M10 x 1.2) 2 1D7-1812700 STOPPER.2) 1 90110-06175 M6 x 1. FLANGE M6 x 1.5) 1 WITH LOCK WASHER 90151-06024 SCREW. SCREW M8 x 1.0 10.75±0. BEARING 2C0-1637400 6 90179-20005 NUT M20 x 1.0±5 (3. Install STOPPER. Install ROTOR. 90105-08113 BOLT. PICKUP.25 35.0±0.15) 1 91380-06012 M6 x 1. SPEED SENSOR x C/C CAM SENSOR x COVER H/C WIRE HARNESS (NEGATIVE LEAD WIRE) 90110-06182 M6 x 1.2) 1 – 62 – . HEXAGON SOCKET HEAD M8 x 1.0±2 (1.2) 1 OVERTIGHTENING LEADS TO DAMAGE. SHIFT.0±0. Install STARTER MOTOR.0±2 (1.0±2 (2.0±5 (8. FLANGE (SMALL HEAD) NEUTRAL S/W ASSY BOLT.6±2 (2. CROSSRECESSED COUNTERSUNK BOLT.5±0.0 10. x pitch BOLT.

x pitch O2 SENSOR THERMOSENSOR ASSY M18 x 1.5 Tightening torque N•m (kgf•m) 45.8±0.To be tightened Part No.5) Q’ty Remarks Install O2 SENSOR. Part Name Screw dia.6±2 (1.0±5 (4. Install THERMOSENSOR.5 17. 13S-8592A00 8CC-8579001 1 M12 x 1.5±0.2) 1 – 63 – .

25 31 – 49 (3.25 35 – 45 (3.6) 2 90105-12228 90179-12248 90105-12228 90179-12248 90149-10002 M12 x 1.25 M10 x 1. HEXAGON SOCKET HEAD NUT.6 – 4.Body To be tightened Part No.1) 1 1 1 1 4 2C0-2214110 90109-10017 SHAFT. x pitch BOLT.25 M12 x 1.9) 58 – 70 (5.3 – 4.2 – 1. FLANGE NUT SCREW M8 x 1.25 M12 x 1. FLANGE NUT BOLT.2 – 1.5) 1 91314-08030 BOLT.25 1 SCREW IN FROM THE LEFT SIDE 95602-10200 NUT.0 – 2.9 – 7. CROWN & OUTER TUBE HANDLE. SELF LOCKING M12 x 1.25 31 – 49 (3.0 12 – 15 (1.2 – 5) 1 – 64 – . Part Name Screw dia. CROWN & STEERING SHAFT HANDLE & OUTER TUBE STEERING SHAFT and RING NUT OUTER TUBE & UNDER BRACKET E/G BRACKET.25 M12 x 1.1) 12 – 19 (12.3 – 2. PIVOT BOLT M32 x 1. REAR UPPER E/G BRACKET.8 – 3.25 58 – 70 (5.25 28 – 35 (2. U FLANGE BOLT M10 x 1. HEXAGON M8 x 1. HEXAGON SOCKET HEAD BOLT.1) 33 – 40 (3. FRONT E/G BRACKET. HEXAGON SOCKET HEAD NUT M8 x 1. REAR UNDER MAIN FRAME & REAR FRAME PIVOT SHAFT & FRAME ARM.25 20 – 25 (2.2 – 12.0 100 – 125 (10.8) Q’ty Remarks HANDLE.25 M12 x 1. FLANGE (SMALL HEAD) BOLT.5) 4 95024-10040 M10 x 1.2 – 5) 1 1 SCREW IN FROM THE LEFT SIDE ARM.9 – 7.25 Tightening torque N•m (kgf•m) 23 – 28 (2. RELAY 1 & ARM 1 90109-12010 90185-12119 NUT.5 1 M10 x 1.6) 2 90179-30691 M30 x 1.7) 1 91314-08030 BOLT. RELAY 1 & FRAME 91314-08030 2 90170-28419 M28 x 1.

