KIT TOOLS MANUAL

Preface

This manual introduces YEC kit tools.

The YEC kit tools are used for assembly of engine parts (standard or KIT) and R1 and R6 chassis
settings.
This manual provides motorcycle teams with clear information on a line of tools that simplify
basic tuning, and we believe that these tools help beginners to get the latest know-how of engine
tuning and bring efficiency to professional tuners.
Through this manual, we present a method of YEC KIT TOOL to:
Set up ride height and vehicle attitude
Install pistons
Measure squish area
Set up timing

Contents
1. Ride height and vehicle attitude setting
1.1 Rear ride height measurement..............................................................4
1.2 Vehicle attitude measurement...............................................................5

2. Piston installation
2.1 Piston installing tool...............................................................................6
2.2 Piston installing method........................................................................7

3. Squish area measurement

3.1 Squish area measuring tool...................................................................8
3.2 Squish area measuring method.............................................................9
3.2.1 Detecting the TDC (Top Dead Centre).......................................................9
3.2.2 Squish area measurement........................................................................10

4. Valve assembly
4.1 VALVE ASSEMBLY TOOL.....................................................................13
4.2 Valve assembly method.......................................................................14

5. Camshaft setting
5.1 Adjustment tool for valve timing basic kit (R1 and R6).....................15
5.2 Attachment tool.....................................................................................16
5.3 Camshaft adjustment method..............................................................17
5.3.1 TDC (Top Dead Centre) detecting tool....................................................17
5.3.2 TDC (Top Dead Centre) detecting method..............................................18
5.3.3 Proper needle fitting.................................................................................19
5.3.4 Camshafts timing measurement.............................................................21
5.3.5 Timing modification..................................................................................23
5.3.6 Valve to piston clearance measurement.................................................25

1. Ride height and vehicle attitude setting

Applicable Settings for motorcycles must be made for getting high performance on tracks. For
this reason, YEC has developed tools which allow you to measure sections of chassis.
Tool number

Name of product

Corresponding model

MGC-A3108-08

RIDE HEIGHT
MEASURING TOOL

2007-2010
YZF-R1

MGC-A3108-07-02

RIDE HEIGHT
MEASURING TOOL

2006-2010
YZF-R6

1.1 Rear ride height measurement

This tool allows you to compare ride height after modification.
To make this operation;
Fix the tool to the chassis as shown below.
Select a fix marking on the motorcycle as shown below in order to check the height.

Tool fix point

Fix marking

Note: The angle measuring tool is not used in this operation.

Ride height and vehicle attitude setting

1.2 Vehicle attitude measurement

This tool allows you to measure the vehicle attitude.
To make this operation;
Fix the angle measurement tool to the support as shown below.
Initialize (reset) the angle measurement tool.

Attach the angle measurement tool to the steering column shaft (as shown below) .
Read the chassis angle measurement value.

2. Piston installation
This tool consists of bronze and allows you to install the pistons easily without damaging the
piston ring.
This tool is designed with a rib on the lower end. With this rib, center the tool to the cylinder
center, and then insert the piston to the cylinder.
The upper side of this tool is conical in shape so that the pistons can be inserted easily.

2.1 Piston installing tool

Tool number

Name of product

Corresponding model

MGC-A2708-07-02

PISTON INSTALLING TOOL

2006-2010
YZF-R6

MGC-A290908-00

PISTON INSTALLING TOOL

2009-2010
YZF-R1

Aligning rib

Piston installation

2.2 Piston installing method

Fit the pistons with the piston ring and connecting rod by following the Service
Manual.
Insert the assembly of a connecting rod and piston to the engine-oiled bronze tool
until the piston skirt becomes visible underneath the bronze cylinder.
Fit the bronze tool upper the engine cylinder.
Slide the assembly of a connecting rod and piston by pushing with your hand.

3. Squish area measurement

The squish area height is the distance between the piston (Top Dead Centre) and cylinder head
(gasket face). This measurement checks the cylinder head gasket thickness and realizes the
recommended value for appropriate model from the KIT manual.

3.1 Squish area measuring tool

To measure the squish area height, use measurement support MGC-A3108-07-05 and gauge
MGC-A3589-80.

Squish area measurement

3.2 Squish area measuring method

3.2.1 Detecting the TDC (Top Dead Centre)
First, check the exact position of the piston TDC.
Note: The timing wheel is not used in this operation.
To get the exact TDC;
Position the support to the corresponding cylinder.
Rotate the crankshaft to lift the piston.
Exact TDC position is got when the gauge needle indicates the maximum value.

The dial gauge indicates TDC when the needle points maximum value.

3.2.2 Squish area measurement

To measure an accurate squish area, you need to measure 4 points (Points A, B, C, and D
pictured). You need to measure each point.