TANK (rear) & REAR FRAME FRONT WHEEL SHAFT & FR FORK REAR WHEEL SHAFT & NUT FR CALIPER & FR FORK DISC BRAKE & FR WHEEL DISC BRAKE & RR WHEEL 90109-12011 90185-12119 95604-08200 NUT.1) 14 – 22 (1.7 – 1.25 M12 x 1. UNION SCREW M24 x 1.25 Tightening torque N•m (kgf•m) Q’ty Remarks ARM 1 & REAR ARM 90109-12010 1 SCREW IN FROM THE LEFT SIDE 90185-12119 NUT. HEXAGON SOCKET HEAD BOLT.8) 1 90111-06071 M6 x 1.2 – 1.5 90 – 130 (9.3 – 3.5 – 0.5 1 90185-24007 NUT.3) 30 – 40 (3.5 – 0.1 – 4.2 – 5) 1 1 SCREW IN FROM THE LEFT SIDE REAR CUSHION & ARM.0 5–8 (0.4 – 2.9) 75 – 115 (7.8) 1 91312-06016 M6 x 1. U FLANGE NUT 2 M12 x 1.25 31 – 49 (3.5 – 0.25 5 – 65 – .7) 55 – 85 (5.6 – 11. x pitch BOLT M12 x 1.5 1 90110-05028 M5 x 0.8 6 90110-06233 M6 x 1.2) 23 – 37 (2.6 – 8.0 5–8 (0.8) 4 90105-14002 M14 x 1. PIVOT & LOCK NUT SHAFT. SELF LOCKING NUT.0 10 APPLY LOCKING AGENT (LOCKTITE®). HEXAGON SOCKET BUTTON BOLT.7) 3–5 (0.0 5–8 (0.To be tightened Part No. 90149-08009 SCREW M8 x 1.0 7 – 10 (0.3 – 0. HEXAGON SOCKET HEAD BOLT. FLANGE M22 x 1. APPLY LOCKING AGENT (LOCKTITE®).25 4 90149-06043 M6 x 1.2 – 5) 12 – 19 (12. TANK (rear) & FUEL TANK BRACKET.2 – 13.0) 2 91312-06090 M6 x 1. HEXAGON SOCKET HEAD BOLT. PIVOT & U NUT FUEL PUMP & FUEL TANK FRONT STAY for FUEL TANK & FRAME Mid portion of FUEL TANK & STAY BRACKET. HEXAGON SOCKET HEAD BOLT. SELF LOCKING BOLT M12 x 1.25 M8 x 1.5) 1 2 2C0-2225200 90185-22002 M32 x 1.25 31 – 49 (3. SELF LOCKING BOLT.8) 1 90401-10012 M10 x 1.5 1 NUT SELF LOCKING BOLT. RELAY 1 CHAIN PULLER ADJUST NUT SHAFT. Part Name Screw dia.

Part Name Screw dia. SELF LOCKING M10 x 1.25 18 – 23 (1.3) 4 – 66 – .1) Q’ty Remarks REAR WHEEL SPROCKET & CLUTCH HUB SPLIT BOLT for FRONT AXLE 90185-10009 6 91314-08040 BOLT. HEXAGON SOCKET HEAD M8 x 1. x pitch NUT.2 – 11.To be tightened Part No.8 – 2.25 Tightening torque N•m (kgf•m) 90 – 109 (9.

Apply engine oil to the bolt threads. 3. – 67 – .8kgf•m). 4. TIP The numbers 1 to 10 show the sequence in which the bolts are tightened. Tighten the bolts in the tightening sequence of 1 to 7 to a snug torque of 28N•m (2. These numbers indicate the tightening sequence.6kgf•m). contact surfaces. Tighten the bolts in the tightening sequence of 8 and 9 to a snug torque of 36N•m (3. Tighten the bolt in the tightening sequence of 10 to a snug torque of 28N•m (2.Tightening the Cylinder Head Tightening the Cylinder Head (Turn-of-Nut Method) 1. and washers. Retighten the bolts in the tightening sequence of 1 to 10 to a turn-of-nut angle of 55°. 2.8kgf•m).

7. Retighten the bolts in the tightening sequence of 1 to 7 to a turn-of-nut angle of 50°±5°. Retighten the bolt in the sequence of 10 to a turn-of-nut angle of 50°±5°. 5. 3. Apply engine oil to the bolt threads and both sides of the washers.0±0. After loosening the bolts once in the tightening sequence of 1 to 10.0kg•m). – 68 – . retighten them one by one to 12N•m (1. Tighten the bolts in the tightening sequence of 11 and 12 to 24±2N•m (2.Installing the Crankcase Tightening the bolts 1. Tighten the bolts in the tightening sequence of 1 to 10 to 20N•m (2. 2. 4. These numbers indicate the tightening sequence. 6. TIP The numbers 1 to 29 show the sequence in which the bolts are tightened.2kg•m).2kgf•m). Tighten the bolts in the tightening sequence of 13 to 29 to 10±2N•m (1.2kgf•m). Retighten the bolts in the tightening sequence of 8 and 9 to a turn-of-nut angle of 75°±5°.4±0.

SELECT SW.LEAN ANGLE CRANK SHAFT SENSOR AIR TEMP SENSOR WATER TEMP SENSOR PRESSURE SENSOR(Pb) PRESSURE SENSOR(Pa) CAM SHAFT SENSOR SPEED SENSOR E/G EARTH E/G STOP SW.RB .COIL 4 MAIN FUSE FUSE(ETV) FUSE(IGNITION) R3 R3 R2 B RL RL SW.L L2 .BL GyR Or RB OrG WB .WR2 .COIL 1 IG.4 YZF-R6 Wiring Diagram G D C WL BrY RL SbW BrB - RL BrY WL . MEASUREMENT TOOL POWER SUPPLY P/C I/F MAIN SW... SW..RW2 RW Br R Br 18 (GRAY) RL GB RB 31 RL R Br 15A RW GW B 29 BL2 L3 G L2 L2 L3 G YB1 BY LB2 TP1 RL B 6189-0934(Dg) (BLACK) B B TP2 6189-0933 BL2 L3 L2 G IJ12 GB GB D GB (GRAY) RL LB GB 32 RL VCC2 TP1 TP2 TC NL SS IJ13 LB LB D LB (GRAY) RL OrB LB 33 RL IJ14 O2 OrBOrB D OrB (GRAY)OrB RL WL 34 RL RW B B RW 24 (BLACK) LB2 25 (BLACK) Y YB GW WY .WIRE GND .B . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 COMPONENTS BTRY.. WIRE MINUS LEAD ACM STARTER RELAY STARTER MOTOR REC/REGU RELAY ASSY IG.STOP SW. – 69 – WR2 .- 59 GyG RB AP1 AP2 BL W L WR RW RL LY WR FWE RST RXD TXD FWE2 RST2 (BLACK) RL RL D G (BLACK) GW RL RL RB IJ11 RB RB D RB L Y G2 60 79 .WB RW SbW2 G WR Gy .WB .G2 GW WR2 P YL BL Y BL2 RL LY R2 RW YL VM MR VB MS LAN IT IG1 Or RB Or C Or Or 11 Or RB (BLACK) RB IG2 GyR GyR C GyR GyR 12 B R3 R 1 GyR RB R 15A 4 (BLACK) RB R R2 RW LW RW R LW LW3 2 73 G2 R Y B RB R 78 Y G2 BL W LW W WR BL2 ST 84 AP1 AP2 SGND2 B IG3 OrG OrG C OrG OrG 13 OrG RB (BLACK) RB IG4 GyG GyG C GyG GyG 14 (BLACK) 9 B 5 R - ..COIL 2 IG..Br..BrW .LB2 BY B .