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Squish area measurement

Make this 4-points-measurement to every piston, and transfer the values to the table below.
Before measuring, position the support to the gasket face of the cylinder, and reset the gauge
needle to 0.

Value recording list

Piston number

Repeat this operation for all the pistons.

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Once 4 points are measured, calculate the piston depth average. The average of those 4points is
the piston depth.
This value is transferred to the table below.
Piston number
1

Piston depth

Average of 4
measurement points

Select the minimum value (piston TDC) of the piston depth.

Add this value to the selected cylinder gasket thickness.
Check that the squish height value is not smaller than the recommended value for
corresponding model from the KIT manual.

Squish height = X + Cylinder Head gasket thickness (X = (A+B+C+D)/4)

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Va l v e a s s e m b l y

4. Valve assembly
To simplify and make easier valve assembly, YEC has developed a VALVE ASSEMBLY TOOL
and a MAINTENANCE PLATE.

4.1 VALVE ASSEMBLY TOOL

Tool number
MGC-A3108-07-06

Name of product
MAINTENANCE PLATE
VALVE ASSEMBLY BOARD

Corresponding model
2007 2010
YZF-R1and YZF-R6

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4.2 Valve assembly method

Refer to the Service Manual for valve installation and assembly.
The purpose for using the board is to make valve assembly and disassembly easier.
This operation makes the cylinder head to be positioned properly and the position is maintained so
you can work more efficient and smooth than working with the Yamaha standard tool.
Note: Make sure that the tool is fixed properly and the thrust bush is completely parallel to the
valve spring.

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Camshaft setting

5. Camshaft setting
You need to adjust camshafts when
Installing the KIT camshaft set.
Changing the STD camshafts timing.
Assembling the KIT-type cylinder head gasket or cylinder gasket.
Surface-grinding cylinder head or cylinder block.
Assembling Racing pistons.

5.1 Adjustment tool for valve timing basic kit (R1 and R6)
Tool number
MGC A3589-80

Name of product
ADJUSTMENT TOOL
FOR VALVE TIMING BASIC KIT

Item
Gauge to measure valve position
Lever to lift up the valve
Timing wheel
TDC (Top Dead Centre) detecting tool

Corresponding model
2006 2010
YZF-R1and YZF-R6
Qty

2
1
1
1

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5.2 Attachment tool

Log manual
Tool number
2C0-28116-70
14B-28116-70

Name of product
ATTACHMENT TOOL
2006-2010 YZF-R-6
2009-2010 YZF-R1
ATTACHMENT TOOL
2006-2010 YZF-R-6
2009-2010 YZF-R1

Corresponding model
2006-2010
YZF-R6
2009-2010
YZF-R1

Note: The attachment tool is delivered separately (A dial gauge is included in the adjustment tool
for valve timing basic kit).

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Camshaft setting

5.3 Camshaft adjustment method

5.3.1 TDC (Top Dead Centre) detecting tool
You can purchase a TDC (Top Dead Centre) detecting tool separately.
Tool number

Name of product

MGC A3108-07-01

TDC DETECTING TOOL

Corresponding model
2006 2010
YZF-R1and YZF-R6

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5.3.2 TDC (Top Dead Centre) detecting method

First, fix the STD or KIT camshaft (refer to the Service Manual), check that the valve clearance
is proper, and then follow the method described below.
Fix the timing wheel to the support, and then fix it to the crankshaft end with a socket
(Check that the timing wheel is fixed to the crankshaft).
Fix the needle with an engine fitting bolt (You can check proper crankshaft position).
Screw the TDC (Top Dead Centre) detecting tool into the spark plug hole of the first
cylinder.
Rotate the crankshaft until the TDC position is got, and then reset the gauge to 0.
Adjust the timing wheel (with the lock side bolt) so that the needle points at 0.
In this operation, check that 0 is properly pointed at the TDC position.

TDC (Top Dead Centre) detecting tool

Timing wheel lock side bolt

Needle indicator

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Camshaft setting

5.3.3 Proper needle fitting

To position the needle at the 0 position on the timing wheel properly, follow the method below.
Rotate the wheel clockwise so that the gauge needle of the TDC detecting tool goes
around the dial twice.
Read X (e.g. 23) directly from the wheel.
Rotate the wheel counter-clockwise to return to the TDC 0 position.
Rotate the wheel counter-clockwise so that the gauge needle of the TDC detecting
tool goes around the dial third-times, and then rotate the wheel clockwise so that
the dial goes around the gauge of the TDC detecting tool once (3 revolutions 1
revolution = 2 revolutions). This operation clears out the back clearance of the chain.
Read X (e.g. 19) directly from the wheel.
If the 0 position of the TDC detecting tool is not proper, reposition the needle.
Repeat this operation until the 2 values become the same (This means X = Y, e.g. 20,
20).
The purpose for this operation is to calculate the average of 2 values, and then get 0 as precisely
as possible.
Note: Be careful not to touch the needle position after this operation.