- (BLACK) MAIN HARNESS WIRE SUB LEAD 3 MAIN HARNESS (BLACK) WIRE SUB LEAD 2 (BLACK) MAIN HARNESS (BLACK) WIRE SUB LEAD 1 16 R 7.HANDLE SUB-LD PIT ROAD LIMIT SW.BrB SbW RL RB GB OrB BL LB . CONNECTOR MARK (BETWEEN MAIN & SUB HARNESS) CONNECTOR SYMBOL No.....COIL 3 IG.LW RW RB B - RW LW GY Br B RB E/G STOP OFF RUN 187 START FREE PUSH BL (BLUE) (BLUE) 187 YB1 Y WY GW 82 POWER TPS 76 W/TEMP TACHO SPEED GND RW Y GW YB1 WY B IJ21 WL WL G WL (GRAY) WL RL SbW 35 RL (BLACK) LB2 B 30 (BLACK) 65 IJ22 OH Gy BL CRK SGND1 VCC1 CAM IJ24 IJ23 SbW SbW G SbW (GRAY) SbW RL BrY 36 RL Br Y B B FUEL OIL BL Gy B Gy Gy BrY BrY G BrY (GRAY) BrY RL BrB 37 RL BY RW 86 NEUTRAL BL 67 L WB BrW BrB BrB G BrB (GRAY) BrB 38 RL Br Y B BY B TACHO SHIFT Brw BL BrW AT VTHM RW2 61 (BLACK) R BR GW BL YB1 YL 68 GW THMTHM+ LgR YR LgR YR YR LgR GW BL EG BY LB2 69 GW WT (BLACK) AI TEMP 80 BL PW L L L D L BL BL D BL PW PW D PW L BR (DARK GREEN) AMP 1-174374-4 PW PB W BR HI BEAM BW (DARK BLUE) 6189-0970 L BL P C EXM+ EXM70 Lg WL2 SbW2 WL2 SBw2 83 HAZARD ON OFF RY BrW WY Y Dg Br .Ch PASS.YL BR YB1 RW .LW3 LY RW .HANDLE R FR.. COLOR CORD EXPLANATION CONNECTING WITH GND..RL . FUEL PUMP METER INJECTOR 11 INJECTOR 12 INJECTOR 13 INJECTOR 14 INJECTOR 21 INJECTOR 22 INJECTOR 23 INJECTOR 24 RW RB LW OIL LEVEL GAUGE APS TPS THROTTLE MOTOR SENSOR.Or GyR OrG GyG LgR Lg LW RB GB LB OrB B4 RW2 YG LY WL SbW BrY BrB B3 R2 YB1 WY . OFF ON DIMMER HI LO HORN OFF ON TURN R N L 54 R B SbW2 WL2 TURN L BL P L (DARK BLUE) TURN R WR2 6189-0970 71 P YG WY C PA FD SP EXP HLR RFR WR2 ILLUMINATION L WB BL L L WB C WB BL C BL B B B PGND CGND P/GND CGND B4 B3 B2 B B B . B.RL B WL2 PW L3 W .GW . VI MOTOR ECU RESISTOR ASSY.L GyG BL .BrW.5A RW2 RB C RB RB WWW 3 B W W R W WWW W W W W W W (BLACK) R 7 R 50A 15 R3 B RB RB B 77 YR LB2 B2 BY . MAP SELECT SW.- (BLACK) 64 85 WR B WR2 B YG L BL B (BLACK) L WY BL WR2 (BLACK) Lg MARK R. C..L YG BL OrR P BW 74 75 72 B B WR2 L (BLACK) L WY BL P OrR BW L (BLACK) B B B Lg B A.L PW GB RB RL LB BL OrB PW L - OrG RB Or GyR GyG L .L 81 L WB BL RW W LY BL 470 (BLACK) R RW BW .

LTD ..Published by YAMAHA MOTOR ENGINEERING co.

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