B,C

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The table below explains a method to adjust the position of the timing wheel properly.

Piston position
2mm BTDC
B position

Angle in Degree
on the timing
wheel

TDC

2mm ATDC
C position

" 0 "

Stage 1

Set timing wheel position roughly

Stage 2

Measurement at 2mm before and

after Top Dead Centre

22

24

Stage 3

1st adjustment of the timing wheel

22.5

23.5

Stage 4

2nd adjustment of the timing wheel

23

23

The angles are symmetrical on each side of the timing wheel =>
the timing wheel correctly indicates TDC
The angles indicated above are used as reference. The actual measured values may be different.
By this operation, 0 is now proper and you can remove the TDC detecting tool.

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Camshaft setting

5.3.4 Camshafts timing measurement

First, to adjust the exhaust camshaft is important. Fix the support and 2 gauges to the
camshaft cap of the first cylinder.
You can now adjust the camshafts timing.
Crankshaft angle measurement at the valve maximum lift
In this measurement, instead of reading values directly from the timing wheel, calculate average
value (The purpose is to read values as precisely as possible). The principle is the same as TDC.
Method
Rotate the crankshaft until the cam pushes the first tappet downwards and then it
reaches to the valve maximum lift (check the gauge needle start to come down).
Set 0 at the present position properly.
Rotate the crankshaft clockwise so that the dial goes around the gauge needle twice.
Read the value X (e.g. 168) directly from the timing wheel.
Return the crankshaft to the maximum lift position (0).
Rotate the crankshaft counter-clockwise so that the gauge needle goes around the
dial 3 times.
Rotate the crankshaft clockwise so that the gauge needle goes around the dial once
(3 revolutions 1 revolution = 2 revolutions).
Read the value Y (e.g. 52) directly from the timing wheel.
Calculation: If this is the case, (X + Y) /2 means (168 + 52) /2 =110.
Note:
1 revolution of the gauge corresponds to 1mm valve lift.
Chain loosening may cause a reading fault. To prevent this, rotate 3 revolutions
backwards, and then rotate 1 revolution forwards.

21

B
A

The table below describes the valve lift curve.

Valve lift

2mm down from maximum

valve lift

A B

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Crankshaft angle

Camshaft setting

5.3.5 Timing modification

Once you have measured the camshaft position, you may need to change it. In any case, adjust it
by following the recommended data from the KIT manual.
Camshafts position modification:
Loosen the camshafts sprocket lock screw.
Rotate the crankshaft to make the camshafts sprocket turning several times around
the crankshaft.
Tighten the camshafts sprocket lock screw.
Repeat this operation until you reach the desired value, and then measure the
camshaft position.

Note: Apply some thread lock to 2 of M7 screw threads (camshaft sprocket) not to loosen.
Tighten these screws at 24 N.m of recommended torque.

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Measurement table
Valve position
2mm down
2mm down
Before
Maximum lift
After
maximum lift
maximum lift

Angle in Degree
on the timing
wheel

Stage 1

Measurement of the original

camshaft position

115

Stage 2

Second measurement after

modifying camshaft position

108

Stage 3

Third measurement after modifying

camshaft position

169

111

53

Stage 4

Fourth measurement after

modifying camshaft position

168

110

52

Measure repeatedly to acquire

the recommended position

The angles indicated above are used as reference. The actual measured values may be different.

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Camshaft setting

5.3.6 Valve to piston clearance measurement

After adjusting the camshafts timing, it is important to measure the clearance between the valve
and piston. Follow the method below.
Move the piston until it reaches to the exhaust TDC so that the 2 cams are located
as indicated (refer to the figure below).
Rotate the crankshaft clockwise so that the needle points at 10 before TDC (R1)
or 12before TDC (R6) for the exhaust camshaft, or 10 after TDC (R1) or 12 after
TDC (R6) for the intake camshaft.
Set the gauge to 0.
Apply force on the lever in order to press the intake valve back until the valve hits the
piston. At the same time, read the needle movement from the gauge.
Read the value (e.g. 2.5mm, this means 2 and half revolutions around the dial).
If you could not make this operation properly, start again from the first step.
Check that the minimum distance is not narrower than the recommended value for
corresponding model from the KIT manual.
Note: Outside scale: exhaust camshaft value

Inside scale: intake camshaft value

Cylinder head
You can measure the clearance between the valve and piston with the thrust lever of the timing
box. The valve opens by pushing the valve tappet with this lever (refer to the picture below).

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The methods explained in this manual are the YEC-recommended ways. It does not
mean other methods may not be applied.
Refer to Yamaha Service Manual of the corresponding model for the technical
specification not described in this KIT manual.

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